INSTITUTE OF PETROLEUM AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS. PART 15 OF THE INSTITUTE OF PETROLEUM MODEL CODE OF SAFE PRACTICE IN THE PETROLEUM INDUSTRY August 2002 2" edition Published by ‘The Institute of Petroleum, London A Charitable Company Limited by Guarantee“The natinue of Pavloum gratefily acknowledges ihe Srancal contributions twerds the scenic and ‘echnical programme rom ie ellawing cempasic: gio UR) Led Ker-MeGee North Ses (UK) Lad ‘Amerada Hess Lid vat Petolevn fnersatonst Ls Marco Petroleum Lid Pegoplus Refining Teeside Lid ‘BP Exploration Operating Co Lid Philips Pesoleurt Co UK Lut BP OH UK Lia Shell UX OM Producss Limite (Chevron evaco Lid ‘Shell UK. Exploration and Production Lid ‘Conoco Limited Sto (UK) Limited ‘Conoso UK Lid Talisman Etergy (UK) Lid Emerprze i PLE ‘Tolalinalf Exploration UK PLE ExxonMobil International Lid ToulinaEl UK Let Copyright © 2002 by The Insite of Petroleum, Landon: ‘A chadtble company Smite ty guarantee Regisered No 135275, Englend Alig reserved Vo part of this book may te reproduced by any means or transmitted or nse ito 1 machine language without the writen permission af th publisher (SBN 065293 223 5 Published by The lnsUtute of Petraes Further copes canbe obtained fom Parle Customer Services. Comsmarce Way, ‘Whitehall esta Estate, Coleheser CO? SHP, UK. Ta: #48 (0) 1206796 351 mal: saies@poriand-sevicescomCONTENTS Page Foreword . eco vik Acknowledgements : 1 si Overview : : : ae . =i 1 Introduction. 1 LL Scope 1 1.2 Area classification - limits of epplicabilicy 1 1.3 Application ofthis Code 2 1.4 Safety principles fundamental to area clssifiation 22 1.5 The management of area classification 3 1.6 Key terms 3 17 Ventilation . 25 1.8 Buoyancy ofrelesse. ... 6 2 The technique of hazardous aren classification Se 3 2.1 Introduction : oa id 2.2 Data required forthe assessment cet : 8 2.3 Application : td : 10 24 The direct exemple approach oo : : 10 2.5 Point source release approach : u 2.6 Apparatus sub-group and temperature class u 27 The area clasification drawing : ; : wel 3. The direct example method for classification of common types of facilities in open areas 3 3.1 Scope ae cee B 3.2 Storage tanks... : M4 3.3 Road tanker loading Classes I! and Il 8 3.4 Road tanker discharge ~ Classes I, I] end Il : 2 2.5 Rail cer loading ~ Classes I, Hand Il : 3 3.6 Marine facilities and jetties - Classes I, I and IIT B 3.7 Drum filing - Open air ventilation - Classes |, Il and II] 33 3.8 Filling and service stations “aContents Cont. 4 Thearea classification 4.1 Introduction rilling rigs, equipment and well operations 4.2 Area classification for drilling, verkover snd wireline operations in epen ress 433 Surface mud systems 44 Gas vent hazardous area 43 Wirelining : 4.6 Miscellaneous sources of release 4.7 Other spaces . 4.8 Well test systems 4.9 Producing oil and gas wells on land 4.10 Emergeney systems 7 4.11 Noneelectrical sources of ignition 5. Classifieation of individual point sources - 5.1 Scope 5.2 Explanation ofthe ‘point source’ concept used in this Code 53 Methodology 34 Point sources 5.5. Shape fectors and lnzard radi for pressurised releases 6 Effect of ventilation on hazardous area classification, 6.1 Introduction 6.2 Open areas 6.23 Enclosed ares 64 Sheltered or obstructed steas cee 6.5 Effect of ventilation on the hazardous are classification of enclosed areas 6.6 The effect of loss of ventilation on the area clessification of an enctosed area 7 Selection, installation, maintenance and use of equipment in hazardous arees 7.1 Introduction 7.2 Standards ... 73 Selection of Group Il apparatus equipment 7.4 Type of protection 75 Selection according to hazardous zone 7.6 Apparatus sub-groups 7.7 Temperature class and ges ignition fempersiue 7.8 Enclosure ingress protection 79 Other requirement 7.10 Documentation 7.11 Marking of apparatus 7.12 Installation 713 Feotection of electrical epparats and cables from physi! damage 7.14 Maintenance and inspection 7.15 Mobile, portable end transportable 7.16 Personal spparatus, 7.17 Battery rooms 7.18 Cathodic protection, earthing and bonding jectrical apparatus and its conn Page 58 59) 59 9 59 6 n B B 8 > BI 81 5a ca 3S sm 8S 3S 3S 8S 8a 87 88 88 88 83 3 8 9-0 3-0 20Contents Cont Page 8 Non-clectrical ignition sources... i= a 8.1 Intvoduction et 31 82 Ignition sources... ... : 91 83 Use of ges detectors in hazardous areas J : 97 8.4 Area classification during maintenance work 99 ANNEXES Annex A Classification and categorisation of petroleum and flammable fluids 01 Annex B Area classification for hydrogen ........... 405 Annex Calculation of hazard radii ......... 407 Part 1: Procedure for establishment of appropriate release frequency level 109 Part 2: Background to risk-based approtch ...... . us Part 3: Background to the calculation of hazard radi in Chapter 5... 19 Annex D Releases within buildings and associated external hazardous areas 123 Annex E Small-scale operations (laboratories and pilot plants) a7 Annex F Types of protestion and electrical apparatus that may have sn internal source of release. 129 Annex G Safeguards on fired process heaters . : 135 AnnexH Glossary ....... 7 7 7 : 137 AnnexI — References . oadFOREWORD Part 15 of the IP Model Code of Safe Practice is a well-established, intermationally accepted Code for the 100°C, may, according to the temperature of handling, cither be considered as non-hazardous or, at temperatures n excess ofthe flash point, be considered as Class I11(2) liquids, However, when unclassified products such as bitumens and heavy residual and bunker fuelsare stored under confined heated conditions in fixed roof tanks (ie, unventilated ullage space), the flash point of the product is not a reliable guide to the presence ot absence of flammable ntmosphere that may have built up in the tank vapour space. For this reason it is prudent, in common withthe ullage space of road or til tank vehicles containing allclesses of flammable fluids, to classify the ullage space of all such tanks as Zone 0, with 1,5 m Zone | area eroand roef vents and other openings. Reference may also be made to the IP Bitumen safety code 3.2 STORAGE TANKS ‘The following type examples apply to tankage as ined in 3.1(a). The examples epply diectly to the storage of Class I liquids, for which there should always bbe such a zoning. This guidance may be applied, where such conditions arise, to the storage of Class 11(2) and WN(2) liquids (see 3. ‘As indicated in Chapter 2, Table A3 and A1.3, Niquids that are stored under Class TI(1) or INC) conditions will not nonnally entail @ surrounding external hazard zone requiterent. It is good practice to restrict electrical apparatus ‘within bunds tothe minimasn nezessery but pumps end their drives should not be sited within tank bunds. ‘The hazard zoning in 3.2.t ot 3.2.2 will normally be adequate forthe fitings on the tank shell, butt should be confirmed that there is no equipment or release ‘within the tank bund which would extend the hazard cea, If this cannat be confirmed, Chapter 5 should be applied.‘THE DIRECT EXAMPLE METHOD FOR CLASSIFICATIONOF COMMON TYPES OF FACILITIES INOFEN AREAS oles: 1 Because ofthe possibility of mis, sprey of foam formation, the ullage space of Class 111) and I!) tanks should also be regarded ws Zone 0. It is wecornmended that the ares surouriing any vents of openings on the roof oF such a tank be regarded as Zone | toa diameter of mat the vem tp. 2. See 3.1.4 forested residual fuel and bitumen tanks. 3. Inthe event of foss of containment causing liquid tobe held vp in the bunded area thehezandous res wouldextend beyond the bund wall, See section 5.4.7 Figure 3.1(a) - Bunded tanks -Cone or dome Phar dqrestion Notes: |. This classification is based on the practice thet the roof will notte grounded on its legs during the operational eyele since the spare space so created below the roof would drew inairand este the possibilty of ignition eaused by friction. Roofs should only te landed forinspection, cleaningand maintenance under creflly supervised work permit central Any vapour space below the roof or between the primary and secondary seals should be treated az Zone 0. 2. See note 3 above, Figure 31 (b)- Bunded tanks Floating roof 15[AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS 3.21 Fixed roof tankage - Classes I, 11) and m@) Fo: fixed (cone or done) mof tanks the ullsge space should be classified a Zone 0. This applies also to tanks fitted with internal floating covers. The vent systern on the tarke roof should be considered a primary grade source of release. Vepour wv travel slong the surface of the roof and flow downwards, close to the tank shell It is assumed thet ce bund wall it contin the epresd of vapour due to venting, The area extending3 mupwardseirightangles to the roof surface, 3 m horizontally from the reof edge and 2 m vertically éovn the shel fom the roof edge should therefore be classified as Zone 1 “The aree within che tonk bund up to @height equal to the top of the bund or upto | m, whichever is the aqeater, should be classified ss Zone 2, and any pits or depressions Zone 1, becase ofthe gester tendency of heaviee-than-air vapours to persist. ‘Ata distance of 3m from the shell, Zone 2 should be extended upwards to meet the Zone 1 area. This is shown in Figure 3.1(a). Ifthe bund wall isless than 3 m from the tank shell, it may be desirable to adjust the zoned distance accordingly. These hazard distances apply to filling rates of up to 250 '/, Additional information and for filling rates greater than 250m'/h can be found in ection 5.4.4.2, 3.2.2 Ploating roof tankage - Classes 1, 1(2) and me) ‘The hazardous zoning around a floating roof tank should be drawn as in Figure 3.1(b), The space within the tank shell above the roof should be classified as Zone 1 The area above and around the tank shell for a Gistance of 2 m should be classified as Zone 2 and should extend, at the height of the bund, to the band wall. Any pits or depressions within this Zone 2 should be classified as Zone | 3.2.3 Tankage with outer containment On any fixed or floating roof tanks with in-built outer conta benween should be classified as Zone 1, whatever class of fluid is stored, The remaining area around the containment ‘should be classified in accordance with 3.2.1 or 3.2.2. 3.24 Underground tanks Underground tanks are normally located st filling stations, orsmall industrial or domestic premises. Their clascification is covered in 3.4 and in Figure 3.12 for the tank manhole end offset fill pipe chamber. If there is @ tank tunnel providing access to an underground or mounded tank, it will normally be an enclosed area and should be clasified in accordance with Chapter 6, after considering the effect of any artificial ventilation system. 3.2.5 Bulk pressurised LPG installations ‘This section is intended to apply to bulk handling in the distribution and marketing of LPG. “The main sources of elease are considered to be ullage level indicators and filing/unloadingconnections which are provided with self-sesling valves. These points should heve nominal Zone 1 areas of radius 3 0 which correspond to the loss of materials from a nominal 1 mm diameter hole. Relief valves which are regularly maintained and tested and flanges, including manhole covers, should have a nominal 3m radius Zone 2 ares ‘Any spill catchment axea provided to retain liquid LPG spillages should be classified as shown in Figure 3.3 and in accordance with section 54.7 ofthis Code. ‘This transient spill area is classified as Zone 2 ‘Any ancillary equipment associated with t storage area, e.g. pump sets, should carry a Zone 2 area dependent on the type of pump and seal system, The ‘extent of the hazardous area should be deterimined in accordance with Chapter 5 of this Code. Diagrammaticrepresentationoftheaboveisshown in Figure 33. 3.2.6 Vent stacks High level vents eg. from underground ot mounded tenkage should be regarded as a primary grade source with the extent ofthe Zone | bazardous area dependeat= fon the vapour emissions rate (or filling rate), in accordance with section 5.44THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIESINOFEW AREAS utr ote wt Figure 3.2 - Tanks with outer protective wall Figure 3.3 - Area classification of LPG storage facilitiesAREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS 3.3 ROAD TANKER LOADING - CLASSES 1, 1 AND IT 3.3.1 Introduetion ‘This section covers both bottom and top loading for flammable materiels in Classes [, 1 and 411 in the normal ease where such facilities ate located in an open area, under conditions defined in 3.1.1. Class 0 (ie LPG-type materials) loading and unloading should be classified by referring 10 3.2.5 or to the point source methodology given in Chepter 5 It should be noted thet under normal ambient conditions, meterials below their flash points such as kerosine and gas cil, ie Clesses II(1) and IT(1), may ive rise to hazardous areas sround equipment in which they are handled under pressure, due to the possibility of mist or spray formation on release, Also, if these ‘materials are loaded into 2 vehicle compartment which thas previously contsined a high vapour pressure product such as gasoline, ie, switch-loaded, they may displace any flammable stmosphere that remains in the vapour space. In suc cases the loading facility should be classified as in 3.3.3 for e Class 1, (2) or IL) product, However, switeh-loading of eargoes should be avoided wherever possible 3.3.2 Open air facilities with weather roofing AAs depicted in the type examples thet follow, loading fecilities should normelly be located in the open air (see IP Design, construction ond operation of distribution Insiallotions). A root for weather protection is acceptable but any sides should not undely restrict atural ventilation. Also, the space below the roof should be regarded asa sheltered area, and classified as Zone 2 as depicied in Figure 3.4. Turbulent airflow above a ventilated roof makes it impossible te calculate 2 specific hazard zone eround :oof vents, Thesefore, it is recommended that electrical equipmentshould notbe Jocated near to roof vents 3.3.3 The loading of Classes lI or IIL The approach to the classification for both bottom end top loading of road tankers should take account of the following situations (1) The loading island and bay ares with no vehicle present (2) The loading island and bay area with vehicle present, including whilst filling, (3). Any spillage of flammable materials. ‘The diect examples in this chapter are only valid providing the design of road tankers is in accordance with relevant nationat end international statutory requirements (guidance is given in IP Petroleum road tanker design and construction), and suitable safety and operating procedures are followed (see TP Design, construction and operation of distribution instollarions). Unless these conditions are met, the movement of vehicles to and from a loading position, (which must take place with the loading island, bay are and vehicle in @ flamnable hazard-fiee state) and the occupation of a loading position adjacent to @ road tanker that is filling may be unsafe. Loss of contsinment on one loading island which spreads to an adjacent vacant loading island, ¢.g, vapour spread, spillage during filling, breaking of flanges or leakage from maintenance, venders the entiy oF departure of \elicles unsafe. It should be noted that certain zones are transient and only exist whilst loading is being canted out 334 — Bottom loading of road tankers - Classes ly Mand tt ‘The hazard zones around al possible sources of release ‘which could arise from the installed loading equipinent and slop facilites, in the absence of a tank vehicle, should be assessed and # practical eavelope devised. This should include zones zrising ffom routine ‘operations such a filter cleaning. ‘The additional zones which arise whilst vehicles ate being filled should be determined. These zones are transient and will not exist when the fll covers are closed and the loading arms have been returned to the parked position, Spllages arising during tank vehicle filing should, however, be considered. Following the steps in 3.3.3 the analysis should be carried out in stages as follows: 3.2.41 Classification of the loading island and bay ‘area -no vehicle present For the purposes ofthis guidance, itis assumed that the fixed loading connections are equipped with self sealing couplings. Due ta the frequency with which the connections are made and broken, causing x small release of liquid ar vapour to occur, they should be= regarded es primary grade releases, giving rise to am Zone 1 area around the couplers in the parked position ofthe loading arms, down to ground level. For releases