Appendix IV Classification of Hazardous Areas

IV.2 Classification of Hazardous Zones

The hazardous zone resulting from a continuous source will be a greater hazard than the zone resulting from a
primary source, because the probability is higher than it will contain a flammable mixture. To show this,
hazardous zones are classified according to the type of source of flammable vapour or gas:
the hazardous zone resulting from a continuous source is normally classified as
Zone 0
the hazardous zone resulting from a primary source is normally classified as Zone 1
the hazardous zone resulting from a secondary source is normally classified as
Zone 2.
The parts of the facility which are not classified as hazardous zones can be designated non-hazardous but may
still contain a flammable mixture under calamity conditions.
Hazardous zone classification depends on the grade of release and the ventilation available as shown in Table
I.!:
Table IV.1 Hazardous zone classification and impact of ventilation
Grades of
release
Open air situation and
adequately ventilated spaces
it! unrestricted air
"ove"ent# ie at least 12
c!an$es per !our
%estricted ventilation# e$
inside "odules it!
ventilation stopped or less
t!an 12 c!an$es per !our
&o ventilation# e$
inside tan'
Continuous Zone 0 Zone 0 Zone 0
Primary Zone 1 Zone 1 Zone 0
Secondary Zone 2 Zone 1 Zone 0
"or land rigs, the open air situation is the norm, with restricted ventilation only present where the drill floor is
shrouded, or inside the free space of active mud tan#s, ditches and well cellar areas. There should be no $one %
areas on any drilling rig installation. &utside $one %, ! or ' the wor#site is (non-hazardous(.
IV.( Hazardous Zone )i"ensions
)ccording to the I* +ode ,!--%. for /rilling and 0or#over Installations ,where diagrams are provided., the
$one ' hazardous zones around the rig e1uipment extend to:
1. A cylinder 7.5 m around the bell nipple extending 9 m below the wellhead deck
(offshore) or to ground level. The upper extent of the Zone 2 is 7.5 m above the rig
floor, extending to the top of any existing wind break around the derrick area.
Only the wellhead cellar and sunken ditches within the Zone 2 are classified as
Zone 1.
2. A space around active mud tanks 3 m from the top and sides of each tank to
ground level extending to 7.5 m from the sides of each tank at a height of 3 m.
Inside the tank walls is Zone 1. Enclosures around the tank, unless adequately
ventilated are classified as hazardous Zone 1 with Zone 2 extending 3 m from
openings to the enclosure.
3. Around the shale shaker Zone 2 extends 7.5 m above and around the exterior
surface of the shaker, and Zone 1 extends 1.5 m from the outer surface . If enclosed
the enclosed space shall all be classified as Zone 1, with Zone 2 areas extending
7.5 m from any openings.
Appendix IV Classification of Hazardous Areas
4. For any gas vent outlets, the extent of the hazardous zone is based on guidelines
provided in Chapter 5 of the IP Code. If flow rates and type of effluent figures are
not known the hazardous (Zone 2) should extend at least 15 m from the vent outlet
in all directions.
5. For wireline operations, the point of reference is not the bell nipple but the
stuffing box with other dimensions and zone classifications the same as with
drilling rigs on land and to the main deck offshore.
"or the purpose of ignition protection against small releases of flammable fluids around the rig floor area, the
interior of the derric# or mast structure is classified as $one '. )ll purge air, cooling air and internal combustion
engine air inta#e shall be ta#en from well outside $one ! and ', ie from a designated non-hazardous zone.
21ually, all electrical e1uipment in the derric# shall be suitably protected. 3e1uirements are defined in the I*
+ode.
+ellars or pits below ground level in a $one ' space should be classified as $one !. )ny enclosed premises,
containing source of hazard which may give rise to a dangerous atmosphere under abnormal conditions should
be classified as follows:
The interior of the enclosure $one !4 the surrounding space in open air within a 5.6 m radius from any point of
egress from the premises as $one '. )ny enclosed premises not containing a source of hazard but located in a
$one ' space should be classified as $one !, unless entry of a dangerous atmosphere is prevented by, eg fire
walls, ventilation, etc where the enclosure may be classified as a $one ' or even as a safe zone if the space is
ventilated and over-pressurised.
In naturally well-ventilated conditions ,eg offshore. outside the limits of the derric# or mast, the vertical extent
of the (hazardous zone( above the highest source of hazard may be reduced to 7 m and extends over the whole
classified area and below the source of hazard to ground level, except as described in the cases above. "or full
details refer to I*!6 +hapter 8.
