HAZARDOUS SOURCE LIST

By- Mayank Gupta (Process)

OBJECTIVE

•Basics of hazards present in a Plant

•Developing the overall picture about Area Classification

•How to prepare Process input- Hazardous source list

CONTENT & FLOW OF PRESENTATION

•Understanding: Hazards & Hazardous Area

•Why classification?

•Hazardous Substance Classification

•Hazardous Area Classification

•Codes and standards

•Hazardous Source List- Hazardous Area Demarcation

HAZARD AND HAZARDOUS AREA (1/2)

•A hazard involves something that could potentially be harmful to:

I) Life,
II) Health,
Health
III) Property,
IV) Environment.

•Major types of Hazards:

-Physical: Radiation, Electrical hazards, Unguarded moving machinery etc.

-Chemical: Depends on physical, chemical and toxic properties of chemical.

Flammable materials and explosives come under this category.

-Biological: Bacteria and viruses, insect bite, blood and other body fluid etc.
HAZARD AND HAZARDOUS AREA (2/2)

•Which Hazards we are going to address here

•API 500
500: Hazardous
a a dous (o
(or cclassified)
ass ed) Area
ea (o
(or Location/Space)*:
oca o /Space)
“A location where fire or explosion hazards may exist due to flammable gases
or vapors, flammable liquids, combustible dust, or ignitable fibers or flyings.”
•These
These terms should be considered interchangeable terms designating a three-dimensional
three dimensional space.
WHY CLASSIFICATION?
•Explosion Protection:
WHY CLASSIFICATION?
•Explosion Protection:

To suppress explosion possibilities (to eliminate dangerous atmosphere)

- To deter ignition
g of electrical equipment
q p
- To deter and prevent leaks and lingering of explosive gases
- To provide appropriate ventilation
- To inactivate facilities (use of N2, CO2)

* However, it is important to keep in mind that, out of the three elements of

explosion, reinforcing electrical facilities against explosion is the easiest means
to prevent an explosion.
WHY CLASSIFICATION?
•Explosion Proofing:
HAZARDOUS SUBSTANCE CLASSIFICATION (1/5)

•Flammable and combustible liquids (NFPA30):

Flammable liquids (Class I liquids), such as gasoline, are defined as any

liquids having a closed-cup
closed cup flash point below 37
37.8
8 °C
C (100°F)
(100 F) and a vapor
pressure not exceeding 276 kPa (40 psia) at 37.8°C (100°F).

Combustible liquids (Class II and Class III liquids), such as kerosene and
diesel fuel,
f are defined
f as liquids having a closed-cup flash
f point at or above
37.8°C (100°F). Class II liquids are combustible liquids having flash points at or
above 37.8°C (100°F) and below 60°C (140°F).
Class III liquids are combustible liquids having flash points at or above 60°C
60 C
(140°F).
Normally, except near points of release, Class II/III liquids do not produce
vapors of sufficient quantity to be considered for electrical classification
purposes.
*Classes as used here to identify flammable and combustible liquids should not be confused with the classes in the National Electrical Code (NEC) that identify
specific types of flammable or explosive atmospheres.

Note: A specific classification for crude oil is not possible since crude oil is a mixture of hydrocarbons of widely varying composition. Some crude oils may
include volatiles ((e.g.,
g , butane,, propane,
p p , or natural gasoline).
g ) However,, crude oil usuallyy is classified as a Class I flammable liquid,
q , and its flash point
p g
generally
y
is accepted as -6.7 to 32.2°C (20-90°F).
HAZARDOUS SUBSTANCE CLASSIFICATION (2/5)

•Flammable Highly Volatile Liquids (HVLs, API 500/505)

Highly volatile liquids (HVLs) include liquids such as butane, ethane, ethylene,
propane, propylene, liquefied natural gas, natural gas liquids, and mixtures of
such. Vapor pressures of these liquids exceed 276 kilopascals (40 psia) at
37.8°C (100°F).
Closed cup Flash point of Flammable HVLs is below 37 37.8
8°C
C (100°F)
(100 F).
HAZARDOUS SUBSTANCE CLASSIFICATION (3/5)

•National Electrical Code (NEC) grouping of atmospheric mixtures (Basis

NFPA 497):

-Purpose: 1) Testing,
2) Approval, and
3) Area classification

-Grouping based on NEC Article 505: This gas and vapor sub-division is based
on the maximum experimental safe gap (MESG), minimum igniting current
(MIC), or both.
1) Group I is intended for use in describing atmospheres containing firedamp
(a mixture of gases, composed mostly of methane, found underground,
usually in mines).
2.1) Group IIC. Atmospheres containing acetylene, hydrogen, or gases or
vapors of equivalent hazard.
2.2) Group IIB. Atmospheres containing acetaldehyde, ethylene, or gases or
vapors of equivalent hazard.
2.3) Group IIA. Atmospheres containing acetone, ammonia, ethyl alcohol,
methane,
th propane, or gases or vapors off equivalent
i l th hazard.
d
HAZARDOUS SUBSTANCE CLASSIFICATION (4/5)