up 10 10 ml (anticipated release From coupling) =‘THE DIRECT EXANPLEMETHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIESIN OPEN AREAS nominal | m hezard radius should be assigned around ensure equipment located on the end of each hose, However, itis recommended that accordingly, as shown in Figure 3.4 the entire loading island is classified asa Zone | ares to jland is specif End Elevation bay (eenctey \Mustrtion of entry into empty bay In safe condition ifn sallage present and al connections anc <— fea a 8 closed Plan - with or without roofing ay area between loading islands and beyond the hazardous area associated with non-hazardous in the absence of spillage 2. inorder thatthe bay is not assigned Zone t, the loading arms should be parked in the vertical postion when not in use loading arms can be considered Figure 3.4 - Loading island - Bottom-loading ~ No vehicle present - Clases 1, 11 and IT][AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIOS 3.342. Classification of lacding island and bay area during loadinedftling- vehile present ‘The vehicle cab should always be treated as a Zone 2 within the Zone 2 classified ares in accordance with IP Petroleum road tanker design and construction. Vapour is piped from the collection manifold on the vehicle top tos low-level connection onthe lading, island, through a self-sealing coupling, From this connection, the vapour is routed lo a vapour recovery nit of, when this isnot provided, to a vent direct to atmosphere (see 3.3.4.6). There is, therefore, no fiee venting in the loeding area from compartment fill covers. However, asmall leakage could result fromthe hose connection point on the tanker during coupling and uncoupling. Due tothe frequency of operation, tis Empty bey =e silage present safe condton Tor vehi ntryféeparure ‘wih vans and atl eannections cose Ganty sn vehi 1 gives vise to a Zone | ates of radius 1 m (see Pigure 3.5). ‘This distance assumes thet the selfsealing ‘couplings normally used for bottom loeding limit che normal release on disconnection to less than 10 ml Since there is no free venting, the only circumstance in which discharge fo the open air can cour is where failure ofthe overfill prevention system leads to the emergency venting of « compartment, This possibility is remote since IP Bottom loading, vapour collection and overfill prevention requires the design of the overfill prevention system to be both self-checking and fail-safe. Accordingly it can be designated & secondary grade release of low probability, resulting in 1 Zone 2 area of | m radius around each relief valve, a8 shown in Figure 3.5. see notat rote uring fing tv pian When bottom loading tankers ere being filled with open Bill covers, the hazardous area duc to vapour emission fiom vane uring loading ato filling rate of 2.5 min exons in all directions for less then | ea for Class | fluids, but should Ee increased ta 1,5 metres to allow forthe possibie rlense of product fom draw-off valves when used for adjustment of loa The ollage spice in the tank should be clessified as Zone 0 Figure 3.5 - Filling road tank vehicle equipped for bottom loading with vapour collection"HE DIRECT EXAMPLE METHOD FOR CLASSIFICATION GF COMMON TYPES OF FACILITIES IN OPEN AREAS 3.3.4.3 Provision for spillage In addition tothe aggregated Zone 1 areas of Figures 3.4 and 3.5 during the filling operation, a transientZone 2 applics to all areas where there could be spillage of (Class. 1(2) or 1112) materists. Such spillage in the loading area should be considered as a secondary grade source of release. It ‘can occur from filters during routine servicing, fromthe failure of pipework system components and, despite the provision of overfill prevention devices, ftom overfilling of vehicle compartments at flow rates up to the meximum losding rate. The extent of a spillage should be assessed eccording to the expected duration of release and with due regard to surface grading end drainage systems. Overfilling 2 vebicle is likely 0 result in the formation of the largest wetted rea or pool Details ofthe surface area dreinage (i.e. the grading of the paved area and positions of collecting points, Boundary of ansentzone 2 Notes: 1. For determination of extest of Zor 2 spillage area (R,) se duets and chennels) will determine the size of pool likely to be formed fora given combination of spillage rate and duration. The spillage is assumed tobe of e Category C fluid and the size of the hazardous area (Zone 2) from these secondary grade sources is based on the recommendations in section 5.4.7. The height of the Zone 2 area should therefore be I m. Where there is 8 drainage chennel, Kerb or other means of containment around the loading area, then no flow of spillage outside the channel or containment area need be considered, but the further extent of vapour travel should be taken into account. The otal hazardous area will therefore normally be greater then thet within the containment area (see Figure 3.6 for typical zoning). IF & means of containment is not provided around the loading facility the likely extent of a spillage must be assessed by considering the surface grading. = Leaingllends Drinage stem sen mate? ion 5.4, 2. The dimensions of L are determined by the means afspllage cantsinment such ss ground contours, kerbs, drainage gulleys or cut-off drains (as shows). 'L' shown ebove isnot aecesearily the same dimension in both directors. 3. If weather roofing is pravited, che space sbave the Zone } area will be Zone 2 up tothe roa. Figure 3.6 - Area classification in case of spillage‘AREA CLASSIFICATION CODE FOR I! 3.3.44 The composite classification drawing From the detailed analysis carried out above it is possible to assemble a composite of Figures 3.4 t0 3.6, resulting in a final drawing illustrated in Figures 3.18) and (b). ‘The whole arrangement should permit the ‘movement of vehieles t and from the loading positions, with the loading island, bay area and vebicle in a flammable hezard-free state. This is ensured by adherence to the operational controls prescribed in IP Design, construction and operation of aistribution installations. 3.3.4.5, Weather protection - bottom loading In the case of bottom loeding, overbead protection against weather can be dispensed with, as filicavers are fot open for loading purposes. Whete, however, extremes of climate make weather roofing desireble, invespective of whether or not pipework is instalied in the roof space, itis recommended that she whole of the roof'space, ather than that which may already be within the above-defined Zone | ares, should be classified es Zone 2 (see Figure 3.4), 3.3.4.6 Safe disposal of vented vapours Where the vapour emitted from vehicle toading is routed to a vapour recovery system, the latter will be stant fiom the loading areas. With the recovery system in operation, any emissions should be lean in hydrocarbon levels. However, to allow for process rmalfuretion the vent should be regerded esa secondary arade release, and its hxzard zone should be assessed in accordance with section 5.44 ‘Where a vapour recovery system is net provided, facilities should be available to enable the road tank vehicle's vapour collection manifold to be connected to 1 discharge system which will ensure that vapours displaced during loading are vented safely away ftom the immediate loading area (IP Bottom loading, vapour collection and overfill prevention). The hazard zone fiom such a vent shoul be assessed in accordance with, section 5.44, Given the frequency of most loading operations, the clesification should be Zone 1 335 Top loading of road tankers - Classes and HIE Lu A detailed analysis, anslagous to that of 3.34 for botiom loeding, should be carried out to produce @ composite classification diagram, As in 3.34, the hazard zones around alt possible sources of release, which could arise from the installed LLASIONS HANDLING FLAMMABLE FLUIDS Joading equipment and product disposal fociities in the absence of # tank vehicle, should be assessed and a practical envelope devised. This should include zones arising fom other routine operetions such 25 filter cleaning ‘Additional zones which arise whilst vehicles are being filled should then be deterinined, These zones are ‘wansient and will not exist when the fill covers are closed and the loading arins have been returned to the parked position. Spillages, which could arise during tank vehicle filling should also be considered Following the principles established in 3.33 the analysis should be carried out in stages as follows: 3.3.5.1 Classification of the loading island and bay area - 10 vebicle present For this condition the loading island should be classified with the loading arms inthe parked position to permit movement of a vehicle (0 and from the loading postion which must take place with the lading island, bay tea and vehicle in lammnable hezard-free sate, The lower part of the arms after use will have intemal and external weited areas and evaporation and iainage oan take place. Therefore a nominal 15 m Zone |araa should be assigned eround the end ofeach loadingarmn. If detachmantis vi 'dry-break’ coupling, 2 typical release of up to 10 ml may result end the rominel hazard radius may be reduced to | m for a closed system, Due to the frequency of operation they shouldbe regerded as primary grade releases. The Zone 1 area shotld be extended vertically down to ground level. However, it is recommended that the entire loading island is classified 28 a Zane 1 erea to ensue ‘equipment located on itis specified azcondingly, shown in Figure 3.8, 33.5.2. Classification oj the loading island and bay area during loading - vehicle present \Whenall the tan compartments of vehicle are closed, the unoccupied space of an empty bay between the Zone 1 areas of adjacent loading islands penmits the safe entry of the road tanker and its departure when Joatled, subject in beth cases to there being no spillage and josding errs being in the parked position, When a road tanker is at the loading position, @ further Zone | is generated when venis and fil covers are opened or filling connections are made or disconnected ‘Whilst the hazardous ares duc fo vapour emission from vents during loading ee filling rate of 2,5 m? per~ amine extends in all directions to less than | m for~ Class 1 petrofenm, it has been shown 2s 1,5 m 10 allow{THE DINECT EXAMPLE METHOD FOR CLASSIFICATION for wh 1e possible release of product from draw-off valves used for adjustinent of losd. The extent of Zone | to be assumed is shown in Figure 3.9, 4.3.5.3 Provivion for spillage This will apply only for Class 1, 1(2) and 1112) materiais. See 3.3.4.3 and Figure 3.1 (OF COMMON TYPES OF FACILITIES IN OPEN AREAS 3.354 The composite classification drawing From the detailed analysis carried out sbove it is chen possible to assemble a composite of Figures 3.80 3.10, resslng in the final drawing istted in Figure 3.11(0) ‘The whole arrangement should permit the movement of vehicles to and from the loading positions, with the loading island, bay area and vehicle ina flammable hezard-ftce state. This is ensured by adherence to the operational controls prescribed in 1P Design, construction and operation of distribution instatations. Side elevation am, Figure 3.7(a) - Composite area classification drawing for bottom loading ~ vehicle during filling, in the case of a spillageAREA CLASSIFICATION CODE FOR INSIALLATIONS KANDLIEG FLAMMABLE ELLIDS Boundary of anstant Eone 2 spillage area senna Plan for Figores 3.7 (5) and (bi: Transient spillage 2one aress normally fe inavera. IT weather octing is provided, al spa For height of Zone 1 area see 3.3.4.1 Figure 3.7(6) - Compos above the Zone | area will End elevation from hazard when no spillage is present, or for Class 111) and IC) 2upio he roof (ee 3.34 area classification drawing for bottors loading - Loading area and vehicle during filing, in the case of spillage 4THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES IL CPEN AREAS Ground Elevation (see note) (see note) Plan ote ‘The above zoning applies to all fied equipment. The bay areas marled 'see note’ between loading iiands can be ennsidered position in readiness far the entry or departure of non-hazardous inthe absence of spillage and whi loading arms in the pat the road tanker with its fill cavers closed, Figure 3.8 - Loading island and bay area - top loading ~ no vehicle presentAREA CLASSIFICA TION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS Ground Side elevation Intemal Zone 0 Ground End elevation able uid Figure 3.9 - Filling of road tankers, top londing through open or vent fill cavers:‘THE DIRECT EXAMFLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES IN OPEN AE i Elevation Plan 12) nates 9038343 spillage contsinment such as ground contour, kerbs, drainage gulleys and cut-off drains fs shown) L shown above isnot necessarily the same dimension in bath directions Figure 3.10- Typical Zone 2 provision for spillage area with drainage[AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS hen foci tang ple ae Zaning when ong tango (Geo note) Simple aggregation of Figures 3.8, 39 and 3.10. Final composite, with infil of erets a5 shown, For tientment of unoccupied bey on right in condition to receive @ rotd tanker, see note 2, Notes: LIP weather roofing is provided, atl space above the Zont 1 aren willbe Zone 2 upto the roof. 2. Normally fiee from flaramiaéle hazard when no spillage presen! Figure 3.1 1(b) - Final composite classification - typical road taker cop loading installation ~ Classes 1, Hand HlTHE DIRECT EXAMOLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES li OFEN AREAS 34 ROAD TANKER DISCHARGE - CLASSES I, If AND ITT 34.1 General Members of the public should be kept outside the classified area during tanker discharge; warning signs and/or barriers mey be needed for this pumpose. S411 The fill connections at the receiving tonk Where flammable fluids are stored underground at service stations, road tankers are discharged by gr using one of the systems shown in Figure 3.12, i. either fill point in the pit or manhole chamber of the tank, or by offset fill point in which the hose connections can be made above ground or ina separate pit. Note that for Class 1(1) and IUI(1) meterials under these low pressure conditions the generation of Inazardous regions by the formation of mists or sprays from leaks is unlikely, so the Zone 2 regions shown around the coupling points are not required. The Zone 0 and Zone | regions shown should, however, be retained as a precaution. ‘The area classification will be, as shown in Figure 3.12 which has been reproduced from IP/APEA Guidanceforthe design, construction, modification and ‘maintenance of petrol filling stations, as follows: (a) Within the tank itself end within any manhole chamber or pit in which there are tanker delivery hhose connection points - Zone 0. (b) Within any manhole chamber notcontaining tanker delivery hose connection points - Zone (6) For the tank hose eannection points in (a) or (6) there will be a Zone 2 hazard zone venically of 1,25 m (nominal) above forecourt level, extending horizontally for 3 m and descending to forecourt level ata radius of4 m from the connections, Note, in other sections of tis code the zone around hose connection points has been taken as 1,5. 