W AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 1 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 DATE: | _NOV05: ORIG. BY: | | CALCOT ‘APP. BY:| _MSIMM CONTENTS 1. PURPOSE...... 2. SCOPE. 3. REFERENCES AND GUIDELINES... 3.1. References. 3.2 Introduction. 3.3. Definitions. : 3.4 Interpretation of IP15.. 3.5 Development of Process Data. 3.6 Hazardous Area Drawing 3.7 Hazardous Area Review.. , 3.8 Possible Pitfalls in Area Classification.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 2 OF 24 (FLUIDS) PROCESS ENGINEERING REV_1 1. PURPOSE 2. This Technical Work Practice assists Process Engineers with the development of hazardous area classification process data The revised Technical Work Practice covers the major revisions made to the IP15 code in August 2002. This second edition is based on an assessment of the risk to operators who work within hazardous areas. In addition it provides an updated, demonstrable methodology for specifying hazardous radii. This is achieved by assigning a level of release for secondary sources, and takes account of the period of time an operator spends exposed to a potential release source, and the probability of ignition of that release. The new IP code is based on dispersion modelling taking into account variables such as pressure and mist/spray formation. As the radius is now based on dispersion modelling of specific release compositions there is no longer a distinction between heavier than air or lighter than air releases. SCOPE The scope of this Technical Work Practice is limited to flammable gas mixtures and excludes dusts. Before commencing work, the applicable codes and standards for the particular contract should be established. The process data can be summarised on Form FWEL 3595 Rev 01. Form FWEL 3595 is based on BS PD IEC 60079 (IEC 60079) Part 10 together with data required by Part 15 of the Institute of Petroleum Model Code of Safe Practice in the Petroleum Industry, July 2005 Rev 3 (IP15). The remainder of this Technical Work Practice is exclusively focused on the application of IP15. Hazardous area classification using IP15 is a specific legal requirement within the European Union under the “Atmosphere Explosive Directive" (ATEX) 1999/92/EC- legal based article 137. ATEX is implemented in the UK under the Dangerous ‘Substances and Explosive Atmospheres (SEAR) Regulations. The ATEX directive, effectively defines equipment groups and categories for use in explosive atmospheres. ATEX Group Il relates to equipment in places likely to be endangered by explosive atmospheres other than mines. ‘* Group II, Category 1 equipment is intended for use in the equivalent of an IP15 Hazardous Area Zone 0. ‘* Group II, Category 2 equipment is intended for use in the equivalent of an IP15 Hazardous Area Zone 1. ‘* Group II, Category 3 equipment is intended for use in the equivalent of an IP15 Hazardous Area Zone 2. This Technical Work Practice is not applicable to projects using API 500/505 or other client standards,AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 3 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 34 3.2 REFERENCES AND GUIDELINES References 1, The Institute of Petroleum “Area Classification Code for Installations Handing Flammable Fluids" Part 15, 3rd Edition Model Code of Safe Practice. ELE A/ETA/36-01"Hazardous Area Classification” Engineering & Construction TWP E17/13 "Fire and Explosion Risk Assessment” Engineering Work Practice 17/60 “ATEX Equipment Directive” Engineering Work Practice DES/E17/08 Safety Integrity (SIL) Reviews NFPA 497 “Recommended Practice for the Classification of Flammable Liquids, Gases or Vapours and of Hazardous (Classified) locations for Electrical Installations in Chemical Process Areas.” 2004 edition (Useful data includes Table 4.4.2 Selected Chemicals, Table 4.4.3 Cross Reference of Chemical CAS number to chemical name.) 7. BS PD IEC 60079-20 (This includes data for flammable gases and vapours, which were previously included in BS 5345, Part 1, 1989, Section 5.) 8. Flammability Characteristics of Combustible Gases and Vapours Bulletin 627 Us Bureau of Mines 9. Fire Protection Handbook - Nat. Fire Protection Association 10. National Electrical Code NFPA 325M 11. 16-05 Engineering Work Practice Hazardous Area Classification Review Rev 02, x ea ae 12. ELE/AETA/36-01 Electrical Engineering Technical Work Practice Hazardous Area Classification. Introduction Area classification is the delineation of a facility into hazardous and non-hazardous areas. Hazardous areas are further divided into zones which are graded according to the estimated probability of the presence of a flammable atmosphere. There are restrictions within these areas and zones on the use of equipment with the potential to cause ignition. The aim of area classification is to avoid ignition of those releases that may occur ‘occasionally in the operation of facilities handling flammable liquids and vapours. by minimizing the probability of coincidence of a flammable atmosphere and an electrical or other source of ignition. There are a number of discrete steps that need to be completed in order to arrive at the hazardous area classification for a process plant. ‘+ Identify the point sources of release and equipment type. ‘© Determine the grade of release and fluid category ‘Establish zone classifications ‘* Determination of release levels and equipment hole sizes ‘© Determine the hazard radiusAREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 4 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 ‘* Preparation of hazardous area drawings © Hazardous area classification review Rigorous hazardous area classification as described in this document is not usually carried out until the EPC phase of projects. However, even at the FEED stage, when a provisional assessment is often made, itis important to undertake a hazardous area exercise using the current approach. Plants that have high operator occupancy or mediutrvhigh ignition sources on the Zone boundary can give rise to larger than expected hazardous areas. (See 2.3a P15) Process Engineering are responsible for the provision of the area classification process data for each equipment item or potential source of release, listed on the forms referenced above. This includes the definition of the hazard radius and assignation of a preliminary zone associated with each equipment item. The Electrical Group are responsible for the production of the overall Area Classification drawing. This drawing Is then reviewed by all the relevant departments including Process. 3.3 Definitions ‘Non Hazardous Area - An area in which flammable mixtures are not expected to be present in quantities such as to require special precautions for the construction and use of electrical apparatus. Hazardous Area - An area in which flammable atmospheres are, or may be ‘expected to be, present in quantities such as to require special precautions for the construction and use of electrical apparatus. Hazardous areas are divided into three "zones', classified in order of decreasing probability of the presence of a flammable atmosphere: Zone 0 : A flamable atmosphere is present continuously or for long periods. Zone 1 : A flammable atmosphere is likely to occur in normal operation. Zone 2 : A flammable atmosphere is not likely to occur in normal operation and if it ‘occurs it will only exist for a short period Hazard Radius - The hazard radius of a source is the largest horizontal extent of the hazardous area which is generated by the source when situated in an open area’.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 5 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 3.4 _ Interpretation of IP15 The block flow diagram below summarises the steps to be taken to determine the hazard radii, No Classeaon ‘ote unites | Coniormate Isto acy ofa ‘ste Grate ot ematons ves | ekaseoour? — | Yes | conmantyreie Ne olose sutra Tsedin Copies 3 ‘Contac or require t—} [>| sss, |-———> Pinay astcalon? “Sexy? se Conte Yes Fray — J Propeies £ te Isthe uid 8,6, Establish lease | Herc? Frequency ug Chie Lever uipebabityet | secondary ese expos) ler Opatons Seto Yes ——_———- || ——— ¥ y ‘the examen 'sthe exipment/ No | tessa feityevendin cantons coveted Secon ingecson 40 (or C9? Yes No sete Ore XS Example Method ] ¥ Dov oii Engle depron Det Hazard Read eke son save ad Maza roel weg Radi fom selon ene Hazard Ras fom Rad sng ‘pected 54. Assess te Sodion or Tal 8, Chapt 384, rsrlane le inpacot Assos ih input ot ‘Asses he impact. Sto dtomine ean — vention - Chapter ‘vation Hazard Chap ChaterAREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 6 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 3.5 Development of Process Data 3.5.1 Identification Of Sources Of Release The starting point for any area classification is to determine all the potential sources of release. To do this, itis important that the process design of the facility is well-developed, and that a plant layout is available in at least a conceptual form. Typically, the following key documents are used when determining the sources of release © Equipment list + Piping and instrument diagrams * Heat and material balance ‘© Plot plan In addition, itis important to consider other potential sources of release which may not be shown on the above documents. Examples of these include oily water drain system, drain hubs and vent pipes, vents from balanced bellows relief valves, analyser vents, sumps etc. Activities such as drum handling operations, shor storage of solvent containers adjacent to the equipment etc. affect the area classification and must also be considered. {tis important that all continuous, primary sources and secondary sources which are likely to have an impact on the extent of a Zone 2 outside the plant boundary are identified at an early stage. Small secondary releases within the process plant are less important, as they are unlikely to have an impact on the extent of hazardous zones. Itis also important to determine ignition sources at an cary stage as they have an influence on the extent of the hazardous area, 3.5.2 Flammable Material This requires the name or composition of the process fluid handled in the equipment. The degree of detail depends on the nature of the material. Actual chemical names or generic words such as gasoline are required, (not e.g. "stripper bottoms’ If the equipment can contain different fluids at different stages of the process operation, all of them must be listed. This includes start-up, shut-down, batch processing, cleaning (chemical). If the equipment contains different fluids in different sections, these must be detailed. (For example a flash drum: vapour and liquid must be classified separately).AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 7 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 The flammable limits of some pure substances are listed