Integrated Management

System Document

Doc. No.: PCD-SF195

Rev.:
0

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Procedure for
Hazardous Area Classification

11 Oct
14

Rev
.

Date

First issue
Description

H.Hosseini

I. Zamani

Prepared
by

Reviewed
by

A. Zamani
Approved
by

Sections changed in the last revision are identified by

This document is the property of Tehran Raymand Consulting Engineers and should not be disclosed or reproduced without a
prior written permission.

Procedure For
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TABLE OF CONTENTS
1.

Scope....................................................................................................3

2.

References............................................................................................3

3.

Definitions............................................................................................3

4.

Procedure.............................................................................................3
4.1.

Specification of Fluids...................................................................4

4.2.

Determination of Release Frequency Level...................................4

4.2.1. Calculation the Probability of Occupancy..................................5

4.2.2. Calculation of N range................................................................5
4.2.3. Calculation of Exposure..............................................................5
4.2.4. Calculation the Probability of Ignition.......................................5
4.2.5. Calculation of Release Frequency Level....................................6
4.3.

Identification of Point Sources.......................................................7

4.4.

Determination the Grade of Release.............................................7

4.5.

Zone Classification.........................................................................8

4.6.

Determination of Equivalent Hole Diameter.................................8

4.7.

Calculation of Hazard Radii...........................................................9

4.8.

Determination of Shape Factor....................................................12

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1. Scope
This procedure defines the requirements governing the classification of
hazardous areas in oil, gas & petrochemical plants.
The purpose of classifying hazardous areas is to avoid ignition of those
releases which invariably occur from time to time in the operation of
facilities handling liquids and vapors, thereby minimizing the probability
of coincident exposure of a flammable atmosphere and an electrical or
other sources of ignition such as, mechanical or radio frequency
electromagnetic radiation for example.
The classification of the hazardous areas according to the frequency of
the existence of a flammable gas/ air mixture provides the means to:

Perform the correct selection of equipment to be installed in areas

according to their degree of hazardous area classification.

Ensure that sources of ignition are segregated from sources of

flammable gas in accordance with code,

Select the location of clean air inlets for ventilation systems or

others safety requirements,

This specification does not apply to catastrophic failure, which is beyond

the concept of abnormality dealt within it.
2. References

IP Model Safe Practice Part15, 3rd edition.

API 505 Recommended practice for classification of locations for

Electrical installations at petroleum facilities classified as class1,
Zone0, Zone 1 and zone 2.

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.

3. Definitions

Pocc

Probability of Occupancy

Pign

Probability of Ignition

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4. Procedure
The methodology described in IP Code Part-15 shall be applied to define
the hazardous area.
4.1. Specification of Fluids

Compositions of fluids that are present in process shall be extracted from

Heat & Material Balance.
The fluid category shall be determined using Table.3 which is referred in
chapter 1 of IP Code-Part15.
Table.3 (From IP Code) Determination of Fluid Category
Fluid
categor
y

Description
A flammable liquid that, on release, would vaporize rapidly
and substantially. This category includes:

(a) Any liquefied petroleum gas or lighter flammable liquid.

(b) Any flammable liquid at a temperature sufficient to
produce, on release, more than about 40% vol. Vaporization
with no heat input other than from the surroundings.

A flammable liquid, not in category A, but at a temperature

sufficient for boiling to occur on release.

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.

G(i)

A typical methane-rich natural gas.

G(ii)

Refinery hydrogen.

Subgroup and temperature class of the suitable equipment shall be

selected based on chapter 7 of IP Code. As the fluids are usually
hydrocarbon mixtures, the most onerous components shall be considered
based on IP recommendation.
4.2. Determination of Release Frequency Level

Release frequency level shall be calculated based on Annex C-Part 1 of IP

code-Part 15. According to IP code definition, workers within Zone 2

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hazardous areas are exposed to multiple sources of release. In order to

take multiple sources into account a parameter called Exposure (Exp) is
defined as follows:
Exp = Pocc* Nrange
Where
Pocc: Probability the worker is on site within the hazardous area.
Nrange: The time weighted average number of release sources which
can affect the individual during their time within the hazardous area.
These parameters shall be calculated as follows.
4.2.1.
Calculation the Probability of Occupancy
Assume that the individual spends an average of one hour per day in
hazardous area; Pocc
will be calculated by determining the portion of
time that the individual spends on site within the hazardous area.
Following is a sample where working hours is 8 hr/day:
Total Hours per Year= (365day/year) * (24 hr/day) = 8760 hr
Total Working Hours = (7day/week) * (8hr/day) * (48week/year) = 2016
hr
Pocc = (2016/8760) * (1/8) = 0.0288
4.2.2.
Calculation of N range
Number of Secondary Grade Release Sources within Range shall be
selected according to table C2 from Annex C1 of IP code. For example
where hazardous equipment does not contain more than 15 release
sources, the parameter is calculated as follows:
Table.4-Calculation of N range
% of Time
Open Plant
1 Source
%20

N range

Congested
Plant 5
Source

Many Release
Source
30 Source

Average Number of
Sources in range
during time on site

%30

%50

16.7

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4.2.3.
Calculation of Exposure
Exposure shall be calculated as below:
Exp = Pocc* Nrange
4.2.4.
Calculation the Probability of Ignition
Probability of ignition shall be calculated based on Annex C1 of IP code.
For example for a fired equipment such as fire heater which has hot
surfaces and contacts to direct flame, shall be regarded as Strong
source of Ignition, therefore Pign=1 shall be assigned to zone 2
hazardous
area.