34.1.2 Connection, discharge and disconnection of hoses for Class 1, (2) and IQ) materials The vehicle engine and double-pole master switch should be shut off before connections are made asthe following releases may occur during connection, discharge and disconnection of hoses: (2) Conditions atthe filpoint, Removal of the sealing cap from the fill-ipe prior to connection mey give rise to a small release of flammable vapour. Toe completed hose connection between the delivery vehicle and receiving tank comprises «& closed system, so that during the period of delivery there is no source of release (other than from the tank ventas in 3.26 and Figure 3.5) unless leakage ‘occurs from the hose connection points. ‘When the hose is disconnected the wetted surface area of the tank fllpipe will be exposed until the sealing cap is replaced, hence there will be fa small release of flammable vapour for a very short duration, In addition, these will be some drainage on disconnection of the hose (see (b) below). The above scenarios should be considered minor secondary grade sources of release despite occuring during normal operation, since they take place under controlled conditions and at relatively infrequent intervals and are covered by the Zone 2 area outlined in 3.4.1.1(¢). (b) Hoseline draining and classification of the road tanker unloading parking area. Disconnection of the hose from the delivery vehicle, which should precede disconnection from the receivingtank, will expose internal wetted aress of both hose and vehicle coupling, and dripping mey occur. This should be considered as & secondary trade source of release, for which there should be 2 Zona area which extends 4 mhorizontally from the tanker discharge connections (due to hose length) end 1,25 m in all other directions from the connections extending down to ground level In addition, because of vapour end drips uring manval measurement of the vehicle teak conten, there should bea Zone area within 1m in all directions from the centre of eny tank top opening, extending 2 m above the tank shell, and also a Zone | atea within 0,3 m of the tank shell, extending vertically down to ground level (see Figure 3.13) 3.41.3 Eniry and departure of the road tanker The above-ground Zone 2 hazard for Claas I, 11@2) and NI@) materials only applies whilst tank filling or 3g of hores is taking piece. Providing ae spillage hhas occurred, with the fill caps in position and fill covers closed then the area is safe for entry and exit of tenkers This section is consistent with the design and construction guidance given in the IPIAPEA Guidance for the design, construction, modification ondAREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLANMADLE FLUIDS maintenance of petrol filing stations. ‘Where local site conditions vary, they should be considered individually. In particular, the horizontal Zone 2 distances quoted will depend upon the likely wwevted ares ofa liquid spillage, and this will vary with the paving and drainage provision and the degree of containment from walls and other obstructions (see 3.3.43). ‘Asan example of asite variation, where there is an imperforate wall atthe boundery extending sideways not less than 6 m from any fill point and not less than 3 rinheight his may be taken to constitute the boundary of the hazard zone (see 6.2.3) For other aspects of service station area classificetion see 3.2.6 and Figure 3.12 in respect of underground tank vents, and 3.8 forthe general aspects cof service station layouts including dispensing pumps and operational buildings. 342 Vapour balancing during discharge Vapour balancing between the vent system of the receiving tanks at a service station and the discharging road tanker's compartments is carted out by 2 hose connection to the vapour collection system of the road tanker. Care must be talen to ensure thet the hose connestion poiat from the tank vent(s) is securely closed in the event that vapour balancing is cot practised for any reason. Failuse to observe this precaittion ean lead to the discharge of flammable vapours at low level, bypassing the normal tank vent outlets, ‘A secondary grade release cen tale place when ‘coupling or uncoupling the vapour balsncing hose connection to the vebicle, which will lie within the Zone 2 area referred to in 3.4.1.2(6), 343 Discharge of a road tanker fo an above-ground or elevated tank, using its own or a separate pump A different situation to that in 3.4.1.1 atises when a road tanker has to be discharged into an sbove-ground tank, and a pump is necessary to provide the required pressure. The location of the discharge point and whether she pump is provided on the vehicle or installation, determine the area classification: (0) Where itis practicable this may be carried out by the provision of a suitable discharge point outside the general installation hazaid zone boundaries, e.g in a convenient lay-by with piped connection to the receiving tankage. If « vehicle-mounted pump 1s to be used, requiring the engine to’be run and the electrics live in order to power the pump, atea classification will be necessary even for Class HC) and I11(1) materials because of the possibility of mist or spray formation flom leekege points ‘The operation itself will give rise to hazerd zone areas as specified in Tables 5.1(2) and (b) forthe vehicle pump and in Figure 3.5 for the coupling point. This operation should be carried out only ‘under worl permit contol. [twill lsobe necessary to ensure thatthe tanker is cated (eg, hough conducting iytes) ad that the the conducive type and is bonded aan receiving pipework and to the tanker shell. (b) Where it is not practicable to allot en unloading location ina non-hazardous zone, the above situation will again arise where a Class 1, Il or It material is to be discharged. Tn addition, and irespective of the class of petroleum, the vehicle will ave had to enter, leave and, during discharge, remain with its sngine running and electrics live, inthe hazardous zone sscribable to the fixed equipment of the installation. This should be permitied only in @ Zone 2 area of the plant, and wil be subject 0 strict work permit conirol, which should include confirmation of the absence of spillage and that the area is gas free, (©) The preferred altemative is 10 camy out the offloading using a fixed pump onthe installation, fed by gravity from the road tanker. This has the advantage that the equipment on the vehicle is de-cnergized duting off-loading and that the \ehicte flexible hoses end couplings are not subject ta pump discharge pressures. In this case ares classification should be prepared for the pump (in accordance with section 5.4), coupling points, hose and line clearing as above, Entry and departure of the vehicle should be controlled by spacifc si regulations,‘THE DIRECT EXAM E METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES IN OPER AREAS 8) Fit points in manhole chamber Zone 1 Zone 2 ) Ose pons in So Se ‘manhole chamber | | 1) Above ground offset i ponte t clu) hkl ‘Note: Figures repraduced from IP/APEA Guidance forthe design, contruction, modifcarion and wsainenance ofperot filing siavions Figure 3.12 - Classification of Class I, Il and III materials discharged to station underground tanks 31[AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS COMM paw (UT s0sse4-) ~# suowors youn fo 200 cyurom pu wonooyip vojun 203 paqavd soxuey pony - eT°e a mnagetan “UBisay a4p s0f 2 e080 19 airvatay wi04] poonposdas samney 10N4 2m puro yon we 91 une fe vaueier hag wen 1 a2 wat “by AENEAN 7 10 eps ou puna anon po zauoz |, euoz,THE DIRECT EXAMPLE METHOD FOR CL ASSIICATION OF COMMON TYPES OF FACILITIESIN OPEN AREAS 3.5 RAIL CAR LOADING - CLASSES I, I1AND It 35.1 General Rail car loading facilities vary in design. They may consist ofa loading siding provided with a number of loading points spaced st intervals to suit rail cer dimensions. An altemative to this multi-point syst 2 single-point installation in which the loading arms are grouped in one position and the train of rail cars is moved 50 that each car is brought into the loading Position successively. Incither case the installtions are fundamentally similar to the road tanker loading facilities considered in 3.3 and should be analysed in the same way. Rail car loading rates and therefore the rate of vapour displacement can be higher than that considered for toad vehicles. The size ofthe hazardous ares should bbe increased at these higher losding rates with allowance for greater width of rail cars and larger lozding arms. ‘The ares classification guidance given in 353 to 3.5.5 for the loading and discharge of rail tank cars isin samt accordance with the more general guidance for such installations as given in IP Design, construction and operation of distribution installations: 352 Top loading of rail cars with vapour recovery Loading of rail cars with vapour recovery should climinste routine emissions of flammable materials ‘rom the fil covers. However, where loading facilities require removal ofthe fill covers prior to loading and closure on completion of loading, this will allow release of vapour which could extend over the full length of the loading gentry (ie. while the reil ear is moved along the track). Due to the frequency of ‘operation this is designated a primary grade release creating @ 2 m radius Zone | area around the fil cover ‘extending to ground level (see Figure 3.14). Where rail cers are fitted with permanent filling and vapour recovery connections, there should be no release of vapour except where failure leads to emergency venting of the compartment, Accordingly this is designated & secondary grade release allowing the Zone 1 in Figure 3.14 to be downgraded to a Zone 2 classification, 7 Notes 1. The Zone 1 area should be extended to cover the total length ofthe gantry to allow for di either inthe ease of a multipoint system or in the case of a single rail ar moving slong open. ‘The extent of the spi (500 3.34.3) To area for Class ,11(2) Figure 3.14 - Top loading of railears, si nd (2) materi wil mine the extent of the Zone 2 are, see section §.4.7. 2 determinedby mesne ofthe pillage contsinmert isle or multipoint, with vapour recoveryAREA CLASSIFICATION CODE FOR AISTALLA IONS HANDLING FLAMMABLE FLUIDS Figure 2.14 continued Loading platform Inflted area Infited area Internal Zone 0 ea [22 End elevation without weather roofing End ther roofing Note: For aif cats with permanent loading and vapourrecovery connestions, the Zone | ares may be downgraded to & Zone 2. Figure 3.14-Top loading of railcars, single or multipoint 3‘THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMBAON TYPES OF FACILITIES IN GEN ABEAS “Thepossible losses of vapour fiom the loading arm itself will genetate a nomine! 1,5 m radius ftom the outlets of the loading arm, Due to the variable location ofthe loading arm, the Zone 1 area should be extended 3 mabove the working level ofthe gentry. ‘The interior of the rail car will as inthe case of a road ear, bo Zone 0 at all times. The following figures show the individual aspects which should be combined to proiiuce the overall hazardous area clessification, 353 Top loading of rail cars without vapour recovery (9) A primary grade source of release occurs whilstithe reil car is being loaded due to vapour emission from the open or venting fill covers, Primary and secondary grade sources of release occur from the loading arms when being removed from the rail cat to the parked position, from spillages due to overflling and from maintenance of filters and ther associated equipment. For loading rates up to and including 2,5 m per minute it is recommended thet an area ‘extending in all directions to a distance of 1 m around each manlid, with a vertical drop to ground Jevel, be classified as Zone 1 and that this be extended to cover the total length of the gantry to allow for éifferent positions of the railcar or cars in the case of a multi-point system. For rates ebove 2.5m? per minute, the area should be extended to 2 1m. The 2 m horizontal extent will cover the grester width of the rail car (see Figure 3.14). {b) The Zone 1 area forthe gantry should extend from ground level to a height of 3 m ebove the working level of the gantry, as in3.5.2 (©) The interior of the rail car will, a8 in the case of a road tanker, be Zone 0 at all times that the vehicle is in service. However, when all fill covers and outlets ere closed, es for the ninning condition and for entry and departure after loading, the exterior of the rail car can be classified as non-hazardous safe entry and (2) Normally, impermeable catchment trays will be provided to contain spillages, in which case the Zone 2 should be assessed as detailed in 33.43. Otherwise, wetted areas from spillage will be restricted by the ballast on the track; in this ease it is recommended that, for Class I, (2) and 11K(2) materials, a Zone 2 area should extend 3 m hhorizontally in all directions from the extremities of the gentry structure, with @ height of 1 m in accordance with Table 5.7. (©) The combination of the above factors is shown in Figure 3.14, It should be noted that the whole of the area below any weather roofing should be classifi Zone 2 down to the Zone | area. 354 Bottom loading of rail Bottom loading of rail cars isa less common practice. However, where it is carried out a similar analysis should be followed as in 3.5.3 for tploading, bearing, in mind that bottom loading is carried out at ground level. Consideration should be given tothe following: (2) Sealed couplings are normally used from which a secondary grade source of release may occur due toleakege. Secondary grade sources of release can arise due to overflling or accidental spillage when couplings ate broken, and fiom filters and associated equipment. (8) Forbottom loading at rates up to and including 2,5, rmilmin the area of the loading sland should be classified as Zone 1 up to a height of 1m sbove any Vent level. For retes ebove 2,5 m'vmin the height should be increased to 2m. (6) The classification of the rail tanker will be as in 353(0). The envelope of the Zone 1 area associated with the fill covers and their vents ‘extends, during filling operations, es described in 5.5.3(a) for top loading down to ground [evel The Zone 2 sree that is required to allow for the various secondary grade sourcesofrelesse arising from spillages should be derived as detailed in 3.5. ‘The composite area classification is shown in Figure 3.15, both with and without overhead weather roofing [Note the in-fill inthis composite ofthe Zone | area vertical heights in (b) and (c) above.[AREA CLASSIFICATION CODE FOR MISTALLATIONS HANDLING FLAMMABLE FLUIDS Zope ie o unflorn height fom height an on without weather proofing Ze UT = ‘ End elevation vith weather proofing Notes: 1. The Zone 1 area should be extended to cover the total length of the gantry to allow far different postions af the rail either in the cese of multipoint system or in the case af a single railcar moving slong the tack whilst open, ‘Theextent of the spi (see 33.43). To 2 Bld cover ts ares for Class 1, mine the extent afte ns of spillage containment Figure 3.15 - Bottom los g of railears, single or multipoint, with vapour recovery 36‘THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES INOPEW AREAS 3.5.5 — Rall car discharge via a hose connection - Classes f, Hand 111 ‘Thearea classification for the discharge of tein of rail cars will follow the general principles forthe discharge of road tanker vehicles in 3.4, though the scale with be in most cases bigger end the concepts in 3.5.3 for sail car loading should be bore in mind (see Figure 3.16) ‘The discharge of a rail car using a tight hose connection is a closed system, usually employing self- sealing couplings. Secondary grade: sources of release may ooour due to leakage and, when coupling or ‘uncoupling, hose and drainage line spillage may occur. A non-return valve, or set of valves in the case of ischarge systems thet have a common menifolding, should be instelled and mainteined ineffective working condition, to ensure that back flow from receiving Figure 3.16 Rail car discharge via hose connect 37 tenkege cannot occur as a result of hose breakage, or when coupling or uncoupling. Where the loading area is paved or eoncreted over, the extent of the spillage aree should be defined 05 shown in Figure 3.15. In such e case, the procedure in 3.3.43 should be applied with due consideration of boundaries such as spillage channels or drains. However, in the case of railcar, itis recommended that, beeause of the degree of manual participation and the multiple number of cars, spillage arees should be classified as Zone 1. When ballasted track underlies the rail car discharge location, the spillage erea will be curtailed. An area horizontally 3 m in all directions. from the limits of hose and coupling positions and for ‘height of 2m (to allow for raised connections) shoud be specified. This applies only to Class 1, 11) and TI) materats. ‘Classes 1, 1 and IIL[AREA CLASSIFICATION COOE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS 35.6 Conditions for safe entry and departure of tank car trains fo and from loading and discharge facilities - Classes I, Hand IL ‘The following points provide an important part of the general analysis of the installation: (a) The movement of vehicles to end from the loading. position must take place with the loading gantry and vehicle in a flammable hazard-fiee state. Certain zones ave transient and only exist whilst loading is being carried out; safety is assured by adhering to prescribed safety and operating procedures (far details see IP Design, consiruerion and operation of distribution instaltations), (b) Tracks serving loading or discharge facilities should wherever possible be reserved spectficely for that purpose. ‘They should be sited a least 5 m1 from the neerest running line or unrestricted roadway. ie) Loading and unloading facilities should be clectically continuous and earthed with means of bonding vehicles to the fixed facility. The installation of earth interlock systems is recomimended to prevent product movements unless proper earthing and bonding connections have been made. Rails should be bonded at all other joints in the loading and unloading arca and bonded to the main earthing system of the unloading equipment The track of the rail siding should also be independently earthed, Rail sidings for loading and unloading of rail {nok cars should be provided with insulating joints to isolate the track ofthe siding from the main line and to prevent contact with stray currents from electrified lines orrailway signalling tack cieuit. (6) Unprotected electric locomotives or diesel locomotives, unless conforming with the EEMUA 107 (QCMA MEC-N "Recommendations for the protection ofdiocel engines eperating in hazardous ‘areas’ (see Chapier 8), should not be allowed within m ofa point where Classi, 1(2) or B12) inateril is being loaded, discharged or stored Withio such distance of these operations only lighting ete. certified as appropriate to the area sification should be permitted. 