Hazardous Area Calculations Scenario

Document number HAC-05-10-001-scenario 1

Revision Date Issued Author Issued By Acc By

Number

O 06/5/10 SvB SvB

Hazardous Area Training & Implementation

HAC-05-10-001-scenario 1 0510
Scenario

 Site:

o Essential and Cosmetics Oils manufacturer

 Following a Regulatory incident, a Regulatory Site Inspection was conducted.

o Large quantities of Ethanol on site and not stored as per requirements

o Hazardous Area Classification not compliled

o Electrical Installations in hazardous area not documented

o Electrical Installations in hazardous areas not compliant

 Result

o Infringement issued

o Corrective Directive Issued

Hazardous Area Training & Implementation

HAC-05-10-001-scenario 1 0510
Introduction

This report is directly related to Directive Number D773.

NOTE: This report mainly deals with the Flammable Vapour Hazards on site.

All references to Hazardous Area Classification etc are for Gas and Vapour Hazardous ONLY.

From initial examination, potentia l explosive dust hazards do not appear to either exist or have as
high an immediate risk as the vapours. Any dust hazardous that may exist will be covered in a
separate report.

The data used for determining the type of hazard is in conjunction with the Dangerous Goods Review
Revision: A – Preliminary Report Date of Issue: 27th March 2006 issued by and
information as below:

Flammable material LEL UEL Volatility

Vapour Group Any other
Relative density of Ignition
vol. pressure Boiling point and relevant
Name Composition FP vol.% gas or vapour to temperature
% @ 20°C °C temp information and
air °C
mm HG class remarks

Data from
Ethanol CH3CH2OH 12 3.1 19 78.3 1,59 363 IIA T2 AS/NZS
60079.20

Data from CSR

Ethanol 13 3.5 19 44 78 1.59 392 MSDS-022

Included in this document are some informative sections, including extracts from the Electrical Safety
Regulations and the owner occupier should familiari se themselves with sections 153 and 154 of the
Electrical Safety Regulation 2002, AS/NZS 3000 cl 7.9, AS/NZS 2381.1 cl1.6 and 1.7 (refer
References section)

Sean Segond von Banchet AFAIM

Qld ACCREDITED AUDITOR Category 3 (Flammable Gases, Liquids and Combustible Dusts (Zones 0,1,2,20,21 and 22) # 02/0074

Hazardous Area Training & Implementation

Page 6 of 36

002-04-06 0406
Specific Work Places

General Conditions

Ventilation

The ventilation (Supply, Return Air and Exhaust) must be considered to be the same Hazardous Area
Classification as the rooms they protect.

Electrical apparatus must be selected and installed according to AS/NZS 2381.1. (Currently not
compliant)

The ventilation systems do not constitute suffi cient compliance with AS 1482 (Protection by
ventilation), nor does the process geometry, proce ss movement or process containment afford
ventilation to be the sole source of protection.

The MSDS for ethanol states “Ventilation: Local exhaust ventilation and/or mechanical (general)
exhaust is recommended where vapours are likely to be generated.

All such equipment must be intrinsically safe.”

AS/NZS 2340.3.3 states

“4.13 Mechanical ventilation exhaust and inlet ducts associated with an enclosed structure classified
as hazardous (see Figure 4.11)

Classification is as follows:

(a) The interior of both inlet and exhaust ducts is assigned the same zonal classification as the
enclosed structure being served.

NOTE: This covers situations when the mechanical ventilation system is operating, when it has failed,
and prior to start-up.

(b) Within 3 m radius of the exhaust duct outlet ....................................................Zone 2”

Hazardous Area Training & Implementation

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002-04-06 0406
Recommendations:

Where the ducting is considered to be a Hazardous Area, any electrical apparatus and the installation
to such, must comply to AS/NZS 2381 series.

Motors may either be able to be located outside the ducts, using a secondary drive mechanism for
the fan, or else certified for use in a hazardous area.

Where heater elements are installed in the ducts, combustible vapour detection and temperature
control may be utilised as an electrical interlock fo r isolating the heaters in the event of either
o
explosive atmosphere becoming present or surface temperature exceeding 299 C.

It is NOT recommended that combustible vapour detectors be used with an electrical interlock, so as
to shut down the ventilation system when an explosive atmosphere may be present.

