Equipment Zoning for Hazardous Area

Classification as per IP 15

Prepared By: Ankur Srivastava

Senior Process Engineer
Mott MacDonald & Co. LLC,
Muscat, Sultanate of Oman

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 What is Hazardous Area?

 A hazardous area is defined as a three-

dimensional space in which a flammable
atmosphere may be expected to be present at
such frequencies as to require special precautions
for the design and construction of equipment, and
the control of other potential ignition sources.

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 Why do we need to classify the area?
 The aim of hazardous area classification is to avoid ignition
of those releases that may occur from time to time in the
operation of facilities handling flammable liquids and
vapour. The approach is to reduce to an acceptable
minimum level the probability of coincidence of a
flammable atmosphere and an electrical or other source of
ignition.
In simple terms, hazardous area classification is a method
of analyzing & classifying the environment, where there is a
partial or total likelihood of a flammable atmosphere to
exist, for the purpose of proper selection of electrical
apparatus to be installed in that environment.

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 Factors Affecting Hazardous Area
Classification-1
 Source of Release
For the purpose of hazardous area
classification a source of release is defined
as a point from which a flammable gas,
vapour or liquid may be released into the
atmosphere.

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 Factors Affecting Hazardous Area
Classification-2
 Continuous grade release
A release that is continuous or nearly so, or that occurs frequently
and for short periods.
 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.
 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 i.e. a release
which, in operating procedures, is not anticipated to occur. Such
releases may be of known size e.g. fracture of a drain, or unknown
size e.g. corrosion hole.

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 Factors Affecting Hazardous Area
Classification-3
 The grade of release is dependent solely on the
frequency and duration of the release. It is
completely independent of the rate and quantity of
the release, the degree of ventilation, or the
characteristics of the fluid, although these factors
determine the extent of vapour travel and, in
consequence, the dimensional limits of the
hazardous area.

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 Fluid Categories (Table 1.2 –IP15)
Fluid Description
Category
A A flammable liquid, that on release, would vaporise rapidly &
substantially. This category includes:
a) Any LPG or lighter flammable liquid
b) Any flammable liquid at a temperature sufficient to produce,
on release, more than 40% vol. vaporisation with no heat input
other than from the surroundings.
B A flammable liquid, not in Cat. A, but at a temp. sufficient for
boiling to occur on release
C A flammable liquid, not in Cat. A or B, but which can, on
release, be at a temp. above its flash pt., or form a
flammable mist or spray
G(i) A typical methane-rich natural gas
G(ii) Refinery hydrogen

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 Zone 0 -Typical areas OOOOOOO
OOOOOOO
OOOOOOO
OOOOOOO
OOOOOOO

(Continuous grade: Release likely to be present for > 1000

hrs per year) (Sec. 1.6.4 –IP 15)

 Vapour space above:

– closed process vessels,

– storage tanks

– closed containers,

– areas containing open tanks of volatile, flammable

liquid
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 How to identify Zone 1 areas
Primary Grade: Release likely to be present for between 10 &
1000 hrs per year (Sec. 1.6.4 – IP 15)

 Flammable gas or vapour concentration is likely to exist in the air

under normal operating conditions

 Flammable atmospheric concentration is likely to occur frequently

because of maintenance, repairs or leakage

 Flammable liquid or vapour piping system (containing valves, meters,

or screwed or flanged fittings) is in an inadequately ventilated area

 The area below the surrounding elevation or grade is such that

flammable liquids or vapours may accumulate therein

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 Zone 1 -Typical areas

 Imperfectly fitting peripheral seals on floating roof tanks

 Inadequately ventilated compressor or pump rooms for

flammable gas or for volatile, flammable liquids

 Oily waste water sewer / basins

 Loading / unloading gantries of hazardous products

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 Typical Zone 2 areas
Secondary Grade: Release likely to be present for 1 to 10
hrs per year (Sec. 1.6.4 – IP 15)

 The system handling flammable liquid or vapour is in an adequately

ventilated area and is so designed and operated that the explosive or
ignitable liquids, vapours or gases will normally be confined within
closed containers or closed systems from which they can escape only
during abnormal conditions such as accidental release from a
damaged gasket or packing

 The flammable vapours can be conducted to the location as through

trenches, pipes or ducts

 Locations adjacent to Zone 1 areas

 Pressurized rooms where flammable gas / vapour can enter in the

case of failure of positive mechanical ventilation

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 Non-hazardous Areas -Typical areas

The following locations are considered non-hazardous from the point of view of
electrical installation:
 Areas where the piping system is without valves, fittings, flanges or similar
appurtenances

 Areas where flammable liquids or vapours are transported only in suitable

containers or vessels

 Adequately ventilated locations surrounding equipment that has continuous

flame sources (e.g. unprotected fired vessels & flare tips)

 DG shed room / shed having adequate ventilation

 GT installation meeting the ventilation (12 ACPH) , pressurization (0.5

mbar )and flange (not more than one pair of flanges inside the turbine room)
requirements

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 Petroleum Fluid Classes as per IP 15
(Annex A- Table A1)
Class 0 Liquefied Petroleum Gases (LPG)

Class I Liquids that have flash points below 21°C

Class II(1) Liquids that have flash points from 21°C up to &
including 55°C, handled below flash point
Class II(2) Liquids that have flash points from 21°C up to &
including 55°C, handled at or above flash point
Class III(1) Liquids that have flash points above 55°C up to &
including 100°C, handled below flash point
Class III(2) Liquids that have flash points above 55°C up to &
including 100°C, handled at or above flash point
Unclassified Liquids that have flash point above 100°C

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 Zone 0

Storage Tanks -1
Zone 1
Zone 2
Non-Haz.