38 (©) Steen locomotives, excapt of the fireless type, and rail vehicles with en oif lamp should not be allowed within 15 m of point where Class [, I(2) cr I11(2) material is being loaded or discharged. 3.6 MARINE FACILITIES AND JETTIES - CLASSES I,If AND IIL 3.6.1 General ‘This section considers the hazardous area on the jetty and merine fecilities arising from the loading or discharging of tanker. It includes the hazardous arca arising from the cargo hoses and from vents om the tanker. The hazardous area from otherequipmenton the Jety should be estimated using the appropriate sections ‘of Chapter 5, Area classification on jetties should always be based on the most volatile product handled. ‘This section does not apply tothe vessel itself for which guidance should be sought in the appropriate maritime coce of regulation, i, International Electrotechnical Commission Publication fEC 6092-502, Tankers - Special features. Further guidanceon the precautions to be taken during handling on tankers aad t terminals for ctude oil and petroleurn products is given in the International Safeny Gude for Oil Tankers and Terminals (ISGOTT). Where jetties are used for both loading (or ballasting of tanks containing vapour) and discharge, # composite hazardous area for the facility should be obtained by combining the hazardous areas for the separate operations 36.2 Jetties - Loading facilites (6) Thehazardous areas should be established for excl: possible primary and secondary grade source of release associated with the jetty equipment. (b) Primary grade sources of release occur during tanker fonding due to vapour vented from tanker ccompariments or during gas freeing of tan ‘compartments, should the later take place whilst the tanker is slongsids or adjacent tothe jetty. For jetties with fecitities for loading (including ballasting), the tanker vents will oreste a primary sade soures of release. Dueto the varying sizes of ships and tidal movement, itis recommended that an area exiending 20 m in all directions“THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES NOMEN AREAS horizontally around the hull ofthe tanker down to ‘water level and vertically io height of 20 mabove the jetty approach level, should be classified as Zone |. Possible hull locations should be based on ‘the maximum breadth of tanker expected to use the jetty and the expected fore and aft positions atthe extreme berthing locations (see Figure 3.17). For this purpose the hull of the tanker should be ‘assumed to be in contact with the jetty: ie. all shore side distances should be measured from the fixed water-sde ofthe jetty. (©) Primary and secondary grade sources of release ‘can occur from fixed and portable equipment such as filters, sample points, siop tanks, loading marine arms and hoses, drainage and drip trays, pump lands and seals, valves, meters and flanges Tae hazardous areas arising from the jetty equipment can be assessed by considering each possible source of relesse in accordance with Chapter 5. The hazardous area created by the tanker can then be superimposed on the hazardous area delennined for the jetty alone. The loading/ustoading equipment, when notin use and in the parked position, creates a source of release whilst draining, During ship loading this equipment can give rise to sources of release but such equipment is encompassed by the hazardous area crested by the primary grade sourees of release from the tank (4) For jetties berthing only berges, coasters of other tankers with loading rates of 10 m'/minor less, the horizontal distance in (b) may be reduced to 15 m and the vertical to 15 m. 3.6.3 Jetties - Discharge facilities For jetties where unloading operations are carried out, the marine arms, hoses, etc., constitute a closed system, and only secondary grade sources of release are likely tooceur.Itis recommended that an area extending from the coupling points, «distance of 20 m horizontally, up io @ height of20 m shove the coupling points and down to water level should be classified as Zone 2(see Figure 3.18), 39 Hazardous arees should be established for each individual source of release from the jety equipment since some may necessitate localized Zone 1 areas within the ebove overall Zone 2 are If ballasting is carried out during unloading into unsegregeted ship's tanks which could contain vepous, or if gas freeing of tanks is carsied out whilst alongei the jetty, then the jetty should be classified in accordance with 3.6.2 For classification onboard the tanker vessel, see 36.1. 3.7 DRUM FILLING - OPEN AIR VENTILATION - CLASSES 1, If AND IIL ‘This section applies to the filling of storage drums of 8 nominal cepecity of 205 litres or less. 3.7.1 General Drum filling shoutd normally be carried out jn an open or sheltered erea. Ifnot, this section does not apply and the drum filling aca should be regarded es en enclosed area with a primary grade source, and focal exhaust ventilation should be provided (see section 6.3.3.1). ‘The drum should be regarded as a primary grade souroe of release, The hazardous area should be classified as Zone 1. It should extend | m in all directions from the edges of the filling or venting ‘openings (cee Figure 319), The spillage area should be determined according to section 54.7. ‘The filling ine outletisalso a primary grade source of release, The hazerdous area should extend 1,5 m in all directions from the filing line outlet. ‘When filling containers with Class I(1) and 11(1) materials, section A1.3 (formation of mists and sprays) will apply. Therefore the 1,5 m hazardous area in all directions from the end of the filling line outlet should also apply. Care should be taken to avoid sources af ignition that could give tise toa hazerd in the event of a ground spill.AREA CLASSIFICATION COE FOR INSTALLATIONS HANDLING FLAMMABLE FLUTOS 220m (S28 0123) MANA i 2m (2 nla) a 20m, Noses: 1 3 ‘The Zone 1 area is additional tn any hazardous ares cessed in consequence of all other equipment on the jetty. May be reduced to 15 m for vesrels with leading or discharge rates of 10m imin or less. ‘The hazardous sree should extend 20 m above the jeny approach level. Thie may be reduced to 15 m for foading rates of 10 mein For Category A fluids, reference should be made to tie methodology given in Chapter 5 These distances may be conservative. However, they cover a great vetiety and size of ships which may be bertied Josding I the size of the vents and losing rates arewelldefined, seston 5.4 may be used to determine more specific savard ri less Figure 3.17 - Jetties -loading facilities only 40‘THE DIRECT EXAMPLE METHOD FOR 1 ASSIFICATION OF COMMON TYPES OF FACILITIES IN OFEN AREAS 20m (Couptng pais Now: “The hazardous ares for cach pioze of equipment onthe jetty should be evaluated. 1 non-segregated ballasting or gas fresing is catied out, then the jetty must For Cetegory A fluids reference should be made tothe methodology given in Chepter 5 ‘The height of the hazardous eres should be 20 m above the coupling point, For 8 Cstegory € material, this is equiv to.25 mm diameter hole inthe coupling. larger hale sizes ae possible reference should be mede to Teble Ca) forthe ‘equivelent hezard radius. Figure 3.18 - Jetty - Discharge 4l[AREA CLASSIFICATION CODE FOR MISTALLATIONS HANDLING FLAMMABLE FLUIDS 3.7.2 Drummed storage areas - Classes I and ne) Where reasonably practicable, such containers should be stored t ground level singly arin stacks of wo more than four high) and in the open cir. This will enable leaks to be more readily detected, and eny vapours arising o be dissipated. Such stacks for Class [or 12) matetials should be placed in one, ot oe compounds if the totsl volume of packed product exceeds 200 m?, with small walls or sils, eg. of 150 mm height, fo prevent uncontolled leakage. The storage and handling of sealed containers will not normally give rise to hazardous releases, but the srea within the walls of sills should be classified as Zone 2 to a height of st least 1 m above the highest container. There is a secondary hazard which could be created by heat from a neerby fire 6 thers should be e sp2ce ofa east 10 m from potential sources of ignition, occupied buildingsand boundary fences, Drums should nat be stored within tank bunds for flammeble liquids or within 1 m of the compound walls. Stacking should allow adequate specing for fork lift tricks or similar materials handling equipment and never be allowed to Fork lift trucks or other materials handling equipment, ifused within the hazardous sreas denoted below, should be manufactured to Zone 2 standards ‘New equipment should be built to BS EN 1753. ‘Where the resommended zone distences cannot be achieved, consideration may be given to the provision offs fixed water spray system or an appropriate firewall as in section 6.2.3, Such a firewall should be at least as. high as the top of the container stack, and be sited 1-2 m from the stack, The firewell may form part ofa bund, unpierced building wall, or boundary wall, and to engure adequate ventilation normaly be on one side only of the stack. 3.1.3. Drum storage in bufldings - Classes I and HQ) When it is not practicable to store containers in the open, they may be stared in suitable storage buildings, which should not be used for other purposes. Such buildings should, as in the case of storage in the open air, have means of containing spillage - e.g. by sills or ramps 150 mm high across doorways. The Mooring should be impermeable to liquid spills. obstruct avenues of escape Storage buildings should be well ventilated, i f ot E The 7 5 | § E \ 7 1 i i : a z Ry at oars of pilage containment ots 1 For determination of extent ofepillage Zone 2 area, see section $47 2. Thedimensions of Lars contralled by means of pl .gecontainment suchas ground contours, ket and drains (asshown) Figure 3.19 - Drum filling in the open atr‘THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION provided openings do nol conflict with the need for 2 ‘wall tobe fire resisting, and be classified as Zone 2 up to a height of 2 m above the highest container. If heatingis provided it should not be source of ignition, For details of package filling end storage building construction, see IP Design, construction and operation of distribution installations. ‘Where artificial ventilation is to be provided the guidance given in Chapter 6 should be followed, with fan motors protected to Zone 2 stendard. 3.74 Package manufacture and reconditioning When packages are to be manufactured st en installation and this entails hot work or the use of any source of ignition, this should be located at least 15 m from any filling area, tankage or storage area where Class 1 or 112) petroleum is stored or handled. Where used drums ere to be reconditioned of repaired, cleaning and ges freeing should be carried out in the open air or in a well-ventilted building, end appropriate precautions taken against any source of ignition ‘No hot work should be carried out on any package until it is cleaned and made gas free (usually by steaining). Such hot workirepair should be carried out within an area that is otherwise designated non-hazardous (sce section 8.4), Containers that have carried a heavy oil ean appear gas free when tested, but when heat is epplied traces of product remaining can veporize to form 2 flammable atmosphere; thorough cleaning out is therefore essential in all cases 3.8 FILLING AND SERVICE STATIONS 3.8.1 Introduction Filling stations store and supply fuel and lubricants to motor vebicles. Additionally, service sistions may include facilities for vehicle servicing, retailing of accessories, storage and retailing of kerosine as well as for vending other products 3.8.2 Area classification for Class 1 petroleum (eg gasoline) This section covers the equipment and found on the forecourt under the normal open tion, R should be applied also to non-real dispensing sites and to dispensing to boats light aircraft (OF COUNON 3YPES OF FACILITIES IN OFEN AREAS and into portable containers. As applied below, the Zone 2 areas indicated cover the possibility oflocalized hazardous atmospheres being present for short periods, ‘with such areas well ventilated under open conditions. ‘The classified arcas indicated relate to the installation of fixed electrical equipment, and should not be considered as extending beyond an unpiereed wall, roof or other vapour barrier or solid pasition (see section 6.2.3). The norml prohibition of smoking, non-electrical soutees of ignition, and the running of engines, during both the fuelling of vehicles and the delivery of fuels from road tankers, should also be vigorously enforced (see Chapter 8) 38.3. Buried service station tankage (Class 1) When classifying buried service tankage, the following should be considered: (6) Yentfrom underground tank (Class 1). Se2 3.26, Note: Where vapour balancing connections back to road tanker ae installed see 3.42 (6) Gravity discharge to underground service station tanks through camlock hose connections. See 3.4.1 and Figure 3.12. (©) Other openings to the tank. As in (b) above. 38.4 Hazardous area classification for dlspenser units (Class T) ‘The following hazardous rca diagrams have been reproduced from IP/APEA Guidelines for the design, construction, modification and matatenance of petro! ‘filing stations; they enable selection of electrical equipment suitable for operation in the vicinity of dispensers. The diagrams can also be used to assess he dangers of other potential ignition sources in the vicinity For any equipment located in hzerdous areas, reference should be made fo the manufacturer andtothe appropriate equipment stendard ‘The situation around a dispenser is complex and the following diagrams show how the various areasare ly aggregated together to produce sn overall diagram, The introduction of Stage 2 Vapour Recovery, on & phased basis, means that some service stations will be fitted with it and some will not. Hen there is @ need to show two sets of diagrams for some parts of the dispensers.AREA CLASSIFIC HON CODE FOR MISTALLATIONS HANDLING FLAMIAABLE FLUIDS (a) Zone around a dispenser housing (this appliss to all dispensers, with and without Stage 2 vapour recovery) ‘Grote wpa 20(a) - No vapour barrier fitted Yo vapour bate acne te spansa hosing ‘yoni Be char norris Za 3 1} eenerases oe wer aro Zone 2 Figure 3.20(0) - ‘apour barrier fitted When the dispenser is not operating, the limited hazardous ree around it allows cars to enter the service stetion safely. (b) Zones at nozzle spout housing (this applies toll dispensers, with and without Staze 2) ‘There are small Zone 1 and Zone. areas in and around the nozzle spout housing, These are sonmelly only relevant to the design ofthe dispenser, but ere important if electronic displays are mounted on the nozzle. (©) Zone where the air separator vents outside (this spplies to all dispensers, with and without Stage 2) one {whi 260 mm aia bony Eine * eS aigntot zane 1 ehagtot ‘ion Tob Figure 3.21 - External air separator vent 4‘THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYPES OF FACILITIES IN OPEW AREAS (@) Zones associated with a withdrawn nozzle When the nozzle is withdrawn fiom the dispenser and inserted into the motor-vehiele fill pipe, the situation staris to change. As the trigger on the nozzle is ‘operated, petrol begins to flow and vapour from the tank is displaced. If the dispenseriservice station is fited with Stage 2, then vapour is recovered and remumed to the underground tank and very litle is lost to the stmosphere, Figure 3.22 refers to this case there is no Stage 2, then as fuel enters the tank, vapour is displaced to atmosphere and, because itis. heavier than air, itrolls down the sie ofthe vehicle and accumulates on