in BS PD IEC 60079-20. For mixtures of combustible gases not containing air or other inert gas, the following method may be used to extablish the flammability of the mixture. Let P;, Pz, Ps etc represent the percentage of each combustible gas present, so that: Prt Pet Py Fcc = 100, Let Ni, No, No etc represent the lower flammable limit in air for each gas separately (in %). Then the lower flammable limit of the mixture L is calculated as: L= 100/(P Y/N; + PoINe +... A similar equation may be used for the upper flammable limit with suitable redefinition of N; etc. The above method is taken from BS 5345, Part 1, 1989, Appendix E, which also contains a method for calculating flammability limits for mixtures containing flammable and non-flammable gases. Although BS 5345 is superseded, the above method is still valid. 3.5.3 Operating Temperature and Pressure These are self-explanatory. If during normal processing, different conditions are to be expected, each case must be considered and given the appropriate "Grade of Release" and "Fluid Category’, 3.5.4 — Flash Point The flash point of a liquid is the lowest temperature, corrected to atmospheric pressure, at which the application of an ignition source causes the vapour of the test portion to ignite and spread across the surface of the liquid under the specified conditions of test. Flash points are dependent on the test method and can only be defined in terms of a standard test method. Itis necessary to know whether the fluid contained within the item of equipment is. at a temperature above or below its flash point. If the normal operating ‘temperature is higher than the fluid's flash point then an entry of low’ will indicate flammable gas/air mixtures will be possible. The actual flash point of the fluid ‘should be recorded if the normal operating temperature of the fluid is below the flash point. Fluids with very high flash points, above say 450°C, can nearly always be considered safe so an entry of ‘very high’ will be appropriate here, and no further entries made on this line.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 8 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 Flammable materials released under pressure forming a mist or spray can be ignited at temperatures far below the flash point. Pressure differentials of a few bars are sufficient to atomise commonly encountered liquids. A fluid at, or near, atmospheric pressure and more than 5 °C below it's flash point, can be treated as non-hazardous. Where it is pumped and under pressure it should be regarded as a category C fluid due to the possibilty of mist formation on release. Flash points of some flammable materials are listed in BS PD IEC 6079-20, 3.5.5 IP 15 Fluid Category The fluid category is defined in IP15 as follows: Fluid Category Description A A flammable liquid that on release, would vaporise rapidly and substantially. This category includes: €) Any liquefied petroleum gas or lighter flammable liquid ) Any flammable liquid at a temperature sufficient to produce on release more than about 40% vol vaporisation with no heat input other than from the surroundings B A flammable liquid not in Category A, but at a temperature sufficient for boiling to occur on release c A flammable liquid not in categories A or B, but which can, on release, be at a temperature above its flash point, or form a flammable mist or spray si) A typical methane-tich natural gas Gui) Refinery hydrogen Unclassified Heavy oils etc with flash point greater than 1000C handled at a temperature below flash point, which will not form a mist or spray on release The IP15 code states that abnormal conditions (e.g. start-up or shutdown) which can affect fluid conditions such as flash points should be considered if the abnormal condition is expected to exist for more than 1% of the year or 100 hours/yr. Refer to IP 15, Annex A, and Section 3.1.2 for Classification & Categorisation Of Petroleum & Flammable Fluids. Note that the same fluid at different stages in its, processing can fall into a different fluid category depending upon its temperature and pressure at the source of release.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 9 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 3.5.6 3.5.7 ‘Where a piece of equipment may contain the same fluid at different conditions, only the most severe case need be entered on the process form. If there is doubt, concerning the controlling case, then enter all cases. Ifthe inlet fluid separates into multiple streams, then all the outlet streams must be entered (e.g. flash drums). ‘The FW schedule includes the atmospheric boiling point to clearly show what has influenced the selection of the fluid category. Ignition Temperature This is the temperature at which, when mixed with air at normal pressure and as a consequence of chemical reactions initiated on account solely of temperature, the substance will ignite and burn in the absence of any initiating source of spark or flame (formerly known as auto or spontaneous ignition temperature). See BS PD IEC 60079-20 for pure substances. For mixtures, the ignition temperature of each component present in significant quantities (greater than 2 vol%) should be determined, then that with the lowest - ignition temperature should be quoted. A typical example is LPG containing a Cs spike. The ignition temperature of the C:'s (285°C) is significantly lower than that of LPG (C3 470°C, C; 365°C). Equipment