It must be clearly emphasised that the dimensions and conditions 1uoted are to be considered as the minimum
case, and where any doubt exists, the dimensions ,or even classification. of the hazardous zone should be
increased by appropriate degree.
Appendix IV Classification of Hazardous Areas
This page intentionally left blank
Appendix IV Classification of Hazardous Areas
*++,&)I- V
O+,%*TIO& O. )I,/,0 ,&GI&,/ I&
H*Z*%)O1/ *%,*/
The following data is ta#en from the document( 3ecommendations for the *rotection of /iesel 2ngines
&perating in Hazardous )reas( ,3ef. 2rror: 3eference source not found.
V.1 Introduction
There are considerable problems in providing assured protection to diesel engines for use in hazardous
$ones %, ! and to a certain extent in zone ' as defined by the document (2lectrical 9afety( ,3ef. 2rror:
3eference source not found. and by (+ode of *ractice for 9election, Installation and :aintenance of
2lectrical )pparatus for ;se in *otentially 2xplosive )tmospheres( ,3ef. 2rror: 3eference source not
found..
The use of permanently installed diesel engines in $one % is unacceptable, and the use of permanently
installed diesel engines in $ones ! and ' should be avoided wherever possible.
Note: The effectiveness of protective devices is dependent upon a high standard of maintenance and
inspection of the e1uipment4 certain items need to be chec#ed regularly.
Table V.1 ecommendations for protection of diesel en!ines on drillin! ri!s "#ic# are
permanently installed in #azardous Zones 1 and 2
&ature of Hazard Zones 1 and 2
$isc#ar!e of spar%s from electrical
e&uipment
'#e starter s#all (e of t#e follo"in! non)electric types* pneumatic+ #ydraulic+ sprin!
recoil+ inertia or #and start,
Any ot#er electrical e&uipment associated "it# t#e en!ine s#all (e flame proof as
defined in -S ./01 2Specification for electrical apparatus for explosive
atmosp#eres2+ or intrinsically safe as defined in -S 1234 2Intrinsically safe electrical
apparatus and circuits for use in explosive atmosp#eres2 5see also -S 31.3 Part 1*
Selection+ installation and maintenance of electrical apparatus for use in potentially
explosive atmosp#eres6,
7lectrical e&uipment s#all (e effectively eart#ed and (onded to t#e main en!ine
frame,
$isc#ar!e of spar%s from mec#anical
causes
Coolin! fan (lades s#all (e made from non)metallic materials,
8eneration and disc#ar!e of static
from (elt drives
All (elts s#all (e of antistatic fire)resistant type,
$isc#ar!e of spar%s or flames from t#e
ex#aust system
A !as conditioner (ox and a flame trap s#all (e installed, Alternatively+ t#e ex#aust
s#ould (e desi!ned to disc#ar!e to a location "it#in a 2safe2 zone,
9las#(ac% t#rou!# induction system :#erever possi(le+ air inta%es for en!ines s#all (e located in a 2safe2 zone as
defined (y t#e Institute of Petroleum 7lectrical Safety Code, Alternatively+ a flame
trap s#ould (e provided 5-ar(er valve6,
;ver#eatin! due to failure of coolin!