the ground. Figure 3.23 covers this +209, Figure 3.22 - Hazardous area for nozzle fitted with Stage 2 Hose and Nozzle out Stage 2[AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS pon a a nent ofZone 2 from nozals dopending ry ‘hase poallon and tangth { ee i : - J. | Osvenser Ir te 1 {Zona ata eapraor vert, Figure 3.24 - Hazardous area sround a dispenser In use ‘Standard 3,6 m hose with Stage 2 vapour recovery (side mounted hoses) leoertot2ane ant 2 om sce {ponding enhars ponte ado Figure 3.25 - Hazardous area around a dispenser in use Standard 3,6 m hose without Stage 2 vapour recovery (side mounted hoses)“THE DIRECT EXAMPLE METHOD FOR CLASSIFICATION OF COMMON TYTES OF FACILITIES MLOPEN ARE Figure 3.26 - Area classification of LPG dispensers 38S Hazardous area classification for LPG dispensers (Class 0) For LPG dispensers fitted with back check velves, hose break-away couplings and other isolating valves, the only source of primary grade release should be the loss of containment when removing the nozzle from the vehicle fuel tank, Self-sealing valves in the filling nozzle limit theloss of LPG, on disconnecting from the vehicle filing point, to a few cubic centimetres and therefore the end of the nozzle carries 2 small nominal Zone | area, This is s0 small that itis covered by the Zone 2 area classification around the dispenser. Dispensers fitted with relief valve settings above the shut-off head of the transfer pump will not lift in normal operation and therefore should not give rise to a primary grade source of release, However, small leakages of the relief valve or fittings within the dispenser result in a Zone 2 atea of radius 2m, around the outside ofthe dispenser. This distance isequivalent toa leek hole size of 1 mm diameter (see Table C9(2) Annex C Part 2), The shumping effect of the vapour dischargeresults ina 2m extension, ata nominal height of 1m. The enclosed volume within the dispenser should then be uprated to Zone 1. Small lesks from the end of the hose on Gisconnection will give rise to the Zone 2 area es shown, controlied by the length of the filling hose and should therefore normally be extended to4 m, Break-away couplings with self-sealing valves in the flexible filing hose limit the loss of LPG in the event of adrive awey whilst the dispenser in till inuse, a ‘This is icely to be an inffequent event and so 8 Zone 2 area should be allowed. Shut-off valves provided toseal the LPG supply lines in the event of a vehicle collision with the dispenser will minimise the loss of LPG but this is also a very infrequent event and is therefore not taken into account in ares classification. 3.8.6 General dispenser requirements All types of pump dispenser should incorporate the following added classification features: {8}, Dispenser nozale housings. Recesses inthe pump housing to hold the nozzle spout, which may be vertical or engled, should be Zone 0, with an external Zone I extending 100 mam outwards, with extension 50 mm above and 100 mm below. ) Aivivepour separator vents. An aicivapour separator which allows air or vapour to escape from the liquid stream prior to is reaching the measuring meters ofthe dispenser is often located 50 that its vent emerges from the side of the dispenser housing, in which case it should be sited rot less than 100 mm from any ventlstion openings in that housing, The vent should be furnished with an apptopriete fine mesh flame arrester and should have a device such 25 a bellow ball float that will prevent the ejection of liquid fuel through the vent. The vent iself should be classed Zone 0 and have a Zone | area extending horizontally 250 mm from the housing anéAREA CLASSIFICATIONCODEFOR INSTALLATIE vertically 100 mm above and down to meet the 250 ram Zone 1 atthe foot of the pump/cispenser unt Altemative positions for the sir'vapour separator between the hydraulic pump and its measuring unit may be selected, one such alternative being to locate itin the Zone 0 area of the nozzie housing, Fuller constructional and other details for the above pipe diameter of 100 mm, assuming that manufacturers" data for a seal failure rate release rate are not available Hole sizes are determined from Table Cé (Annex C). “ezard radi are based on the dispersion distances given in Annex C Patt 3, Table $.1(a) - Hazard radii for standard pumps without throttle bushes DP = diometer of discharge pipe (mm) 4 Forthis release, the azsté radusexeosds 30m The ease sul be avoided. — TEVELT LEVEL TT LEVEL 1 Hote size fam ole se (mm) je saa (mm) |, coco [AE | om | eoaoe | | sor | a 375 70 10 6 30 + B a 3 10 16 30 * 35 7. 1 7 30 t B= ahah daneter (a yest shan Dat nally ensidere for are clsiienon and ‘Fable $.1(b) - Hazard radii for standard pumps with theotle bushes Tid TEvELT TevELAT eve cateall | Hate seer ap | Heestze Gm) ap | Hasse mm TR tm) a be. 01D Ritmy Le. ODE Rim) ie, 0.3DP_ x 35 3 io @ 30 t B 25 1 6 Fa € 2s i6 i 3 + B= ahah danstor toed DP. = diameter of diechege pipe (mm) t thould bo avoided the neste radius exceods 39m, The slest ie reser dan thal norrallyconedered for aaa casifcation andAREA CLASSI ‘Table $.1(c) - Hazard radii for high integrity pump: 108 CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUICS ,s aa LEVELT LEVEL I LEVEL ehttgsrs Taam Hole size (amy ate size (mm) gory | Holesize(mm) | R,(m) eke R,(m) tose | | a 2 3 10 is 30 t 5 2 4 10 16 30, + © 2 5 © 7 30 t ‘ois igh iiegrlty pra aren ts pumps und with Gouble wal ond tole bon, or Bair DP = diameter of eischag® pipe (mm) 4 For this release, the hacard ratius execs 301m, Thevelemi Is grater than tat normaly coaster fr ara classifstion and should be evoied, 54.2 Equipmentdrains and tiquid sample points precautions are taken to ensure that draining of The hezard caused by equipment drains and sample, points depends upon design, which can include, for (a) open valve disining to the ground; (b) open valve draining to tundish end drain system; (©) velve draining to closed cabinet and drain system. ‘The drain design affects the zone of release. Gaseous sample points or drain points from gas systems should bbe considered as vents. Good practice is to allow for abnormal release if sample valve were to be jam open, for example by double valving For other release points not individually covered (e.g, cleaning or filter changing openings), the classification approach should follow the principles outlined, noting the comparability of the release quantity and STuid category with those of other listed examples and whether the equipment is to bbe drained to an open or closed system. Systems should be designed to avoid draining or sampling of Category A ot B liquids direct to ‘atmosphere, Where possible, such liquids should be cooled before draining or sampling te avoid the release of vapour, Where this is not feasible (e.g. with LPG), equipment drains should be connected to a closed system, Samples should be taken ina closed container such as a sample bomb. When the lines end bonab ere not purged to a closed system there should be an additional hazardous area extending from the pois! of purging (On some process dtains the fluid normally drained is non-flammable, but flammable materiel could ultimately be drained. A typicel example is water draining from a process vessel. The hazardous area should be based on the flammable figui unless flammable liquid is improbable. Suiteble precautions which would reduce the process drain to 3 secondary gtade source of release include: (@ draining into an intermediate drain pots (b) the use of multiple valves on the drain inchuding at Teast one valve which springs closed unless heid open by the operator. 5.4.2.1 Point sources ‘The point sources are equipment end instrument drains, and liquid sample points which relesse flammable Auids direct to atmosphere, 5.42.2. Grode of release Drains and sample points should be graded accordingto the expected frequency ofuse. They should be regarded 4s atleast primary grade sources ifused more than once a day ‘When classifying = drain point used only at shutdown, the fluid estegory should be based on the ‘material at shutdown and the drain should be regarded as. secondary grade source of release. 5.4.23 Determination of hazard radtus ‘The hazard radius may be determined using the tables in Annex C (Part3), However, amore accurate value o hazard radius may be determined using dispersion models which tke into account the actual cheracleristics of process fluid, and the physice 1 characteristics of the drain/ Teble 5.2 shows the maximum hezard redius for fluid categories A, B and C for the “worst cist dischaige pressure given in Annex C (Part 3). (For fai categories A and B the maximum dispersion distance is nal fo the pressure.) smple point 64(CLASSIFICATION OF INDIVIDUAL POINT SOURCES. ‘Table $.2 - Hazard radii for drains and liquid sample points Heard radi Rap aaa Pressure (Bar) umneter ~Diometer iameter Diameter’ category ce oon ers “omm 20am x 166 3 2 FA i 3 ia 5 To 20 t Cc 100 Ts 2 23 t 7 for his dimer he rad ox clastifcaign and shouldbe avoided Som The sine afte potential lene i reales an nary coniared forarea ‘Table 5.3 - Example caleulation for compressors — leak hole size and hazard radius Tiazard radius R (m) Release ea} Type ole Size (mm) se Source ‘Seal Typ Hole Size (mm) on ‘Gai ieee Floating Ring 3 4 6 Purged Labyrinth 2 io 3 LEVEL WA 2 7 t LEVEL NA 70 t t Those hole ies a than shouldbe vt far ares slotifcstion purposes This Code dosent teeta give frzard rao hese hole sizes. The user may dette hs haar ai by clewaten. 54.3 Compressors Piping on compressor systems may be subject to vibration. The distances recommended in this section assume that failure of joints and nozzles due to vibration are considered separately 5.43.) Sources and grade ofvelease Sources on compressors include seals, glands and Joints. However, for the purpotes of ares classification the compressorshould bereganded as secondary grade point sure. 5.4.3.2 Leak hole size and determination of hazard radius Itis recommended that the manufsctucets’ data for seal failure leak rates are used to establish the hazard radius equivslent to LEVEL I release, In the absence of vendor dats Cox, Lees and Ang Classification of hazardous areas suggests an equivalent release hole diameter of 0,12D for a Purged Labyrinth seal and 0,053D for a Floating Ring seal, where D is the shsft diameter in mm (sce Table C6, Annex C). LEVEL t and II] hole sizes arz provided based on E&P Forum data, These hole sizes are independent of seal type, and are considered to be larger failure cases than normally ‘considered for area classification puspos: Having determined the hole size, the hazard radius may be determined using the Tables in Annex C (Part 3). Table 5.3 gives the hazard radii determined by this process for an example case of s compressor witha seal pressure of 100 bar with a shaft diameter of 100 mm for, typical gases described by Categories G(i) end Gti). ‘Any vents or relief valves on flammable material duty, including vents from the seal and ube ol system, should discharge to aclosed system or to atmosphere at f norshazardous location, The hazardous area around the vent should be based on 5.4.4. Similarly, liquid from knock-out drums or pulsation dampers should preferably drain through a vented degassing pot to closed drain system. ‘The hazardous distance for drains end vents should be determined independently of the compressor, based on 5.42 and 5.4.4 S44 Vents to atm sephere 544.1 Determination of bozardous area is recommended that specific dispersion modelling tsing sctual process fluids and venting conditions is sed to determine the vertical and horizontal extent of the hazardous area. For some vents there may be 2 continuous oF primary grade release during normal operstion with aAREA CLASSIFICATION CODE FOR INSTALLATIONS HANOLING FLAMMABLE FLUIDS larger, secondary giade release during ebrormnal or emergency operations, The hazardous area for such a vent is defined by 2 Zone 0 ot | hazardous area corresponding to the continuous or primary grade release, surrounded by 2 larger Zone 2 hazardous area, corresponding to the secondary grade release. The following sections give the hazard radii for unimpeded vents for specific conditions bused on IP Calculations {in support of IP15 (see also Annex C Part 3). Where ‘any impedance to venting exists (e.g, weather plates) the hazard radius is likely tobe greater. [Fthe caleulated hazard radius is grester than 30 m, then the size of release is greater than that wormally considered for ares, classification purposes. 5.44.2 Tank vents Freely vented tanks will allow vapourlair mixtures tobe released in normal operation, The pressure within the tank rises very little above atmospheric. High level vents from tankage should be regarded as @ primary grade source of release with the extent of the Zone 1 hazardous area dependent on the vapour emission rate {or filing rate). For low venting rates under very low or zero wind conditions material may flow down the outside of the vent pipe, [tis therefore eppiopri extend the hazerdous atea beneath the Zone } area down to ground level. However, due to the low fiequency of such conditions occurring this need only be classified as Zone 2, Figure 5.3 together with Table 5.4 gives the hazardous area around the vent from the storage of e typical category C fluid. 5443 Process vents Process vents may release mixtures of lydrocerbons undiluted with air, or gas/vepour mixtures with sir oF any composition. The pressute driving the release witl often be much greater than atmospheric. The hazard radii forprocess vents have been caleulated for amatrix of venting retes and vent diameters for both a lighter and a heavier than air selease and are given in Teble 5.5 to be used in conjunction with Figure 5.3. For specific vent conditions not given ia Table 5.5, actual hazard radii may either be calealated or, for a conservative hazard radius, the hazard redius for the next greater vent size may be used. Pressure ielief valves are not covered in this section because the design should ensure that they are discharged to 2 sefe location, Table 54 - Hazard radius from tank vent for Category C fluid Vent Rate (Nis) 750 500 1006 2500 a ([Gaastian Table (by of IP CalevTaon in seppar FIPS. Table 5.5 - Hazard radius, R,, for process vents 0 Hazard Radius, (a) Yent Demeter mm) 100 r (ening ‘Vent diameter (mm) ‘Vent diameter (mm) 66[CLASSIFICATION OF INDIVIDUAL POINT SOURCES (a) Piney Grade Roose Notes: 1 For process vents, h 2 Ry +2 (mets). be anay fiom open windows, doors ee. 3 4 the vent stack, 5 (0) Secondary rode loose E} ret (6) Vont ts ut regulon ‘Vent pipe opening should have a east R, metres of free space around it in all directions toellow disperse of vapours, and For road tanker delivery systems the height of s vent sbove the working level should be greater than the possible Tquic level inthe rosd tanker to prevent overspill, and in no cas less than Sm above worlcng level “To avoid placing a working platform in a Zone J area, h shouldbe measured fiom eny working level within R, metres of Im (e),R, for Zone | should be forthe primary grade release and R, for the Zone 2 should be for the secondary grade Figure 5.3 - Typical hazardous zone around vents 5.444 Instrument vents ‘The diameter ofthe smallest iter on the vent fine (e.g the line, vent or restriction orifice} should be used to determine the hazard radius, Gaseous sample points should be designed so that the flow rate is less than 10 m'/hr under ambient conditions. it may be necessary to fit a flow restrictor ‘on high pressure systems. Hazard radii may be determined using data given in Table C9(2), Annex C (Part 3) 54.5 Piping systems Piping systems designed and constructed 10 ANSI/ASME B31.3 (SO 15649 Piping) or equivalent and without velves, instruments or significant flanges should not be considered as sources of release. The importance of choosing the correct constructional materials is paramount. In addition, materials for gaskets, jointing compounds, gland packings etc. should be selected, installed and maintained in accordance with the piping materiel specification. ‘Small bore piping systems are particularly prone to accidental damage and possible release to atmnosphere. Support and bracing of small bore connections used for purging, draining, venting, sampling, pressure gauge comiestions injection poins,etc.,shovld beconsidered im eccordance with 1P Guldelines for the management, design, installation and maintenance of smal! bore tubing syste. Pipes smaller than 15 mm diameter should be avoided, Where this isnot possible, 6. on ixstrument systems, tubing with an upstream isolating valve close to the vessel or main line should be provided. ‘The possibility of