Haz

FIRE
ardous Area Instrumentation

TABLE OF CONTENTS
1WHY CLASSIFY HAZARDOUS AREA?.............................................................................................3 2AREA CLASSIFICATION STANDARDS ...........................................................................................4 3EUROPEAN STANDARD OF AREA CLASSIFICATION...................................................................5 4AMERICAN STANDARD OF AREA CLASSIFICATION....................................................................6 5WHAT HAPPENS IF YOU IGNORE AREA CLASSIFICATION ?......................................................8

WHY CLASSIFY HAZARDOUS AREA? The most destructive element in nature is Fire. The primary cause of fire is Inflammable materials. Inflammable or Flammable materials, as is commonly called, create a Fire Hazard only if (based on common Fire triangle knowledge) there is also a simultaneous presence of (initial or continuous) Source of ignition and (undiminished) Combustible Air/ gas. The Flammable material can be solid (including dust), liquid or gas or a combination of them in a homogeneous or heterogeneous or in any morphed form. (Note: There is a difference between flammable and combustible liquids based on flash point but this article treats both as same for the purpose of simplicity) But avoidance of fire by avoiding Flammable material is not a relevant discussion since these Flammable materials are also sources of energy & product-of-use manufactured in the industrial process. The hazard caused by Flammable materials is a function of number of factors/ properties such as flashpoint, flammability Index, auto ignition temperature, combustion energy released etc. Therefore some possibilities exist in reducing the risk of fire by getting rid of unwanted materials to reduce the higher limits of Fire Hazard based on the properties cited above. The presence of air cannot be avoided, as earths atmosphere is an infinite reservoir of air and its 29% component of Oxygen is the most combustible part of it integrally present, apart from our obvious human need of it to survive. But action to reduce the presence of other unwanted vapors and gases that heighten the fire hazard (e.g. Oxygen rich atmosphere) may be taken. Manual source of Ignition in the presence of flammable materials such as matches may be controlled by its absence enforced by Industrial Security in the area of flammable materials. But the most common source of Ignition is Electrical energy in the form of arc or spark or even heat plasma in the industrial plant. The major potential Electrical ignition source is sparking in electrical equipments such as Motors. The other potential source of ignition of flammable mixtures that concerns us as Instrument Engineers is that from Electrical / Electronic (process control) Instrumentation, controller, communication, computer systems and instrument auxiliaries. These are required to be controlled in order to avoid or insure/ensure against a Fire Hazard. A hazardous area is a space in which a flammable atmosphere may be expected to be present at such frequencies as to require special precautions for the control of potential ignition sources including fixed electrical equipment. By classifying the properties of Flammable materials with combustion air and correlating with their associated ignition (electrical) energy, a method of scientifically classifying (Fire) Hazardous area can be evolved along with their hazard radii of influence & spread or dispersion. Then mechanisms & devices can be developed to control/ prevent fire hazard and its spreading or dispersion from the hazard radii. This is the objective behind the (Electrically Fire ) Hazardous Area Classification.