 Fixed Roof Tanks for Classes I, II(2) & III(2) for filling
rates up to 250 m3/h
Blanketing Gas

m
3
2m
Bund height

Liquid Level

Tank Wall Dist. To Bund

Collection or Drain Pit

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 Zone 0

Storage Tanks -2
Zone 1
Zone 2
Non-Haz.

 Internal Floating Roof Tanks for Classes I, II(2) & III(2)

2m
Bund height

2m
Floating Roof

Collection or Drain Pit Tank Wall Dist. To Bund

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 Zone 0

Storage Tanks -3 Zone 1

Zone 2
Non-Haz.

 Above Ground Pressurized Bulk LPG Installations

m
3

m
1.5
Ullage Level Indication
m
3
1m

Spill Catchment Slope

Note 1 Loading & / or unloading connections

Note 1: Provide a 1 m, Zone 2 section from the edges of the spill catchment area

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 Zone 0

Storage Tanks -4 Zone 1

Zone 2
Non-Haz.

 Pit mounted KO drum or Oily Water Drain Vessel

R=3m

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 Zone 0

Pumps Zone 1
Zone 2
Non-Haz.

 Adequately Ventilated Areas for Oil, Oily Water Pumps w/Double Mech. Seal &
throttle Bush (High Integrity Pumps) ee
=S
R 1 le
b
Ta

Fluid Level I
Cat.
Hole Size R1
(mm) (m)
A 2 4

R1 =See Table
B 2 4

C 2 4.5

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 Pumps (continued)
Notes:
1. ‘Level’ defines the release frequency which are based on achieving
an overall value of individual risk of less than 1.0E-5/yr.

‘Level I’ is the highest frequency (≥1.0E-2) & would be the most

commonly encountered. For more information about ‘Level’ refer
Annex C-Part 1 & 2 of IP 15.

2. For Levels II & III the hole radius and corresponding Hazard Radius
are different & reference is made to Table 5.1(c) of IP 15.

3. Above slide & table is for ‘High Integrity Pumps’. For standard pumps
without throttle bush refer Table 5.1(a) of IP 15. For standard pumps
with throttle bushes refer Table 5.1(b) of IP 15.

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 Zone 0

Zone 1
Compressors (Adequately Ventilated) Zone 2
Non-Haz.

Release Seal Type Release Hazard

Frequency hole dia. Radius R1
a ble
(mm) (m) e eT
=S
R 1
G(i) G(ii)

LEVEL I Floating Ring 5 4 6

Purged Labyrinth 12 10 13

R1 =See Table

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 Zone 0

Pig Launchers & Receivers Zone 1

Zone 2
Non-Haz.

 Pig Launcher (Pig Receiver will be similar)

R
=
3
m

Equivalent Dia. of Hazard Radius

Pool Pool/Collection Pit, (m) R1 (m)
Less than 5 3
5 to less than 10 7.5
L R1 10 or greater 15

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 Gas-Oil-Water Separator (Test/Bulk)
 Following guidelines should be considered:
1. Consider R = 3 m from the furthest flange/valve in the associated
piping of the ‘Separator’ & draw a Zone 2 envelope encompassing
the ‘Separator’.

2. If there is a liquid sample point on the separator, it should be

considered separately, with the Zone 2 envelope drawn with R = 5.5
m from the sample point.

3. The above mentioned radius & zone class have been referenced
from the ‘Mabrouk Full Facilities Development’ project ‘Hazardous
Area Classification’ drawings.

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 Flares

 Adequately ventilated locations surrounding equipment that

has a continuous flame source e.g. ‘Flare Tips’ need not be
classified (non-hazardous area) solely by the reason of the
fuel gas being considered as a source of release.

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 Pipe Rack

1. Pipe Rack need to be classified, if required, considering

secondary grade release i.e. Zone 2 only.
2. Area classification for pipe rack need to be considered only
for the portion where there are flanges & valves. A Zone 2
envelope considering R = 3 m from the flange/valve
packing should be considered for the pipe rack.

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 Valves

 Frequently used valves (including control valves) with

packed glands should be regarded as producing an
additional primary release (Zone 1) with R = 0.3 m.
Electrical equipment within 0.3 m of any valve gland shall
be suitable for operation in a Zone 1 area. Reference is
made to HAC drawings of ‘Mabrouk Full Facilities
Development’ project.

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 Zone 0

Road Tanker Loading Zone 1

Zone 2
Non-Haz.

 Top Loading through open or vent fill covers

1. m
5 5
m 1.

Ground

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Recommended Apparatus Sub-group & temperature
class for some flammable liquids (Table 7.2 – IP 15)

Flammable Apparatus Temp. (T) class of

Liquid sub-group suitable equipment
Methane IIA T1
Ethane IIA T1
Propane IIA T1
Crude Oil IIA T3
Diesel IIA T3
LPG IIA† T2

† If LPG contains significant qty. of 2-butene then the appropriate apparatus

group is IIB

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 Definition of Temp. Class (Table 7.3 – IP 15)

 Relationship between temperature class & maximum surface temperature of

the apparatus (in accordance with IEC 60079-0)

Temperature Class Maximum Surface

temperature (°C)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85

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 Thank you for your valuable time
and
presence

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