release due to fracture should be ‘considered for these small lines. They shauld be trested 2s potential drains or vents, Flanges should be designed and constructed in accordance with IP/UKOOA Guidelines for the monegement ofthe integrity of bolted pipe joins.AREA CLASSIFICATION CODE FDI INSTALLATIONS HANDLING FLAMMABLE LIDS ‘Table 5.6 - Hazard radit for flanges and valves Tevet TevEL LeveL i ute Pressure rar aan azar fait | ese Three | ESR Pare | i? [icin | Bd fem) rtm | | rey | | x 10 i 2 z 5 i M4 B 10 7 3 2 5 é a c 100 1 3 z 5 a a a 100 1 7 2 B g 5 Gin io i rota ype i 5.4.5.1 Point sources and grades of release 1¢ majority of flange joints ate rarely broken, eg. only during major maintenance work, ‘ypically at intervals of about two years ormore. Therefore flanges should be considered as sources of secondary grade releases, However, flanges should be regarded as primary grade releases when they are broken during normal operation (eg. for spade changing) where a tolease is likely 10 oeeur or where factors such as pressure spikes, thermal shock, mechanical stresses end corrosion increase the risk of leak. As guide, a flange should be considered as a primary grade release when itis broken with a frequency greater than once per week. Where flanges are broken under normal operation, there should be valves adjacent to the lange to minimise any release. Also, if there ares large number of potential leak sources(es a guide, 50 0 100) inclose proximity (ie. where the Zone 2 areas overlep) the combined hazardous area may be regarded as @ Zone 1 Leakege is unlikely on well-maintained, infrequently used valves and these should therefore be regarded 25 sources of secondary grade release, On frequently used valves (including control valves) with packed glands, whete leakage is more likely, due to weer on the packing, these should be regarded as producing an additional primery grade release with @ romninal radius of 03 ma. For both individual anges and valves, the likelihood ofa release from an individual items is very ly and mey not hazardous, If & risk-based approach is follow individual items may not requite a specific hazardous srea and only when there are a number of possible leak sources together e.g. ata plant be should this area be classified. As a guide, where there are greater than 10 leak sources (from valves or flanges) wit close proximity (2. where the Zone 2 areas overlep) the area should be classified as a Zone 2 area 5.4.5.2. Determination of hazard radivs Equivalent hole sizes for flanges and valves ere given in Table C6 in Annex C (Part 2) for the appropriate level of release frequency. Table 56 gives typical ‘hazard radi based on the upper bound hole sizes at @ pressure of 100 bar, and hazard radii in Table COa), Annex C (Part 3). Actual hazard radii, may be determined using the hole sizes in Table C6 for specific system pressures. 54.6 Pig reeeivers and launchers ‘Operating procedures should ensure that pig receivers and leunchets are isolated from the line and vented down to atmospheric pressure and drained before they are opened, Thus the design of the pig recziver and launcher closure should be such that it cannot be ‘opened while under pressure; this may be echieved by sn interlock with the vent and drain system, end the provision af a properly maintained pressure gauge. Doors om traps and launchers sequite @ stringent inspection aad maintenance regime to ensure they remain leak tight under pressute. Vents and dreins should discharge 10 a safe location and the hazed radius from any vents, equipment drains or open sumps estimated using the appropriate section of this chepter. 54.6.1 Grade of release Pig receivers and lsunchers are likely to be opened {requenily and should normally be regarded as sources of primary grade relaace, The hazardous area should bes clascified as Zone | 3.4.6.2 Determination of hazard rads With an interlock system 25 recommended above, the= openings on the seceiver and launcher should bes regarded as minor release sources aad it is suggeste=t that a nominal hazard radius of 3 m is 3, This coCLASSIFICATION INDIVIDUAL PONT SOURCES distance may be reduced to 1,5 m if the equipment is purged with nitrogen or water washed through before opening, (On pig receivers and launchers without an interlock system on drains, venta and the oor, the probability of ‘release is increased and a prominent warning notice against such a practice should be displayed Nevertheless itcannot be ruled out, hence there should bbe an additionel Zone 2 area from the equipment door. ‘The hazard radius should be determined; Table C9(8) may be referred to as a goide to the hazard radius depending on the possible release size and process conditions. However, note that for equipment an large and/or high pressure lines the resulting hazard radius may well be much larger than that generally considered for area classification. Other precautions such 2 re- designing the system or strictly controlled Work Permit procedures are necessary 8.4.7 Liquid pools due to spillage Plant design should minimize liquid spills by providing tundishes or other suitable collecting points for sarmple points, dreins and liquid overflows. However, inadvertentspills ean occur, and this may influence the Elevation Notes: Ris the extent of the hazardous area from the edge ofthe pool. L'_ is length of the pool inthe same b depends on the temperature of release and the volatility of size and area of an overell Zone 2 boundary. On each facility the positions at which spillage is credible should be identified. If they cannot be eliminated by economically practicable changesto plant design, then the size and position of the likely pool should be estimated. This requires information on the grading ofthe site, the location of collecting points for drains and the position of bunds or collecting walls. Inn open area the resulting hazardous eeashould normally be classified as Zone 2 because plant design should prevent spillage in norinel operation. ‘The size of the hazardous area should be determined from Table 5.7 and Figure 54. These distances are supported by calculations in IP Coleulotions in support of IP15 and are applicable to Category C liquids for temperatures up t0 50°C. For gases of Category A and B liquids the size of the hhazardous area will often be determined by the initial flash vapour release rather than the evaporstion from ‘he on-ground accumulation. The exactextentshould be determined by celculation. ‘Any resultant liquid pool should be considered as Category C liquid. This is because any vapour will already have been released and therefore the liquid pool cannot be boiling. Plan the material released For Category C fils up 0 50°C, his rrominelly 1m; for volatile fluids er at elevsted temperatures, a nominst height h, of at least 3 m should be applied However, itis recommended that this height is verified by caleulation Figure 5.4 - Liquid pool due to spillage Table 5.7 - Hazardous area from liquid spills Tength of pi, 1 Gm) Hiazard radius, Ry (=) Tass than Stoless than 10 Wor greater as 5AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING PLANMAMLE FLUIOS Notes: | TheZone 2is applicable where there is possibilty of seceniry release end the hazard reds R, forthe primary relesse is less dan 1S m Dimensions from Table 5.7 3. depends onthe tempersture of release and the volatility of the msterial released. For Category C fis up to S0°C, bis nominally 1 m; for volatile fis or a elevated temperstures, a nominal height, fh, of at least 3 m should be applied However, itis recommended that ths height is verified by ealcultions 4 Figure 5. 8 Sumps, interceptors and separators For the purposes of this Code a sump means a vessel, open or vented to atmosphere, used to collect flammable liquid usually as a result of deliberate draining. Other liquids, eg. water, may enter the sump bbutthe flammable liquid is normally anappreciable part of the total liquid entering. A sump is usually below ‘ground level ‘Open sumps, interceptors and seperators should preferably be located in an open ares. For vented sealed sumps, interceptors and separators, the hazardous area should be drewn from the vent in accordance with 5.4.4, based on the expected flow-rate Sumps ond vessels covered with eg. ventilated ‘concrete slabs or metal grills, should not be regarded as sealed vessels but should be treated as open surmps. In contras, interceptors and separators are vessels open or vented t0 atmosphere, used to separate flammable liquids from other non-flammable liquid Ceypically water) in which the flammable liquids are not present in appreciable quantity. Typically they ere found on the main ofl/weter effluent system from a facility 548.1 Grade of release Where sumps, interceptors or separators ere intended to contain Rammmable liquids they should be consi continuous or primary grade sources depend Fora secondary grade source the areas shown as Zones 0 and 1 would be Zones 1 end 2, ‘Open sump ~Zoning shown for primary grade source Frequency with which flammable material is expected to enter. ‘They may be regardedasa secondary grade source ‘when flammable material enters infrequently e.g during major maintenance at intervals of about two years oF longer, or as 2 result of equipment failure e.g. tube failure in a cooling water system or in a major spillge. ‘The possibility of more frequent, unplanned maintenance should always be considered, Where there is a possibility that, in normal operation, appreciable quantities of flammable g2s of materials in fluid Categories A or B can enter, 2 ‘degasser installed upstream cf the suinp or ¢ sealed but vented sump is recommended. Otherwise the system should be designed so that normally only oil in Category C below 50°C ean enter: $48.2 Determination ofhazordous area ‘Thetypical layout of sumps interceptors and separators isshownin Figure 5.5. The space within the walls ofr open sump or to ground level, whichever is higher, should be regarded as an enclosed erea, For a primary gad source of release it should be classified as Zone Oand fors secondary grade source of release as Zone | ‘The hazardous ares ebove ground and outside the= valls should be drawn as shown from the= periphery of the "sump" using the appropriate hazard radius R, obtained from Table 5.7 where it can be= assumed that entry of Category C fluids only (belowCLASSIFICATION OF MDIVIOUaL POmNT SOURCES 50°C) can occur. Generally this assumption can be ‘made only in the ease of installations such as storage and tankage areas, This area should be classified as Zone | or Zone 2 depending on whether the source is primary or secondary grade. Where there isa possibility that a hot material (eg. Category C fluid above S0°C or steam condensate) could enter the sump in sufficient quantity to produce sn appreciable Samnmable vapour, or that Category A or B material could inadvertonily enter, a hazard redivs Ry of at least 15 m should be used with an increased vertical distance of 3 m. 54.9 Pits or depressions ‘Where a pit or depression exists in a hazardous arcs, without itself containing a source of release, i should be regarded ac inadequately ventilated and therefore classified as Zone 1 5.4.10 Surface water drainage systems Oily water and chemical sewers can become contaminated with flammable fluids during normal operations, and openings to atmosphere should therefore be regarded as sources of primary grade release Open drainage systems handling flammable materials can be teated conservatively as elongated sumps in accordance with Table 5.7 ‘The vaporisation rate from any vents on drain systems should normally be low and a Zone 1 hazardous area should be drawn in aczordance with, Table 5.5 assuming a vent rate of rot more then 10m!fur st ambient conditions The possibility of abnormal releases (eg. hot water) entering the drains and the vaporization of volatile liquids should be considered, Based on this it ‘ay be appropriste to define alarger Zone 2 area using dimensions given in Table 5.5 consistent with the higher vapour emission rate, ‘The possibility of vapourrelease should always be considered when manhole covers are lite temporarily removed Note: Drainage systems should be consideration given to the principfes Environmental guidelines for petrolewn distribution installations. Inthe ease of service stations, the design should be in aceordsnce with IP Design, construction, modification and matnenance of pete! filing stations. 55 SHAPE FACTORS AND HAZARD RADII FOR PRESSURISED RELEASES ‘The relationship between the hazard radius R, (as determined in the preceding section) and the full 3- dimensional envelope of the hazerd zone is determined using Figure 5,6. The shape factor depends upon the height and orientation of the release and the hazard radins. The key features are: — Releases below a height (H) of 1 mare influenced by the ground and have a hezard radius Ry —— Releases above | m, but at heights below the hazard radius Ry + | m sre influenced by the around if the release is directed downward and passes below I'm. — Releases ata height above the hazard radius Ry + 1 mare independent ofthe ground “The ground effect radius R, can be estimeted from the hazard radius R,, using the relationships given in Table 5.8. A more precise value of R, catt be found in Table ‘€O(b), Annex C (Part 3). The ratio Ry, decreases as release pressure increases due to improved mixing. Table $.8- Quick estimator for the hazard radius at ground level, Ry. RR Fluid Category Tow High pressure | _pressore x 30. 22, B 26 20 € 35) 2.0 Gia 1d | ei 3 id [fable Sof Catevevons temper‘AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS round tm Ir Ground t t i (0) Relesses whore Hs 1 (c) Ralaases where H= Ret Figure $.6 - Shape factors for pressurised releases6 EFFECT OF VENTILATION ON HAZARDOUS AREA CLASSIFICATION 61 INTRODUCTION Ventitation comprises the movement of air within and through a volume t© achieve the introduction of fish ait into, and removel of conisiinated air fiom the volume, and the mixing of air and contaminants within the volume. Gas or vapour released to the atmosphere eventually be diluted by dispersion in free air until its concentration is ata safe limit (below LFL). The time talcen for this to occur end the size and spatial location ofthe gas cloud depends upon the nature of the release, the vapour properties such as density relative to air, the movement ofthe air and the presence of turbulence 10 promote mixing, Where the release is not into ‘completely free air (i.e. not into an open area) then i air flow, of ventilation, is also a fector in determining the rate of gas oF vapour dispersion. However, itis important to also consider, ita sheltered or obstructed open area or enclosed area, whether any recirculating motions may lead to a gradual accurnutation of gas oF vapour over time, The processes of movement of air and remnaval of contaminated air occur, to differing degr ventilation process. The limiting eases are — Efficient displacement without mixing, Here 2 contaminant is swept out of = volume without much mixing, This is sometimes referred 10 as ‘dieplncement ventilation’. By inference, high ccancenirations of contaminant may exist within the volume and be emitted from it Gradual displacement with good mixing. Here any ‘contarsinant is well-mixed through the volume. A Jorge part or all of the volume can became contaminated, while displacement removes the mixture oF air and conteminant. A specil case of this is sometimes referred to as ‘dilution tiation. Whatever the situation, the ventilation of a confined space is typically quantified by a single parameter - the umber of air valune changes per hour. Ventitaton is 2 complex subject and in earrying out an assessment it is necessary to consider both the type of ventilation and, ‘within the type, the level of ventilation to be provided, its degree of reliability and the consequences of its failure. These considerations need to take account ofthe potential size of release and the affected volume which may bea subdivision of a larger volume, for example @ bay in a large warehou: The different types and levels of ventilation are deseribed the sections Open A Enclosed A which cover the subdivisions of 'outdoor’ and ‘indoor’ -ventilaion used In other Codes. Figure 6.1 may be used. te determine how to any given situation.AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMEGABLE FLUIDS Determine type of area to be classified by Inspaction af Installation layout and process details. ‘Open Area Open air conctions en oi con Enclosed Area. “Ds ea trequerlly>2.ars02,) G2 Anse | ey. | Meihere> 12 aches ety natal cease, [_ves_| “Srmoverontovoriha whoo sem natural wind e334 ‘enttaton? 