that operates at temperatures above the temperature of the contained fluid should also be shown on the schedule — see Section 8.2.6 in IP15 for details. Drain/VenSample Diameter The drain/vent/sample diameter should be provided when there will be a release of flammable material to atmosphere, to enable the hazard radius to be determined, In the IP 15 Code, the hazard radius for drains and sample points is tabulated as ameter versus fluid category. The table only indicates for drains and sample ‘connections up to 20mm — but note that drain/sample points of 20mm can give rise to an unacceptable hazardous area extent and therefore should be avoided. This should be taken into account during the design of the drainage/ sample system where large quantities of flammable fluid are involved. See Section 5.4.2 IP15. ‘On some process drains the fluid normally drained is non-flammable, but flammable material could ultimately be drained, e.g. water draining from a process vessel. The hazardous area should be based on the flammable material, unless suitable precautions are in place to ensure the draining of flammable liq improbable.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 10 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 3.5.8 Temperature Class (T-Class) This divides up the flammable mixtures into classes governed by ignition temperature. The aim is to specify an appropriate temperature class such that the ‘maximum accessible surface temperature internally or externally will not exceed the ignition temperature of the gaseous vapours to which it may be exposed. The temperature classes are as follows: Maximum Surface TemperatureClass Temperature °C 1 450 T2 300 13 200 14 135 15 100 16 85 35.9 Gas Group Apparatus sub grouping Is applied specifically to the type of protection as defined by the method of flame proof enclosure or the limiting energy levels for intrinsic safety. Each gas is allocated to an apparatus sub group named by a representative gas, which reflects the minimum ignition energy of the gas or vapour likely to be present, as follows: Apparatus Sub Group Representative Gas (IEC 6079-20) Hla Propane * NB Ethylene lic Hydrogen lic Acetylene Industrial Methane, such as natural gas, is categorised as Sub-Group IIA, provided it does not contain more than 15 %v hydrogen. Group | is for electrical equipment for mines susceptible to firedamp (methane). ‘The sub-groups are listed in increasing order of severity. Hydrogen and acetylene appear in sub-group IIC as the gases most susceptible to ignition, ‘The apparatus sub-groups for a large number of fluids are listed in BS PD IEC 6079-20. A tabulation of the more common fluids is given in IP 15 (Section 7, Table 7.2) ‘Apparatus may be used only with compounds allocated to the appropriate apparatus sub-group as indicated above and whose ignition temperatures are not less than the temperature given by the T Class of apparatus. Apparatus certified for a particular sub-group may also be used with compounds allocated to a lower ‘sub-group subject again to temperature classification. Where mixtures are concerned, group the whole mixture according to the component (present above 2% with the exception of H, where a 30% limit applies) with highest sub-group number. FW consider that only gases containing more than 30 vol% hydrogen should be considered as being in the hydrogen sub-group IC (see IP15 Annex B).AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 11 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 Care must be taken when working with mixtures containing a significant amount of carbon monoxide - see BS PD IEC 60079-20 (and BS 5345 Section 38.2). 3.5.10 Source of Release The source of release is defined as "a point from which a flammable gas, vapour or liquid may be released into the atmosphere”, The information required here is to describe the potential points of emission from the system. Even a closed system has valves and flanges which (statistically) will leak at some time. The IP 15 Code contains tables for the hazard radius from these point sources according to the fluid category of the material released. Therefore a general description should be provided, for example: tank bund; drip tray; floating roof tank; pump with high integrity seals (or not); atm vent; PSV ‘outlet; closed system with valves, vent and drain; relief to flare; drum handling; ‘charging of vessel through open manway; filter to be cleaned ‘A process drain, vent or sample point on, of related to an equipment item should be recorded (Instrument Department will advise instrument vents and drains separately). Also, see BS PD IEC 60079-10, Annex A, for examples of sources of release, However, large diameter drains and vents that are blanked off or plugged and play ‘no part in normal operation (but are provided to enable draining or venting and gas-freeing in preparation for inspection or maintenance) should not be considered. The large releases they would give rise to are not relevant to area Classification. Work permits would be required before they were activated. While plant design should minimise the probability of liquid spills by providing tundishes for sample points, drains and overflows, inadvertent spills can occur. Positions where spillage is credible in normal operation should be identified, 3.5.11 Grade of Release The Grade of Release is defined for flammable emissions to atmosphere and is an expression of frequency and duration, Continuous grade release: A release that is continuous or nearly so or that frequently and for short periods ie. more than 1000 hours per year. Primary grade release: A release that is likely to occur periodically or occasionally in normal operation, i.e. a release which, in operating procedures is anticipated to occur i.e. 10 hours or more but less than 1000 hours per year. Secondary grade release: A release that is unlikely to occur in normal operation and, in any event, will do so only infrequently and for short periods. This is a release which, in operating procedures, is not anticipated to occur i.e. for 1 to 10 hours per year. A regular operation should be considered as a primary release even if the duration is less than 10 hours per year and carried out under a permit to work systems.