Hazardous Area Training & Implementation

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002-04-06 0406
Equipotential Bonding

To avoid Potential ignition by static, metal vessels and metallic parts should be bonded.

The MSDS for ethanol states; ”All vessels must be earthed to avoid generation of static charges when
agitating or transferring solvents.”

AS/NZS 2381.1 3.4 EQUIPOTENTIAL BONDING* (Currently not compliant)

3.4.1 General

To avoid sparking between metallic parts of structures, potential equalization is always required for
Zones 0 and 1 installations and for exposed conductive parts of electrical enclosures in Zone 2.
Potential equalization may also be necessary for other installations in Zone 2. Where necessary,
exposed and extraneous conductive parts shall be connected to the main or supplementary
equipotential bonding system.

Recommendations

A bonding system be incorporated with the electrical design and tested accordingly.

This should consider the need for bonding to transportable vessels as well.

Procedural conditions

Certain procedures may be implemented to comply with AS/NZS 2381.1 cl 1.10 (eg: Hot Work
Permit, temporary bunding, doors to be closed etc).

These procedures MUST be adhered to.

Hazardous Area Training & Implementation

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002-04-06 0406
 03/21/06

VENTILATION - requirements for accumulated flammable vapors

SYSTEM : Ethanol Formulation (16)

AREA : 2325 sq feet or 215.9996 sq meter

fluid = Ethanol MW : 46.069 mol. weight

FORMULA : C2H6O L.E.L. : 3.10% lower explosive limit

· determine vapor pressure @ 20 °C using Antoine Eq.

Coefficient A : 18.9119
Coefficient B : 3803.98
Coefficient C : -41.68

⎡ ( −A ⋅ T − A ⋅ C + B) ⎤
VP 20C := ex p⎢ = 44.032 mmHg
⎥
⎣ ( T + C) ⎦

· determine wet bulb temperature

⎛ ln ( VP 20C) ⎞
Wet BULB := 41 − ⎜ ⎟ = 15.901 °C
⎝ 0.1508 ⎠

· determine vapor pressure at wet bulb temperature

VP WETBULB := ex p⎢
⎡ −( A ⋅ T − A ⋅ C + B) ⎤
⎥ = 32.352 mmHg
⎣ ( T + C) ⎦

· determine rate of evaporation

3 1.25
0.570 . 10 . VP
WetBulb
Cs = 0.014483 ft3/min per foot2
0.29
Mol wt
or : 0.264863 m3/hr per meter2

· ventilation below 25% LEL

vent-16-03-06 Psafety© January 2001

 03/21/06

VENTILATION - Design @ 25% Lower Explosive Limit

SYSTEM : Ethanol Formulation (16)

AREA : 2325 sq feet or 215.9996 sq meter

Fluid : Ethanol Cs : 0.0144829 evaporation rate, CFM/sq. ft.

Formula : C2H6O Va : 1.87 cu ft air/sq. ft. @ 25% LEL

Mol. Weight : 46.069 or : 0.264863 m3/hr air per meter2

L.E.L. : 3.10% Vr : 4,345 CFM, Ventilation Req'd for this Area

or : 7381.966 m3 hour

Current Rate, CFM : 3696.0 equates to 6,279.54 cubic meter/hour, resulting in 29.39 % of LEL.

cfm % ofLower
LEL Explosive Limit vs. Air Flow
2392.5 0.454
2610 0.416
50%
2827.5 0.384
45% 3045 0.357
3262.5 0.333
40%
3480 0.312
35% 3697.5 0.294
3915 0.277
% of L.E.L.