33 . | Does enctosed arse Consider general or local sont nenal fife vantiaton Ca raeeee! Yes 41.7.2 and 6.3.3 Na 5 ox] [/ iesemalsouce | poss venation aytem give» 12 crascutoes gana, | —— ‘outside pressure of Sone 7 e233 ver ‘Are thre alien a Ghanges to ave dtion iol | ventaton et atigion ves fources? 83.9.2 Nes Ne Open Area] [Sheltered] [Encioned ] [Enciosed ] [Enclosed | [Enclosed wea ‘seat post ‘ree "ares Noturat Restricted Neon Inadequate | | Adeguste aitution entation Sawai’ | [Haztrdous| —fyontiation | | Ventlation | | Ventilation Ventilation e338 622 ee 062 62 64 and 6.6.3 Table 64 Tables 6.1 ‘Tables 6.1 Table s2 womessin| | “and82 and 6.2 ial Sree ties not covered by Chapter Figure 6.1 - Determination of ventilation for faci SortEFFECT OF VENTILATION ON HAZARDOUS AREA CLASSIFICATION 6.2 OPEN AREAS An open arca is defined as an arca that is open-air without stagnant regions, where vapours are rapidly dispersed by wind and natural convection. Typically, air velocities will rarely be less than 0,5 metres per second and will frequently be above 2 metres per second. ‘The area classification exercise is simplified if all continuous and primary grade sources of release can be located within open areas. However, obstructed ot partially obstructed situations cannot always be avoided in the layout of facilities, particularly where there is @ space limitation. The advantages of considering area classification at an early stage of plant design are covered in section 1.5 6.2.1 Natural ventilation tion is caused by wind or convection pect of ‘natural ventilation’ IEC 60079-10 (8) Open air situations typical of those in the chemical and petroleum industries which compris? open structures, pipe racks, pump beys ete, Notes Ry isthe hazard radi brained from Chapter 5. (&) Open buildings which, heving regardtotherelative density ofthe gases and/or vapours involved, have openings in the walls and/or roof so dimensioned and located thatthe ventilation inside the building for the purpose of area classification can be regarded as equivalent to thet in an open ait tation Where a facility is classified as an ‘open area! with adequete natural ventilation, the area classification avcording to Chapters 3, 4 and 5 apply without further ventilation considerations. 62.2 Obstacles to free al movement TEC 60079-10 recognises that obstacles may impede natural ventilation, and this may enlarge the extent of the zone and possibly increase the severity of the zone number. However, itis also noted that somve obstacles such as dykes, walls and ceilings may limit the movement of gaseous release, reducing the extent of the zone, Examples of this use of ‘deflection wall’ are provided in 6.2.3 ‘Source ofrelasee 1 2. The wall should extend to at least the full vertical height ofthe hazstdous area if itis to be wsed asa defection wall 3. Sie the shortest distance from the source tothe edge of te reuning wall Figure 6.2 Extent of hazardous ares around wall producing sheltered areaAREA CLASSIFICATION COOE FOR MISTALLATIONS RANDLING FLAMMABLE FLUIDS 623 Effect of a “fire or deflection wall’ on open area hazardous zone Where limitation of space will not allow @ source of ignition (electrical or otherwise) tobe located outside hazardous area, the alternetive may be to separate them with an imperforate firewall. This would be sized so that the equivalent vapour travel distance around the ends of or above the wall will be atleast equal to the straight line distaness derived fiom the standard assessment ofthe hazard zone dimensions. This widely used rule of thumb is ilustrated in Figure 6.2. It has no formal technical basis, and its adoption reflects an engineering judgement or assessment Such a deflection wall should be constructeg to an adequate fire resistance standard and be located so esto minimise the flame engulfient of facilities containing a significant quantity of flammable materia, and may form partof the site boundary or the well of a building. ‘The well should be on one side only of the facili containing the source(s) of release, allowing free ventilation in all other directions. Examples ofthis application include the bund wall scound e tank compound (as in Figures 3.1 and 3.2), the reduction of separation distances as in LPG facilities, the separation between power-driven equipment and process oquipment by a gas-tight wll with a drive shaft seal (Chapter 8) and numerous cases in the compest circumstances of an offshore platform. 624 Buildings adjacentto open hazardous areas A building may contain no interna! sowices of release, but have openings direct into an adjacent open classified area. If the openings are not 100 large, ventilation with fiesh air forced into the building may allow it to remain unclassified. In any case arrangements that will ensure vents, doors ete. cen be closed promptly following a release in the open area should he provided. The altemative is to assign the building the same zone number as the adjacent area or higher zone if itis possible for any leakage to persistin the building (see Table 6.2). 63 ENCLOSED AREAS ‘An enclosed atea is any building, room or enclosed space within which, in the absence of artificial ventilation, the air movement will be linsted and eny flammable atmosphere will not bs dispersed naturally This section applies to buildings, rooms or enclosed spaces where there are potential sources of release of flammable vapours or gases, but natural ventilation does not provide a minimum of 12 ait changes/hr throughout the space. Normally, ertficial ventilation (ie, mechanical ventilation) would be piavided in order to difute and remove flammable gases ‘or vapours released within the building. In most eases there will also be openings inthe walls, through which flammable gases may migrate as @ result of draughts, convection currents, or disturbance caused by cequiprent within the enclosed area Itis generally easier toensure that flammable gases removed froman enclosedarea are diluted and released safely ifthe ventilation system is designed to extract sic from the building. In this case, itis elso possible to monitor the air exhausting from the building, and fo talce additional precautions if flammable gases are detected, Enelosed areas are further qualified by various levels of ventilation, ie. adequate, inadequate, dilution and over-pressure 63.1 Adequate venti ‘Adequate ventilation, natural artificial ora combination ‘of both, is not fulf ventilation as typified by an open ares, but i a ceference condition used extensively and defined in a number of Codes worldwide and particulary offshore as the achievernent of @ uniform ventilation rate of at leet 12 sir changes per hour, with no stagnant area!. As such it will usually tiave air velocities lower than inn open area. A ventilation rate of 12 air changes/hris likely to be sufficient, ifthere are fo stagnant regions, to ensure that the flammable atmospheres arising from an improbable short term release of gas or vapour will nt persist for longer than about ten minutes, The extent of the flammable stmnosphere thet will exist during the release from a Tow momentum source can beestimated using the equations given in TEC 60079-10 or by specialist calculations, as appropriate The objective of adequate ventilation isto ensure that the building can be properly classified as Zone 2 tn large buildings it may be possible to classify son parts as nion-hezardous, while other parts ate Zone 2 Continuous or primary grade releases slould not be discharged internally, butshould be piped drecily toan extemal safe location dhraugh ducting, With suitable ventilation design, any areas of Zone | should be of very limited extent Although adequate ventilation is defined by the 12 air changes per hour criterion it must be remembered[EFFECTOR VENTILATIONON HAZARDOUS AREA CLASSIFICATION that the hazard zone that wilh be formed is also dependent on the size of the release and the building volume directly affected by the release. In small buildings, 12 air changes/hour ean often be achieved simply by providing sufficient ventilation openings, at high and low levels, and in more than one wall of the building. With larger buildings or structures artificial ventilation is often needed to achieve 12 air changes, and where this is provided, careful design and balancing of air inlet or extraction points is needed to ensure no stagnant areas exist. Measurements made after the ventilation system is installed may be nesded to check for stagnant areas, and the tests may need ta be carried out both on an empty building, and after lerge items of plant, or stocks of products have been introduced. With very large buildings it may become impracticable to provide artificial ventilation to achieve 12 air changes/hour; itis certainly inefficient to blow very large amounts of air around constantly, simply to deal witha small secondary grade souce ofrelease that may occur quite infrequently. An altemative approach is needed, and the best solution will depend on the ‘number, location and probability ofthe secondary grede sources of release occurring. Localised exhaust ventilation (LEV sez 6.3.3.1), gas detection or other means of prompt identification of releases of flammable materials should be considered. No general guidance can be given about the size of bul that suit these three alternatives, as other factorssuchas, the prevailing wind conditions atthe site and whether the building is heated also need to be considered If hazardous concentrations are crested within & building then there is the potential to produce @ hazardous zone outside of the building. An extreme ‘worst case scenario is for the whole building contents, to reach a hazardous concentration. There may then be the potential for ignition to occur externally to the building, producing a flame that bums back into the building creating @ confined explosion within the building. itis therefore essential that the potential for g0s build-up to, say, concentrations above 20% of FL bbe avoided within the bulk attmosphere in the building. In g building with a well-mixed atmosphere into which 2 constant flow of flammable gas is released, 2 siruple calculation allows the steady state concentration of gas to be calculated. Ifthe release is intermittent, or controlled before the steady state concentration is reached, the maximum gas concentration will be less. ‘The minimum ventilation flow rete required to ensure that concentrations of above 20% of the LFL ate not produced cen also be estimated by similer methods from the size of the release and the lower flammable Timit of the ges. The recommended design target is to ensure that the average concentration of flanumeble atmosphere within the building doesnot exceed 20% of the LFL in the event of a prolonged release from 2 secondary grade source. The zoning external 10 the building should take account of the location of release points relative to openings. Where it is possible for a Telease to be directed through en opening the hazard radius should be atleast R, as determined by Table COs and may extend to R, in the event of interection with the ground. In cases where the release impinges internally within the building, specialist advice should be sought because :he outcome may bebuilding release ‘and material specific. It is possible that, in certain circumstances, there is no need to assign a hazardous area beyond any openings in the building, unless the opening is within the local zone immediately sumounding the release location. However, it is recommended thatspecialistadviceiis soughttoconfirm this i the case Ventilation rates greatly above the terget 12 air changesthr are likely to cause discomfort to operators ressed for indoor conditions. A buildingsized 1000 m* and having ventilation design that encouraged mixing, of the release, rather than displacement, would experience a problem in that significant regions of flammable mixture may arise for releases of about 0,03, gis and larger for Category A, B and G(i} fluids and about 0,01 kg/s and larger for cetegory Gti) fuids. 1f foreseecble secondary grede sources of release exceed thre values, the design of the whole installetion should be reviewed. For a G(i) fluid this release rate comespands approximately toa 5 mm diameter hole in 4 line at 10 bar; the corresponding figure for a GC) fluid is 2 5 mm diameter hole ina line at 50 bar. Leaks of this size should be detected promptly. Category C fluids will generate locslised Zone | areas around open liquid surfaces, anda larger Zone 2s often assigned as ‘well, but it may not be necessary to classify the whole building as Zone 2, especially if there are no sources present in the upper parts of the enclosure. 6.3.2 Inadequate ventilation Where an enclosed area is not provided with artificial ventilation, air movement is likely to vary substantially, and no general assumptions can be made about the mixing of @ release. Continaous and primary grade sources of release should be avoided in such en area Inadequately ventilated areas should be olessified as Zone | since a secondary grade source may form a localised flammable atmosphere and persist for tong,AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS periods, Inadequately ventilated areas should be avoided, ~partiowaily where personnel acce: to the UK Confined Spaces Regulations 1997 St 1713, ‘These requize, in addition to the controls on entry, the provision ofairangements for dealing withemergencies including rescue froma confined space and equipment to enable resuscitation. If ventilation cannot be the use of flammable ges detectors should be considered (see section 8.16). When these are installed it should not be possible for any substantial volume of flammable atmosphere to forin and persist undetected allowing safety measures to be taken, as an ignition ‘would be very hazardous. If fixed gas detectors are not provided, access should be controlled, and testing ofthe atmosphere before entry should be required 6.3.3. Ventilation options ‘The assumption of good mixing is likely to be reasonable for releases from pressurised sources, which entrain air into jet, For releases with low momentum, very careful design of the air extract points may be needed 10 ensure good mixing is achieved, Meesurement of localised air movement within the building afterall equipmentis installed may be needed. Hf exteactive ventilation is used, the outlet should normally be et high level, and in paiticuler it is important that it is sited so thet recirculation of flammable gases bacle into any other building or structure Is aot possible, even under very still air conditions, If ventilation is achieved by blowing fresh air into the building, diluted vapours will escape through all the openings. The flows are likely to be influenced by wind and convective ferces. In any cese, provided the atmosphere inside the building does not teach the LFL and the local zones around the source of the release do notreach any of the openings, this should not [ead to the formation ofa hazardous area around the ‘outside as a result of release sources inside. Where Category B or C fluids can be released, these mnay flow in liquid fonmtowards any openings out of the enclosed ares. Suitable drains and silis are needed to prevent the flow into non-hazardous areas Normal doors, including fire doors are not likely £0 prevent such flow. 3.1 Local exhaust ventilation Local exhaust ventilation (LEV) is e recommended means of controlling the release of flaramable geses to the general stmosphere, where there are asmall number of readily identifiable primary or secondary grade eqqired subject —point-that-is-regularly-tsod;-erownd equipment. B sources. This is a common situation, including for example: a joutine drum filling operation; # sampling needs regular opening for cleaning LEV systems can only effectively capture released gases and vapours over quite short distences, determined by the inlet velocity and correct design of the inlet, Factors that need to be considered when the system is designed include: the rate of release, the momentum of the gas flow, any air movement Gu 0 general ventilation nearby, and the position of the ‘operator. Capture velocities in the ange 0,5-1,0 n/sare typically used for releases at low velocity into rmoderetely still air. The concept of air change rates does not apply to the design of LEV. With a suitable design, LEV should prevent any Aamnmnable atmosphere formigexceptin the immediate vicinity of the release source. An enclosed area may then remain unclassified, even though primary grade souirces are present. More commonly it will be Zone 2, {o allow for various possible secondaty grade sources. ‘Where primary grade sources ave present, an audible of visual waming should be provided if the LEV systernis not functioning correctly LEV may also be provided to control secondary grade sources that are generated by operator action eg. sample points, In this case, the extraction may only need to operste during the sampling operation, Some tneans to ensure the LEV isalways operating when itis needed is required. 