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 12 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 During design, effort must be made to minimise the number of primary releases as far as is practicable. This can include such measures as installation of closed ‘sampling systems, closed drain systems, and reducing the diameter of vents and drains. ‘Some typical examples of equipment containing flammable liquid giving rise to flammable atmospheres are as follows: ‘Areas containing strainers may be considered as giving rise to a flammable atmosphere less than 10 hours/year providing the strainers are on guard duty only, and its only expected to open them say once a year. If itis expected that the strainer will be opened frequently, or that the strainer is one of many in the same general location, then the chances of a flammable atmosphere being present will be more than 10 hours/year. Most items, such as pipes (but not necessarily flanges), vessels etc will rarely leak and would not normally be considered as giving rise to a flammable atmosphere more than 10 hours per year. IPIS has now introduced a lower limit of 1 hour per year as a break point, for secondary releases, see Annex C, Section 2.5 for justification. An exception to this rule would be when pipework is opened as part of a normal operating procedure. Tank breathers would normally give rise to a flammable atmosphere more than 10 hours/year. Hydrogen compressors are notorious for leaks and should normally be considered as giving rise to a flammable atmosphere more than 10 hours/year unless the seals are Nz purged. This must be checked with Mechanical Equipment Group. Pumps in a well ventilated location will not normally be considered as giving rise to a flammable atmosphere more than 10 hours/year. However, if pumps are located in a pump house then itis likely that a flammable atmosphere will be present for more than ten hours per year. ‘tank containing pentane will have a continuous loss of hydrocarbon from its vent (due to the very high vapour pressure of pentane at ambient conditions). This will give rise to a zone 0 rating immediately adjacent to the vents. Hydrocarbons in pits such as API Separators etc must give rise to a flammable atmosphere above the surface, which will be almost continuously present. Fired heaters are a constant source of ignition when in operation and usually have ‘a 16m spacing requirement around them. This is intended to keep vapour releases (from other sources) away from the heater and is not related to area classification. Although fired heaters are not considered to be a source of release, there is likelihood of a flammable atmosphere being present, particularly during initial urging of fuel gas lines. For this reason it is usual to specify at least zone 2 equipment for use with these items. See Section 8 IP15 for a more detailed iscussion on non-electrical ignition sources. Where releases are likely to be present for less than 10 hours/year but are anticipated in normal operation (e.g. routine sampling points) they should be regarded as primary grade releases and carried out under a permit to work system,AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 13 OF 24 (FLUIDS) 3.5.12 3.5.13 PROCESS ENGINEERING REV 1 Flammable fluids falling into the Unclassified Class (le. flash points > 100 °C) may be considered as non-hazardous or Class III(2), according to operating temperature. However, when unclassified products (e.g. heavy fuel oils) are stored under confined heated conditions in fixed roof tanks (i.e. unventilated ullage space), the flash point is not a reliable guide to the presence or absence of a flammable atmosphere that may have built up in the tank vapour space. The ullage ‘space of such tanks may be specified as Zone 0, with a Zone 1 around roof vents and other openings. However, in some cases, the codes completely define the zone classification for Particular items of equipment, and this may override the data given here. The extent of zoning is also given in codes. It is the responsibility of Electrical Group to Use the appropriate data in confirming the extent and type of zoning, with the agreement of the Process Group. Zone Classification For an open, freely-ventilated area, the following Zones apply (depending on the grade of release): * Continuous: Zone 0 ‘© Primary: Zone 4 * Secondary: Zone 2 For enclosed areas, such as an analyser house, compressor shelter, and sumps, reference has to be made to IP15 to determine whether the applicable zone has to be increased to take account of inadequate ventilation, Determine Hazard Radius ‘The method used to