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Table.5 (From IP Code) - Probability of ignition (Pign) for varying sources

of ignition strengths
Source of
ignition

Description

Probability
of ignition
given
release

Controlle
d

Where control of sources of ignition extends

beyond Zone 2 (e.g. on offshore facilities
where ignition sources are linked to fire and
gas detection systems).

0,003

Weak

Typical sources of ignition within a Zone 2

area.

0,01

Medium

Ignition due to road traffic, substations,

buildings, unclassified electrical equipment,
engines, hot surfaces etc.

0,1

Strong

Continuous strong sources of ignition such

as fired heaters, flares etc.

4.2.5.
Calculation of Release Frequency Level
Release frequencies are banded into three levels as per follows and
shown graphically on Figure C2 of IP Code-Part15.
LEVEL

Frequency of release per leak sourceyr

LEVEL I

Greater than 1,0E-2 /release sourceyr

LEVEL II

1,0E-2 to 1,0E-3 /release source-yr

LEVEL
III

1,0E-3 to 1,0E-4 /release source-yr

Two required data for calculating the release frequency level are taken
from previous sections.
Using the following figure from IP code, release frequency level can be
obtained:

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Figure.1 Calculation of Release Frequency Level

4.3.
I

dentification of Point Sources

The followings standard equipment are usually found in a process plant:

Pumps;

Equipment drains and liquid sample points;

Compressors;

Vents;

Piping systems;

Pig receivers and launchers;

Liquid pools due to spillage;

Sumps, interceptors and separators;

Pits or depressions;

Surface water drainage systems.

Point sources of each of above equipment shall be identified according to

section 5.4 of IP code.

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4.4. Determination the Grade of Release

The majority of flange joints are rarely broken, e.g. only during major
maintenance work, typically at intervals of about two years or more.
Therefore flanges should be considered as sources of secondary grade
releases.
Leakage is unlikely on well-maintained, infrequently used valves and
these should therefore be regarded as sources of secondary grade
release. On frequently used valves (including control valves) these
should be regarded as producing an additional primary grade release
with a nominal radius of 0.3 m.
For leakage from pump seals, glands and pipe flanges, a secondary grade
of release is applicable.
For other point sources of equipment stated in 4.3, refer to section 5.4 of
IP code.
4.5. Zone Classification

The zone classification (i.e. Zone 0, 1 or 2), is a function of the grade of

release, the duration of a flammable atmosphere and the degree of
ventilation and should be determined according to Chapter 6 of IP CodePart15.
Usually all sources of release within a process unit are located in open
outdoor area (adequate ventilated area); As per IP code there is a direct
relationship between the grade of release and the zone classification for
those sources located in adequate ventilated area as per follows:

Continuous grade of release leads to Zone 0;

Primary grade of release leads to Zone 1;

Secondary grade of release leads to Zone 2.

4.6. Determination of Equivalent Hole Diameter

The frequency of a flammable release due to secondary grade release

point sources may be estimated by examining failure data for various
items of equipment considered to be point release sources. The extent of
the hazardous area depends on the size (diameter) of the hole in the
equipment and the characteristics of the process fluid.
Table 6 which is referred in Annex C-Part 2 of IP Code-Part 15,
summarizes the hole size distribution for secondary grade releases at
various frequencies from the items of equipment covered in section 4.3.

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Table.6 (From IP Code-Table C6) - Equivalent Hole Sizes for a range of

Release Frequencies

Example:
For flanges, assume that the Spiral Wound Joint (SWJ) flanges are used,
the hole diameter of 0.2 mm is obtained for Level 2 release frequency.
For Valves with Level 2 release frequency, 2 mm hole diameter is
obtained.
4.7. Calculation of Hazard Radii

Hazard radii appropriate to the release hole sizes obtained from previous
section can be directly read off Tables 7 (a) and (b).
Example:

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For the flanges, the appropriate hole size which has been calculated in
section 4.6, is 0.2 mm, as this hole size diameter is not covered in Tables
8(a) and (b), the radii will be calculated considering a hole size diameter
of 1 mm, which is available in Tables 8(a) and (b).
Table 8 shows a typical hazardous source list with an example.
Table.8 (a) (Table C9 (a) of IP Code) - Hazard radius (R1)

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Table.7 (b) (Table C9 (b) of IP Code) - Hazard radius (R2)

Table.8- Typical Hazardous Source List

.
Ite
m
No

Nam
e

EQ01

2
3
4
5
6

Sourc
e of
Relea
se

Elevati
on (m)

Flang
e

5.7

Flamma
ble
Material

Natural
Gas

Operati
ng
Press.
(barg)

IP
Code
Releas
e
Diame
ter
(mm)

Relea
se
Press
ure
(barg)

Level
I/II/II
I

0.2

II

Hazar
d
Radiu
s (m)
R
1
<
1

R
1
<
1

Zon
e
No.

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4.8. Determination of Shape Factor

The relationship between the hazard radius R1 (as determined in the

preceding section) and the full three dimensional envelope of the
hazardous area is determined using Figure.2.The shape factor depends
upon the height and orientation of the release and the hazard radius. The
key features are:

Releases below a height (H) of 1 m are influenced by the ground

and have a hazard radius R2.

Releases above 1 m, but at heights below the hazard radius R1 + 1

m are influenced by the ground if the release is directed downward
and passes below 1 m.

Releases at a height above the hazard radius R1 + 1 m are

independent of the ground.

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Figure.2- Shape Factor for Pressurized Release

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