-Grouping
Grouping based on NEC Article 500: This gas and vapor subsub-division
division involves
determinations of maximum explosion pressure, maximum safe clearance, and
other characteristics of the atmospheric mixture.
Group A: Atmospheres containing acetylene.
Group B: Atmospheres such as butadiene, ethylene oxide, propylene oxide,
acrolein, or hydrogen (or gases or vapors equivalent in hazard to hydrogen,
such as certain manufactured gases).
Group C: Atmospheres such as cyclopropane,
cyclopropane ethyl ether
ether, ethylene
ethylene, hydrogen
sulfide, or gases or vapors of equivalent hazard.
Group D: Atmospheres such as acetone, alcohol, ammonia, benzene, benzol,
butane, gasoline, hexane, lacquer solvent vapors, methane, naphtha, natural
gas, propane, or gases or vapors of equivalent hazard.
HAZARDOUS SUBSTANCE CLASSIFICATION (5/5)

-Temperature
Temperature Class (T
(T-Rating):
Rating): The temperature rating system is used for
explosion protection of electrical equipment.

T5 mm is
i th
the minimum
i i iignition
iti
temperature of a 5mm layer of
dust.
T12.5 mm is the minimum ignition
temperature of a 12.5mm layer
of dust.
HAZARDOUS AREA CLASSIFICATION (1/8)
Having decided that a location should be classified, and having designated the
gas or vapor as Group IIA, IIB, or IIC (or as Group A, B, C, or D), the next step
is to designate the location as:

1) Class I, Class II or Class III

2) Zone 0, Zone 1, or Zone 2 (or Division 1/ Division 2)*.

*Note: Zone 0/1/2 or Division 1/2 are meant for Class I only.
HAZARDOUS AREA CLASSIFICATION (2/8)
Class I, Class II or Class III:
Class I locations are those in which flammable gases or vapors are, or may be,
present in the air in quantities sufficient to produce explosive or ignitable
mixtures.

Class II locations are those that are hazardous because of the presence of
combustible dust
dust.

Class III locations are those that are hazardous because of the presence of
easily ignitable fibers or flyings, but in which such fibers or flyings are not likely
t be
to b iin suspensioni iin th
the air
i iin quantities
titi sufficient
ffi i t tto produce
d iignitable
it bl
mixtures.
HAZARDOUS AREA CLASSIFICATION (3/8)
Class I- Division 1 / Division 2 (as per API 500)- American style:

(A) Class I, Division 1.

1)) In which ignitable
g concentrations of flammable ggases or vapors
p can
exist under normal operating conditions, or
2) In which ignitable concentrations of such gases or vapors may exist
frequently because of repair or maintenance operations or because
of leakage, or
3) In which breakdown or faulty operation of equipment or processes
might release ignitable concentrations of flammable gases or vapors
and might also cause simultaneous failure of electrical equipment in
such a way as to directly cause the electrical equipment to become
a source of ignition.

(B) Class I, Division 2.

1) In which volatile flammable liquids or flammable gases are handled
handled,
processed, or used, but in which the liquids, vapors, or gases will
normally be confined within closed containers or closed systems
from which they can escape only in case of accidental rupture or
breakdown of such containers or systems or in case of abnormal
operation of equipment, or
HAZARDOUS AREA CLASSIFICATION (4/8)
2) IIn which
hi h iignitable
it bl concentrations
t ti off gases or vapors are normally
ll
prevented by positive mechanical ventilation and which might
become hazardous through failure or abnormal operation of the
ventilating equipment, or
3) That is adjacent to a Class I, Division 1 location, and to which
ignitable concentrations of gases or vapors might occasionally be
communicated unless such communication is prevented by adequate
positive-pressure ventilation from a source of clean air and effective
safeguards
f against ventilation failure
f are provided.
HAZARDOUS AREA CLASSIFICATION (5/8)
Class I- Zone 0, Zone 1, Zone 2 (as per API 505)- European style:

(A) Class I, Zone 0.

1) Ignitable concentrations of flammable gases or vapors are present
continuously, or
2) Ignitable concentrations of flammable gases or vapors are present for
long periods of time.
(2) Cl
Class II, Z
Zone 11.
1) In which ignitable concentrations of flammable gases or vapors are
likely to exist under normal operating conditions; or
2) In which ignitable concentrations of flammable gases or vapors may
exist frequently because of repair or maintenance operations or because
of leakage; or
3) In which equipment is operated or processes are carried on, of
such a nature that equipment breakdown or faulty operations could result
in the release of ignitable concentrations of flammable gases or vapors
andd also
l cause simultaneous
i lt failure
f il off electrical
l t i l equipment
i t iin a mode
d tto
cause the electrical equipment to become a source of ignition; or
4) That is adjacent to a Class I, Zone 0 location from which ignitable
concentrations of vapors could be communicated, unless communication
is prevented by adequate positive pressure ventilation from a source of \
clean air and effective safeguards against ventilation failure are provided.
HAZARDOUS AREA CLASSIFICATION (6/8)
Class I- Zone 0, Zone 1, Zone 2 (as per API 505):

(C) Class I, Zone 2.