63.32 Dilution ventilation In some restricted circurnstances, « very high low of tic applied to a space, perhaps within some larger enclosed area, may be used to dilute and remove mucta larger releases than thase controlled by LEV. A force draft fan may be used in conjunction with an extract fan. This arrangement has been used inside the acoustic hhoaes for gas turbines, where the complex pipeworl.< provides meny potsntial sources of release, but thee inition source created by the hot surface ofthe turbin-e be prevented. The objective is to dilute even quite lerge releases very close to the source, so thest jenition cannot ozour. The maximum size of release t © be controlled needs to be carefully essessed and each installation will be different, so generalised advice o-n ventilation rates cannot be given, See section 8.2.5 for further information on gas turbine drives. 6.3.3.3 Overpressurisation “This term is used 10 describe e system of ventilation forEFFECTOOF VENTILATION ON HAZARDOUS AREA CLASSIFICATION 4 room or other enclosed area, and also a protective ‘method for a single item of electrical equipment. ‘Where it is applied to a room, it may allow a room that contains no sources of release to be classed as non- hazardous although it is connected to another room classified as Zone 1 or Zone 2, or allow a room surrounded by & Zone J to be classified as Zone 2 if it contains only secondary grade sources of releate. Where it is applied to a single item of equipment, or & ‘group of equipment items inside « single well-realed cabinet, it is designed to prevent ingress of flammable a5, and hence prevent the formation of « flammable atmosphere inside. This technique may allow electrical equipment that is unobtainable in an ignition-protected form to be insttled in a hazardous ares. it isa form of rtficial yned so that a pressure Gifferentil ofat least SON/n* (Smm WG)is meintained between the enclosed area and sny hazardous ares. Warning, preferably audible and visual should be provided for loss of pressure differential. 1f direct access is provided between the pressurised area and a Zone | area, airlock doors should be instslled between the ateas and classified as a Zone 1 ares Section 6.6.3 gives advice on other actions thet should follow any failure of the ventilation system. AS air locks may ellow pressure differentials to be briefly lost, some delay on the activation of any shut down of electrical equipment may be considered. Such 2 delay following an eudible alarm should not normally exceed 30 seconds. Detailed requirements for the application of pressurisstion to electrical apparatus are described in BS EN 50016. This distinguishes between static pressurisation, where the inside of the apperatss is held above the pressure of the surroundings, pressurisation with leakege compensation, and pressurisation with continuous flow ofthe protective gas. Itrequiresthe use of an inert gas for static pressurisation, The standard sets requirements for equipment to be used in Zone 1 A variation of this, which will specify less rigorous requirements for equipment that will only be used in Za is under active development by the international standards bodies, 633.4 dlr intekes and exhausts ‘The location of ar intskes (including intakes to: heating and ventilating systems; air compressors for istrument, process or breathing air; 2s turbines) should be chosen to avoid transfer of a flammable atmosphere to a1 ignition source, Air intakes should be located as far as is reasonably practicable from the boundary of any 9 hazardous area, The location should be selected after considering the effects of (2) Air contamination with flammable material (b) Any additional safety systems, e.g. equipmenttrips fon detection of flammable material ia the air intakes. ‘The exhaust outlets of heating or ventilation systems secving installations classified as hazardous should themselves be classified appropriately. 64 SHELTERED OR OBSTRUCTED AREAS A sheltered or obsitucted area is defined a5 an area within oF adjoining an open area (which may include = partielly open building or structure) where, owing to obstruction, natural ventilation may be less than in & tree open ares. The area classification exetcise is simplified if all continuous and primary grade sources of release cen be located within openareas. Thereare, however, a variety of naturally ventilated situations where the assurnption of minimum wind speeds given in IEC 60079-10 for an open area (i.e, wind speed rarely less than O.Sm/s and frequently sbove 2 mis) may not apply, but air change tates are adequate and will be much greeter than those found inside enclosed aress or even well-ventilated buildings. It should be noted that air movement may be funneled selectively in particular directions due to the layout ofa facility. Typical examples include: closely- spaced pipe racks within open air plant; within structures having @ roof but only partial wells (compressor houses, road tanker loading areas); open air plant where air movement is obstructed by large tanks or walls; tank bunds and below-grade areas such spits and pipe trenches. In such locetions, neither the classification by direct example (Chapters 3 and 4), nor the classification by point source method (Chapter 5) may be appropriete (although some of the direct examples do include sheltered areas), With partial buildings, wind-flows pastthe building will ereateareas of high turbulence and rapid dispersion of releases, patticulerly around the edgesof the building and above rooflevel. The extent of any classified area beyond the boundasies ofthe buildingneed not be greater than that caleulated using the method in Chapter 5. ‘The hazardous extent around sources of ges at pressure in the open air is natso affected by windspeed because releases at high pressure induce theit own mnixing, The hazardous extent of a release ina shelteredAREA CLassisicar N CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS ‘area will be of a similar size to that in the fice — conditions, precautions need to be taken ifthe vepours atmosphere provided that there isa sufficient supply of or gases ate denser than air (categories A, B, C) or air to remove the diluted mixture from the lighter then air (categories G(), Gli) to ensure that neighbourhood of the release and there are no directly there is no scope for vapour trapping at floor/roof level enclosing surfaces to encourage recirculating motions respectively because the density stratification can for retain the diluted mixture, Provided the surrounding seriously impede local mixing rat atmosphere dozs not contain concentrations above 20% ‘The use of a wall to restrict the extent of @ of the lower flammable limit, the zone around high hazardous area in particular direction and so increase pressure gaseous releases will not be grester than twice the effective distance between a source of release and a the zone size in free air. [any mixture accumulation source of ignition is covered in 6.2.3. does occur, however, then the zone size may be ‘Wherea sheltered area thathes n0 source of release increased through the re-entrainment of gas mixture adjoins horizontally @ classified open area, it should slong with the air. Releases from low pressure or nonmelly be given the same zone number as the evaporation sources ere dependent upon the ventilation adjacent atea. This would particularly be the case ifthe flow to induce mixing as wellas transport. Under these sheltered ares is surrounded by 2 classified open aret. ‘Table 6.1 ~Enclosed area with an internal source of ralease - effect of ventilation type on zone Grade of ierhal ‘Type of ventilation release veeese | inadequate | Adequate” ae Over-pressure Continuous | Zoneo™ Zoned” Wonhezardous | Nat applicable where there is en internal primary or eeatinsous grade of release, but Primary | Zone!” Zone Non-hazardous | may be applicable in conjunction with tideqvate ventilation to maintain an enclosed Seeondary | Zone} Zone? Non-hazstdous | area containing only secondary grade releases 1s Zone 2 when surrounded by a Zone O oF | Tar 1. Location of eontinuoas or primary grade sources within an enclosed area isnot aezeptble practise and should te avoids avdequte venation, fora ouice within an enlosd ar the exleraal zone larfctin willbe: Fr continues grade eles: Zone fora primary pede celeas: Zone I; fora secondary grade release: Zone 2 aque vnilation, for ®eparse widan enclose es the extmal zone 7 4 See 6.332 Dilution vention 5 Amarea within a lnrger enclosure sje tloel anita venation, ie by extato fan shoul be cls osorcing oth ace) ‘ventilation rate in that local area, je ele dilaton or aguas depencing on wiih met & —Witha source of small hrzard ras, g a snmp pin te venilaonWoesly can sometimes be high xough o preven the zouce influencing the elesification ofthe whole enclosure There would ui ea leal Zone | or 2 around the source and hs extent of his {ation wil be the ras tatof he encased ‘zane should be greater than i sh open alr, pity bout ice the dimensions 80[EFFECT OF VENTILATION ON HAZARDOUS AREA CLASSIFICATION Table6.2- Enclosed area with no internalsource of release but adjacent fo an external hazard zone- effect of ventilation type on zone Grade of "Type of ventilation external Taliaie ssaroh Inadequate ‘Adequate Dilution ‘Overspressure™ Coniinious, Zone Zone ‘Nat applicable Won-hazardous with i.e. Zone 0 source outside enclosed Primary, Zone 1" Zone |" [Not applicable ‘rea, buts file mode ive. Zone (662) Secondary, Zone 1" Zone 2 ‘Not applicable i.e. Zone? War 7 |. Location ofan enclosed arn without overpressure potetion ins Zone O oF 1a not acceptable prctice and shouldbe avolde 2 Aninadequataly veailtedenclsad sree withinenestemal Zone 2and not containing rouref leas may soretimer be casted Zone? when the enlyaperur iss selFclosing vapau-tlght doc. The requeny af dsr opeingend the vetlaion evel mast be considered ase thers, 65 EFFECT OF VENTILATION ON THE HAZARDOUS AREA CLASSIFICATION OF ENCLOSED AREAS Section 6.3.1.1 considered the objective of providing artificial ventilation to enclosed areas ie, those confined volumes in which naturel ventilation provides tess than 12 air changes per hour throughout the whole volume. The consequences of releases in these ‘enclosures were briefly discussed, The purpose ofthis section is to define the zone ratings that should be applied in such enclosed areas. The rating depends on the degree of ventilation and the grade and location of the release. Table 6.1 considers the zone ratings for enclosures containing sources of release within the volume, whilst Table 6.2 considers the zone ratings for enclosures that do not have internal sources of release but that are adjacent to other hazardous arees, ersing from extemal sources. Figure 6.1 provides 8 flow chart that defines when the different categories of ventilation apply. Attention is drawn to the notes to this Table, in patticular to Note 1. Continuous grades of release in enclosures are not acceptable practice unless small with local artificial or dilution ventilation, and primary grades should be avoided ss far as is practicable or ade a5 small as possible. This zoning would be applied to the whole of the enclosure, with the exception of the situation in Note 6, in which the zone created by a release is small in relation tothe size ofthe building, and sufficient ventilation is presentio prevent accumulation above 25% of the lawer flammable limit of the bulle atmosphere, Under these conditions, local a zoning may be allowed. Thesitustion when there areno internal sources is specified in Table 6.2. The footnotes ‘o Table 6.2 explain the reasoning forthe differentzone classifications. 6.6 THE EFFECT OF LOSS OF VENTILATION ON THE AREA CLASSIFICATION OF AN ENCLOSED AREA In enclosed areas with artificial ventilation, the classification guidance given in Tables 6.1 and 6.2 is based on the specified ventilation operating effectively. If this ventilation were to faibthe classification situation ‘would revert to that of inadequate! ventilation in these tables, hence it is necessary to consider what measures should be taken to prevent this occurring, or what additional back-up systems are needed. The ventilation system should be designed to be reliable, with, for example, autometic start-up of a standby fan in the event of primary fen failure. Power far the main and standby fans should not be from a common supply. However, whilst total ventilation failure is unlikely tis foreseeable and the actions required are considered below. 6.6.1 Provisions for loss of adequate ventilation ‘An enclosed area classified as Zone 2 by virtue of adequate ventilation normally contains only secondary sgrade sources of relesse andlor openings into Zone 2 areas. It may sometiries contain stall primary grade scurces, On loss of adequate ventilation there will notAREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMIARL necessarily be an immediate development of @ flammable atmosphere and it may be considered acceptable, subject to monicoring ofthe atmosphere and of plant conditions, to continue for @ chort period to operate equipment only suiteble for Zone 2. Nevertheless, there should be an audio-visual alarm to indicate ventiletion loss and a written procedure to caver both the degree of monitoring necessary and the action tobe taken if mechanical ventilation fils. Fixed {gas detectors should normally be provided. Equipment not suiteble for Zone I should be electrically isolated immediately if gas is detected, or the source of the release stopped if more practicable. A master switch is normally provided to facilitate the electrical isolation when necess 662 Provisions for ventilation the loss of dilution Anenclosed area clastified as non-hazardous by virtue of dilution ventilation normally contains primary grade sources of release and may contain small continuous grade sources. If dilution ventilation is the basis of safety, an automatic switch-over to a back-up power supply must be provided. The back-up supply must, as minimum, operate for sufficient time to enable the planttobe shut down, An audio-visual alarm should be provided. 6. 3 Provision for the loss of over-pressure ventilation An enclosed area with over-pressure ventilation is separated by vapour-tight barriers fiom adjacent hazardous areas and contains no continuaus or primary grade sources of release. On [oss of over-pressure ventilation, therefore, the development of flammable atmospheres within the area is likely to be slow and it EFLUIS is not normally necessary immediately 10 isolate electrical equipment, Nevertheless, there should be an audio-visual alarm fo indicate ventilation loss and a ‘written procedure to cove the electrical isolation that ‘would be required if the ventilation loss persisted. A master switch is normally provided to facilitate the electrical isolation when necessary. In general this should be applied to any equipment not of a type of protection suitable for use in the adjacent hazardous area. Fixed gas detectors should normally be provided. Equipment not suitable for use ina Zone | area should be electrically isolated immediately if ges is detected, 6.6.4 Reliability, location and choice of fixed gas: detectors ‘The need for fixed gas detection to monitor, larm and, 4s appropriate, initiate shutdown has been sited inthe preceding messures for protection against loss of artificial ventilation by dilution ventilation or pressurisation. The comments in section 83 are pettinent. In view of the difficulties in regard to the accuracy of some gas detector ypes,spevslist guidance should be sought in respest oftheir selection and siting, and also the choice of slarm settings {in sore cases these may be as low as 10% LEL for audible slacm, with a second trigger, say, at 50% for shutdown). It= nay wel be nacessary, to avoid false indications nd possible inadvertent shutdown, to epply coincidences Voting arrangements where monitoring is carried out employing three detestors in which operation. of an detector at low level will sound an alarm and where= coincidence operation of two out of the three at high level will activate the shutdown Stshiould be noted thet gs detectors are not intrinsically safe and must bes cerlfied for the groups of gases in which they will operate, Bath gas group and temperature cless musi baw specified (see Chapter 7).