30%
4132.5 0.263
25% 4350 0.250

20%
15%
10%
5%
0%
0 1000 2000 3000 4000 5000
Air Flow, CFM % LEL

vent-16-03-06 Psafety© January 2001

 Ventilation Characteristics

Flammable material FM Ethanol

Molecular mass of propane MM 46.069 (kg/kmol)
Source of release SR Drum spill
Lower explosion limit (LEL) 0.059 kg/m3 (3,1% vol.)
Grade of release RG primary
Safety Factor k 0.25
Release rate (dG/dt)max 0.002 kg / s
Ventilation Characteristics VC High Artificial ventilation
Quality Factor f 3
Avg Ambient Temp Tamb (avg) 293.15 K ( 20°C)
Building size Va 756 m3
Avg Atm Press Atm (avg) 1.01 bar
Initial Concentration Xo 0.95
Initial Concentration Xo 0.05605
Actual Free Volume Vo 756 m3
Actual Air Flow Af 1.743 m3/s
Minimum volumetric flow rate
of fresh air (dV/dt)min 0.135662637 m3 / s
Ventilation Relationship Vk 58.84162554
Number of air changes C 0.002305556
Evaluation of hypothetical
volume Vz 176.5248766 m3
Time of Persistence t 1737.10984 sec
Time of Persistence t 0.482530511 hr
Corrected Air Flow (dVo/dt)max 1.743 m3/s
Density of air D air (avg) 1.2 kg/m3

room 16 ref ASNZS 60079.10 22/03/2006

 03/21/06

VENTILATION - requirements for accumulated flammable vapors

SYSTEM : Perc Packaging (15)

AREA : 1689.93 sq feet or 156.9996 sq meter

fluid = Ethanol MW : 46.069 mol. weight

FORMULA : C2H6O L.E.L. : 3.10% lower explosive limit

· determine vapor pressure @ 20 °C using Antoine Eq.

Coefficient A : 18.9119
Coefficient B : 3803.98
Coefficient C : -41.68

⎡ ( −A ⋅ T − A ⋅ C + B) ⎤
VP 20C := ex p⎢ = 44.032 mmHg
⎥
⎣ ( T + C) ⎦

· determine wet bulb temperature

⎛ ln ( VP 20C) ⎞
Wet BULB := 41 − ⎜ ⎟ = 15.901 °C
⎝ 0.1508 ⎠

· determine vapor pressure at wet bulb temperature

VP WETBULB := ex p⎢
⎡ −( A ⋅ T − A ⋅ C + B) ⎤
⎥ = 32.352 mmHg
⎣ ( T + C) ⎦

· determine rate of evaporation

3 1.25
0.570 . 10 . VP
WetBulb
Cs = 0.014483 ft3/min per foot2
0.29
Mol wt
or : 0.264863 m3/hr per meter2

· ventilation below 25% LEL

vent-15-03-06 Psafety© January 2001

 03/21/06

VENTILATION - Design @ 25% Lower Explosive Limit

SYSTEM : Perc Packaging (15)

AREA : 1689.93 sq feet or 156.9996 sq meter

Fluid : Ethanol Cs : 0.0144829 evaporation rate, CFM/sq. ft.

Formula : C2H6O Va : 1.87 cu ft air/sq. ft. @ 25% LEL

Mol. Weight : 46.069 or : 0.264863 m3/hr air per meter2

L.E.L. : 3.10% Vr : 3,158 CFM, Ventilation Req'd for this Area

or : 5365.594 m3 hour

Current Rate, CFM : 2306.0 equates to 3,917.92 cubic meter/hour, resulting in 34.24 % of LEL.

cfm % ofLower
LEL Explosive Limit vs. Air Flow
1738 0.454
1896 0.416
50%
2054 0.384
45% 2212 0.357
2370 0.333
40%
2528 0.312
35% 2686 0.294
2844 0.278
% of L.E.L.

30%
3002 0.263
25% 3160 0.250

20%
15%
10%
5%
0%
0 500 1000 1500 2000 2500 3000 3500
Air Flow, CFM % LEL

vent-15-03-06 Psafety© January 2001

 Ventilation Characteristics

Flammable material FM Ethanol

Molecular mass of propane MM 46.069 (kg/kmol)
Source of release SR Drum spill
Lower explosion limit (LEL) 0.059 kg/m3 (3,1% vol.)
Grade of release RG primary
Safety Factor k 0.25
Release rate (dG/dt)max 0.002 kg / s
Ventilation Characteristics VC High Artificial ventilation
Quality Factor f 3
Avg Ambient Temp Tamb (avg) 293.15 K ( 20°C)
Building size Va 550 m3
Avg Atm Press Atm (avg) 1.01 bar
Initial Concentration Xo 0.95
Initial Concentration Xo 0.05605
Actual Free Volume Vo 550 m3
Actual Air Flow Af 1.088 m3/s
Minimum volumetric flow rate
of fresh air (dV/dt)min 1.088 m3 / s
Ventilation Relationship Vk 550
Number of air changes C 0.001978182
Evaluation of hypothetical
volume Vz 1650 m3
Time of Persistence t 2024.588036 sec
Time of Persistence t 0.562385566 hr
Corrected Air Flow (dVo/dt)max 1.088 m3/s
Density of air D air (avg) 1.2 kg/m3

room 15 ref ASNZS 60079.10 22/03/2006

 03/21/06

VENTILATION - requirements for accumulated flammable vapors

SYSTEM : Wash Room (18)