1) In which ignitable concentrations of flammable gases or vapors are
nott likely
lik l tto occur iin normall operation
ti and,d if th
they d
do occur, will
ill exist
i t
only for a short period; or
2) In which volatile flammable liquids, flammable gases, or flammable
vapors are handled, processed, or used but in which the liquids,
gases or vapors normally are confined within closed containers of
gases,
closed systems from which they can escape, only as a result of
accidental rupture or breakdown of the containers or system, or as a
result of the abnormal operation of the equipment with which the
liquids or ggases are handled, processed, or used; or
3) In which ignitable concentrations of flammable gases or vapors
normally are prevented by positive mechanical ventilation but which may
become hazardous as a result of failure or abnormal operation of the
ventilation equipment; or
4) That is adjacent to a Class II, Zone 1 location
location, from which ignitable
concentrations of flammable gases or vapors could be communicated,
unless such communication is prevented by adequate positive-pressure
ventilation from a source of clean air and effective safeguards against
ventilation failure are provided.
p
HAZARDOUS AREA CLASSIFICATION (7/8)
Comparision Zone vs Devision:
Division Zone Frequency of Grade of Flammable Mixture
Occurrence Release* Present
1 0 Continuous Continuous 1000 hours per year or
more (~10%)
1 Intermittent Primary Between 10 and 1000
Periodically hours per year or more
(0.1%~10%)
2 2 Abnormal Secondary Less than 10 hours per
Conditions year (0.01%~0.1%)
None None None Unclassified Less than 1 hour per
year (Less than 0.01%)

*Grade of release is strictly connected to the time of release.

HAZARDOUS AREA CLASSIFICATION (8/8)
Class I- Zone 0, Zone 1, Zone 2 (as per API 505):
Codes & Standards
1.API:
API RP 505 Recommended Practice for Classification of Locations for Electrical Installation at Petroleum Facilities
Classified as Class I, Zone 0, Zone 1 and Zone 2 (2002).

API RP 500 Recommended Practice for Classification of Locations for electrical Installation at Petroleum Facilities
Classified as Class I, Division 1 and Division

2.IEC:
IEC 60079-10 Electrical Apparatus for explosive gas atmospheres- Part 10: Classifications of hazardous Area.

IEC 60079
60079-12
12 Classification of Mixtures of Gases or vapors with air according to their maximum experimental Gaps
(MEGs) and minimum ignition currents ratio (MIC).

IEC 60079-20 Electrical Apparatus for explosive gas atmospheres- Part 20: Data for flammable gases and vapors,
relating to the use of electrical apparatus.

3.NFPA:

NFPA 30: Flammable and Combustible Liquids Code

NFPA 70: National Electrical Code

NFPA 325: Guide to fire Hazard Properties of Flammable Liquids, Gases, and volatile Solids

NFPA 497: Recommended practice for the Classification of Flammable Liquids, Gases or Vapors and of Hazardous
(classified) Locations for Electrical Installations in Chemical Process Areas.
Codes & Standards
4.OISD:
OISD 113: Classification of areas for electrical installations hydrocarbon processing and handling facilities.

5.IS:
IS 5571: Guidance for selection and installation of electrical equipments in hazardous areas. .

IS 5572: Classification of hazardous areas having flammable gases and vapors for electrical installation
Hazardous Area Demarcation (1/4)

Required materials:

1) Client requests & codes/standards

2) Plot plan

3) Equipment list

4) Hazardous source list

Hazardous Area Demarcation (2/4)
1) Client requests & codes/standards:

- Relevant codes (NFPA, API, IEC,OISD,IS).

- Marking method to be applied (Div, zone).

- Non-hazardous area in process areas.

- Explosion protection types of products to be applied in hazardous areas.

2) Plot Plan:

- Spatial representation of hazardous areas

3) Equipment List:

- Equipment dimensions, operating conditions

Hazardous Area Demarcation (3/4)
4) Hazardous Source List:
- A list prepared by Electrical+Process Departments and issued by the
g
Electrical engineeringg department
p that contains information such as the
types and characteristics of substances each equipment handles, explosion
proof level based on codes/standards, T rating, and sometimes the extent of
the classified location.
- Parts of Hazardous Source List:
a) Component classification data list
b) Area classification data list
Hazardous Area Demarcation (4/4)
a) Component classification data list- Process Input:
1- Formula
2- Molecular weight
g
3- Auto-Ignition Temperature
p
4- Flash Point
5- Vapor density
4- Boiling point
5- LEL/UEL

b) Area classification data list- Process Input:

1- Composition
p
2- Operating conditions
3- Flash Point
4- Auto-ignition Temp.- Least one is taken
5- Explosion range- Range as per “Product classification data list”
6 Gas density
6-

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