determine a hazardous radius is dependant on the grade of release, For primary and continuous releases, where the potential leaks sizes and fluid categories are within the limits of the tables within IP15 section 5 and Annex 6, the hazardous radius can be determined directly from these tables. For cases outside the limits, it is necessary to undertake dispersion modelling to determine the extent of a flammable cloud. Dispersion modelling should not normally be required. In cases where this has been found to be necessary, Foster Wheeler typically use PHAST (Process Hazard Analysis Software Tool) from DNV Software. There is however a methodology in BS PD IEC 60079 Part 10 for determining the volume of a release that could be used to assess the size of the expected extent of a hazardous area. For a secondary grade release it is first necessary to determine the level of release, and then to determine the hazardous radius either directly from IP15 or from dispersion modelling. The procedure used for determining level of release is described below.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 14 OF 24 (FLUIDS) PROCESS ENGINEERING REV 4 3.5.14 Level Of Release The level of release takes account of the period of time that personnel are ‘exposed to a risk, determined from the number of sources of release to which they are likely to be exposed, and the likelihood of ignition, The level of release is either Level |, Level I! or Level Il and is described as the release frequency. The release frequency is based on personnel risk only. Itis the general intent that the level be assigned to an installation rather than determine the level for each individual point source. This can prove to be quite difficult when the boundary of an installation may have varying risks of ignition. The first step in determining the level of release is to establish exposure of personnel, In the IP Code exposure is determined from: EXD= Pos X Neange Where Pox: is the probability of an individual being on site within the hazardous area. Nrange is the time weighted average number of release sources which can affect the individual during their time within the hazardous area IP15 provides four values for Poe: * 0.22: Individual spends 100% of all shifts exposed to a hazardous release ‘* 0.13: Individual spends an average of 5 hours per shift exposed to a hazardous release * 0.055: Individual spends an average of 2 hours per shift exposed to a hazardous release 0.028: Individual spends an average of 1 hours per shift exposed to a hazardous release ‘The likely exposure of personnel needs to be discussed with the plant's operating ‘team, but in practice Foster Wheeler has found that in modern automated plants, (with the exception of pharmaceutical applications) the exposure of personnel tends to be between 2 and 5 hours, giving rise to a P... of between 0.13 and 0.055. It is essential that the assumptions made in determining the probability of ‘exposure are well documented and recorded in order to provide an audit trail for later review and to meet HSE requirements. The next step is to determine Nrane. The tables in IP15 give the average number of sources to which an individual will be exposed during his period within the hazardous area, depending on the activity which he is undertaking. Three levels are indicated: low, medium and high.AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 15 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 The percentage of time an individual is then exposed to each of these levels then needs to be assessed. It is important that these values are discussed with the client's operating personnel. The basis for all decisions taken must also be recorded for record and audit purposes. " Typical values of time an individual is exposed, used on previous projects are: © Low: 20% © Medium: 50% © High: 30% The use of these figures should be discussed and agreed with the client. Its now possible to determine the exposure from table C2 (in IP 15). Depending on the assumptions made we would typically expect to arrive at an exposure of between 1.5 and 2.0. Before determining the level of release it is now necessary to determine the probability of ignition. In table C3 of IP15 the following four strengths of ignition are given: * Controlled, probability of ignition, 0.003, + Weak, probability of ignition, 0.01 ‘+ Medium, probability of ignition, 0.4 ‘* Strong, probability of ignition, 4 By taking account of the proportion of time the most exposed individual will spend ‘exposed to each of the strengths of ignition, a value for P,, can be determined, Using the values of exposure and Pin, the appropriate level of release is, determined from Figure C2 (in IP15). Referring to Figure C2, Foster Wheeler has found that in most instances, level | is applicable for process plant, but with certain areas close to strong sources of release exposed to Level Il, in practice Level Ill has not been encountered. The calculation of release frequency level is required to be made as a minimum for each type of plant area e.g. process area, utlity area, offsite area. These calculations are carried out by the process department with input from client (operations/maintenance), and engineering disciplines as necessary. The output of these calculations should be to provide a release frequency level for all areas of the plant which is subsequently used to establish hazardous radius for releases as per IP Code section 5.4. 