"ater system or loss of lu(e oil
pressure
Alarms or automatic s#utdo"n devices s#all (e provided+ actioned (y excessive
"ater temperature and lo" lu(e oil pressure,
Table V.1 ecommendations for protection of diesel en!ines on drillin! ri!s "#ic# are
permanently installed in #azardous Zones 1 and 2 5continued6
&ature of Hazard Zones 1 and 2
7xcessive en!ine vi(ration A system usin! an alarm or trip device to protect t#e en!ine from excessive
vi(ration s#ould (e considered,
7xplosions in en!ine cran%case<
disc#ar!e from cran%case and cylinder
#ead relief valves and (reat#ers
An en!ine #avin! a cran%case volume of over 0,3 m
1
s#all (e provided "it# relief
devices, elief valves+ prefera(ly of -IC7I desi!n+ or (reat#ers on en!ines s#all
(e fitted "it# flame traps or alternatively disc#ar!e into t#e induction system
do"nstream of t#e flame trap+ if fitted+ and upstream of t#e s#ut)off valve+ if fitted,
$ipstic%s and=or filler caps s#ould (e scre"ed or effectively secured (y ot#er
means,
Appendix IV Classification of Hazardous Areas
7xplosions in inta%e or ex#aust
systems
Inta%e and ex#aust systems s#all (e desi!ned in accordance "it# Appendix 1,1 of
t#e ;C>A >7C)1 document,
9lame transmission to atmosp#ere (y
openin! of decompression pots
$ecompression systems s#ould not normally (e provided, Ho"ever+ if t#ey are
essential+ t#en t#e decompression ports s#ould (e provided "it# flame traps and
ducted a"ay to a safe zone,
everse runnin! of en!ine '#e fuel in?ection pump and !overnor "#ere fitted s#ould (e so desi!ned t#at
reverse runnin! of t#e en!ine is not possi(le,
7xcessive temperature of ex#aust
!ases and excessive surface
temperature of en!ine and ex#aust
system
'#e surface temperature of t#e en!ine and ex#aust system s#all not exceed 230@C
"#en tested under full load conditions, In some situations coolin! of t#e ex#aust
manifold and pipin! may (e necessary+ usin! "ater ?ac%etin! or finned coolers
and=or #i!# temperature cut)outs or alarms s#ould (e provided,
In t#is connection it s#ould (e noted t#at air cooled or superc#ar!ed diesel en!ines
!enerally #ave si!nificantly #i!#er ex#aust temperatures t#an "ater cooled
en!ines,
Conversely+ en!ines operated (elo" t#eir maximum po"er ratin! "ill #ave
correspondin!ly lo"er ex#aust !as and surface temperatures,
8iven conditions of normal operation+ for t#e ma?ority of refinery and
petroc!e"ical flamma(les in t#e re!ions of natural convection surroundin! t#e #ot
surfaces of diesel en!ines+ surface temperatures of 230@C are accepta(le,
7xceptions are*
"#en free movement of air is restricted (y t#ermal or acoustic
s#ieldin!
"#en t#e auto)i!nition temperature of t#e flamma(le+ determined (y
AS'> test $2133)// is (elo" 200
o
C,
If eit#er of t#ese t"o conditions exists+ no en!ine exposed surface temperature
s#all exceed t#at determined for t#e flamma(le (y t#e AS'> test,
&ote2 '#e IP Code indicates t#at "#ere t#e principal mo(ile com(usti(le fluid is
%no"n to (e met#ane !as+ t#en #i!#er en!ine surface temperatures 5e! 300
o
C6
may (e considered accepta(le,
;verspeedin! of t#e en!ine due to
induction of flamma(le !as or vapour
A means s#all (e provided to stop t#e en!ine "#en flamma(le !as or vapour in t#e
atmosp#ere can cause t#e en!ine to overspeed,
"or a complete specification, discussion and explanation of the above re1uirements, reference to the
original document is recommended.
The document ()rea +lassification of "lammable <as )tmospheres( ,3ef. 2rror: 3eference source not
found. is also used as a source to define the principles of diesel engine operation in hazardous zones.
Fixed diesel-engine e1uipment shall be located outside a hazardous zone, unless ade1uate and effective
protection to all electrics, hot surfaces, exhaust systems, etc can be achieved, in which case it may be
located in $ones ! or '. 9uch protection should normally include the provision of an air source from a non-
hazardous zone. However, if this is impracticable, the engine shall be fitted with an automatically operated
combustion air cut-out to prevent engine runaways in the event of flammable vapour ingestion.
Mobile diesel-engine e1uipment should preferably not be used in a hazardous zone, but if this is
unavoidable it should be fully protected as for fixed diesel installations or have a minimum of protection
and operate under a permit-to-wor# system. The minimum protection should be spar# arrestors, hot surface
cooling and, in addition for $one !, an automatic air cut-off.
Note: In no case should a diesel engine be allowed to operate in $one %.
3igs which have been designed and e1uipped with diesel engine power supply to the drawwor#s, rotary
table and mud pumps according the document (+lassification of )reas for 2lectrical Installation at /rilling
3igs and *roduction "acilities on =and and>or :arine "ixed and :obile *latforms( ,3ef. 2rror: 3eference
source not found. do not always comply with hazardous zone restrictions as defined under the I* +ode. )s
it is costly to retrofit diesel engines on rigs, they should, in relation to the document (3ecommendations for
the *rotection of /iesel 2ngines &perating in Hazardous )reas( ,3ef. 2rror: 3eference source not found.
preferably be selected for conformity with the I* +ode.
Appendix IV Classification of Hazardous Areas