AREA : 678 sq feet or 62.98826 sq meter

fluid = Ethanol MW : 46.069 mol. weight

FORMULA : C2H6O L.E.L. : 3.10% lower explosive limit

· determine vapor pressure @ 20 °C using Antoine Eq.

Coefficient A : 18.9119
Coefficient B : 3803.98
Coefficient C : -41.68

⎡ ( −A ⋅ T − A ⋅ C + B) ⎤
VP 20C := ex p⎢ = 44.032 mmHg
⎥
⎣ ( T + C) ⎦

· determine wet bulb temperature

⎛ ln ( VP 20C) ⎞
Wet BULB := 41 − ⎜ ⎟ = 15.901 °C
⎝ 0.1508 ⎠

· determine vapor pressure at wet bulb temperature

VP WETBULB := ex p⎢
⎡ −( A ⋅ T − A ⋅ C + B) ⎤
⎥ = 32.352 mmHg
⎣ ( T + C) ⎦

· determine rate of evaporation

3 1.25
0.570 . 10 . VP
WetBulb
Cs = 0.014483 ft3/min per foot2
0.29
Mol wt
or : 0.264863 m3/hr per meter2

· ventilation below 25% LEL

vent-18-03-06 Psafety© January 2001

 03/21/06

VENTILATION - Design @ 25% Lower Explosive Limit

SYSTEM : Wash Room (18)

AREA : 678 sq feet or 62.98826 sq meter

Fluid : Ethanol Cs : 0.0144829 evaporation rate, CFM/sq. ft.

Formula : C2H6O Va : 1.87 cu ft air/sq. ft. @ 25% LEL

Mol. Weight : 46.069 or : 0.264863 m3/hr air per meter2

L.E.L. : 3.10% Vr : 1,267 CFM, Ventilation Req'd for this Area

or : 2152.677 m3 hour

Current Rate, CFM : 3276.0 equates to 5,565.96 cubic meter/hour, resulting in 9.67 % of LEL.

cfm % ofLower
LEL Explosive Limit vs. Air Flow
698.5 0.453
762 0.416
50%
825.5 0.384
45% 889 0.356
952.5 0.333
40%
1016 0.312
35% 1079.5 0.293
1143 0.277
% of L.E.L.

30%
1206.5 0.263
25% 1270 0.249

20%
15%
10%
5%
0%
0 200 400 600 800 1000 1200 1400
Air Flow, CFM % LEL

vent-18-03-06 Psafety© January 2001

 Ventilation Characteristics

Flammable material FM Ethanol

Molecular mass of propane MM 46.069 (kg/kmol)
Source of release SR Drum spill
Lower explosion limit (LEL) 0.059 kg/m3 (3,1% vol.)
Grade of release RG primary
Safety Factor k 0.25
Release rate (dG/dt)max 0.002 kg / s
Ventilation Characteristics VC High Artificial ventilation
Quality Factor f 3
Avg Ambient Temp Tamb (avg) 293.15 K ( 20°C)
Building size Va 217 m3
Avg Atm Press Atm (avg) 1.01 bar
Initial Concentration Xo 0.95
Initial Concentration Xo 0.05605
Actual Free Volume Vo 217 m3
Actual Air Flow Af 1.545 m3/s
Minimum volumetric flow rate
of fresh air (dV/dt)min 1.088 m3 / s
Ventilation Relationship Vk 152.812945
Number of air changes C 0.007119816
Evaluation of hypothetical
volume Vz 458.438835 m3
Time of Persistence t 562.5150185 sec
Time of Persistence t 0.156254172 hr
Corrected Air Flow (dVo/dt)max 1.545 m3/s
Density of air D air (avg) 1.2 kg/m3

Room 18 ref ASNZS 60079.10 22/03/2006