3.5.15 Hazardous Radius For each source of release the hazardous radius can be determined using Chapter 5 and Annex C3 of IP15,REIS ESELEEESELSSE EPS SESR SEEESESESESE TE SEISEISSSSSSSSTSEEEETSTET AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 16 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 ‘The leakage rates of hydrocarbon, and hence the extent of hazardous radius, is." dependent on the hole size through which the leak occurs combined with the operating pressure. Guidance is given in IP15 on the size of holes likely to occur for certain credible scenarios. If necessary, air dispersion modelling can be undertaken to determine the extent of hazardous zones. Opportunities exist to modify the design of a process plant, to remove or downgrade hazardous releases to reduce the zone classification or the extent of a hazardous radius. By undertaking the hazardous area classification in a structured manner, these opportunities can be identified more easily and resolved. 3.6 Hazardous Area Drawing The hazardous area zones and radii are represented on a hazardous area classification drawing by the Electrical Group. This drawing is based on the plot plan for the process unit with the hazardous zones overlaid. Drawings are produced in both plan and elevation to give a full three dimensional representation of the hazardous area. 3.7 Hazardous Area Review Once the preliminary hazardous area classification drawing has been prepared a formal review is undertaken to confirm that the proposed area classification is in accordance with project requirements, and is endorsed by the various engineering departments and importantly the client/operations representative. (References 11 and 12) The formal hazardous area classification review is an important part of the process as it brings together a range of disciplines, and helps to ensure that the classification is agreed and accepted by all parties concerned, and that it meets Itis important to ensure that the client is involved throughout the process and particularly during acceptance and agreement, it ensures that the design process is understood and accepted by the operator. The review team should typically be composed of the following personnel; Process engineer * Project engineer * Electrical engineer Instrument engineer Design safety engineer) ‘ Client representatives, (including operations and maintenance personnel)ra AREA CLASSIFICATION FOSTER WHEELER ENERGY LTD GEN/DTA/13-07 PROCESS DATA TECHNICAL WORK PRACTICE PAGE 17 OF 24 (FLUIDS) PROCESS ENGINEERING REV 1 The review will typically be chaired by the Project Engineer and follows a check list to ensure that the area classification drawing has correctly interpreted the information contained in the hazardous release schedule and to gain buy in and agreement on the various assumptions made during the hazardous area classification process, particularly with regard to operator occupancy and ignition sources. All actions arising from the review must be recorded and should be entered into a project design safety action tracking register to ensure an auditable trail to close out exists. Following the review meeting the hazardous area drawing will normally require to bbe updated to incorporate the actions of the review team before being released for engineering design use. 3.8 Possible Pitfalls in Area Classification The development of area classification drawings is a complex task based largely on identification and assessment of possible flammable risks. It shall only be done under the direction of Authorised Engineers. The following points are some of the typical pitfalls encountered in area classification and may arise during the drawing review meeting. Consider a source of hazard that by itself causes a zone 2 area classification. Ifa large number of these sources are grouped together, then the risk of a flammable atmosphere being present at any other time is increased and the possibility of increasing the area rating to zone 1 must be seriously examined. 1. The hazard areas associated with pipe flanges and valve glands are frequently not shown in the classification drawings, but are covered by notes. This practice generally assists with the clarity of the drawing, but can lead errors. Consider particularly those areas, likely to occur in tank farms, where great manifolds of flanged valves are located. Here the hazard zones for the many individual sources are likely to overlap, or nearly so, and so in this case the whole area merits inclusion on the classification drawing. 2. Consider the effects of elevation. Multilevel structures will require classification drawings for each level and the effect of interaction must be considered. For equipment built on hillsides, the effects of liquids and heavier than air gases flowing down hill must be investigated. 3. The relevant codes of practice describe the areas required for classification in certain generalised instances. This information should be used as a guideline to propose requirements for the many unusual situations encountered in practice. 4, Be realistic when determining the level of release. Adopting a conservative approach may result in a very large Zone 2 area. (A level 2 release gives a much larger extent of Zone than Level 1.) 5. The objective of area classification is to cover ‘normal’ releases of hydrocarbon. It is not intended for major releases. 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