AREA CLASSIFICATION STANDARDS The Hazardous Area Classification, now simply called as Area Classification, is standardized so that any industry can relate to it and classify their Fire hazard. It must be remembered at all times that the Area classification is a risk based approach and is not a certainty, since many permutations & combinations of properties (e.g. climate changes, ventilation etc.) can alter the degree of fire hazard. Manufacturers provide standardized solutions and devices to control or totally mitigate the Fire hazard based on such classification. Since the first energy industry with major fire hazard material (coal & methane gas) was the underground coal mining, many of the Codes & standards of Area Classification and associated Protection systems, evolved from coal mining industry. In India it is CMRS (Central Mining Research Institute), Dhanbad that was responsible for evolving standards (that are now incorporated as part of Indian Standard) and act as certifying authorities on measures to meet the classified Hazardous Area. The British were the first to classify Flammable materials but the Germans were the first to extensively relate products to meet Hazardous area. And the Americans were the first to broaden both and occupy the market with products to meet the classification. Until recently, the European code & practice was generally considered the most comprehensive. Now a consensus to unify and universally harmonize the requirements of classification has practically brought parity in classification between the major players essentially the European and American Code of practices & Standards, with some local idiosyncrasies as per past practice and to protect local product manufacture. Any one standard may be used for Classification but the rule requires that areas classified as per various standards cannot overlap but only abut. Generally the norm is not to use more than one standard for a given industrial plant location, to avoid code-rules-mismatch problems. Electrical Engineers with active participation of Chemical Engineers are responsible for classifying the Hazardous area. The classification is marked on a geographically surveyed plot plan of the Industrial plant provided by a Civil engineer marked with firm details of locations of equipments & machinery along with all auxiliaries & accessories including buildings. Instrument Engineers need to pick up the Hazardous area correctly from this marked classification drawing and specify in the data sheet &/or procure products to meet the requirement. It is important to remember that the Area classification is for a three dimensional space and the classification is a division of a facility into Hazardous and Non-Hazardous areas. The explosive nature of Flammable atmosphere is a special case as per some variation in codes, since there could be explosion (pressure wave) without fire but many use the word explosion protection to qualify that equipment provide Explosive-Flammable-Fire protection. The code for Area classification is different from the code/ Standard for protection devices. This part will be covered under a separate article. In Instrument data sheets either the area classification only or the Area Classification and the Protection Code required are specified. All devices for Hazardous area such as flameproof protection or explosion protection devices are always to be procured labeled as suitable for area specified & with code designations only. Labeling code is also laid out in standards. Protecting a plant with hazardous area classification with coded labeled devices is the first requirement to be satisfied for Plant (life) Insurance. More on this will be covered in a companion article.

As the Indian standard is based on European codes (mainly British) and as the general preference nowadays is to specify as per European Codes and as American classification is moving towards harmony with European codes, the European code is discussed first. 3 3.1 EUROPEAN STANDARD OF AREA CLASSIFICATION The Institute of Petroleum , London has issued an AREA CLASSIFICATION CODE FOR INSTALLATIONS HANDLING FLAMMABLE FLUIDS Part 15 of the Institute of Petroleum Model code of Safe Practice in the Petroleum Industry in its 2 nd edition dated August 2002 and generally available as a reference in most engineering libraries. It is also the European Classification code under harmonized European Union or EU Codes (although language rendered may be different in different countries). 3.2 In this classification, Three important attributes are taken into account for classification and a relationship established 1) Zone classification based on Likelihood of Occurrence and Duration of a flammable atmosphere. 2) Grade of Release based on release source frequency and duration in unrestricted open air. 3) Fluid Category Note : Table 1 Zone Zone Explanation Grade of Release Continuous Table 2 Grade explanation Release that is continuous or nearly so or occurring even frequently but for short periods Release that is Periodically or Occasionally anticipated to occur in normal operation Release that is unlikely to occur or anticipated to occur under normal operation Fluid Catego ries A Table 3 Fluid category Description Any flammable liquid that on release would vaporize rapidly & substantially Any flammable liquid not in Cat. A but at a temperature sufficient for boiling to occur on release Any flammable liquid not in Cat. A or B but on release be at a temperature above flash point or form a flammable mist or spray Methane rich natural gas Refinery Hydrogen

Zone 0

Flammable atmosphere continuously present or present for long periods Flammable atmosphere likely to occur in normal operation

Zone 1

Primary

Zone 2

Flammable atmosphere not likely to occur in normal operation but even if it occurs, will exist only for a short period Areas that is not any of the above

Secondary

NonHazardous

G (i) G (ii)

1. Flammable liquids are further classified as Class 1- Petroleum, Class 2- Petroleum, Class 3 Petroleum etc. based on their flash point as stated earlier and correlated to Fluid category above but not shown in the above table for clarity. 2. The IEC method of grouping gases as Group 1, Group IIA, IIB and IIC etc. is not included in Part 15 (rev. 2002) but included in API RP 505 (1997) as the link to European standards. 3.3 Flammable dust atmospheres that are classified as Zone 20, 21 and 22 are not included in above table and are outside the scope of this article. 3.4 The practical means to interpret the code definitions stated above has led to some guide line basis for quick checks : Zone 0 : > 1000 hours per annum (10%) Zone 1 : > Between 10 and 1000 hours per annum(0.1 to 10%) Zone 2 : < 10 hours per annum(0.01 to 0.1%) Unclassified : Less than 1 hour per annum(0.01%) (Percentages are based on year normalized to 10,000 hours) 3.5 Zone and Fluid category are only specified. Although Grade of release is a property attribute, it is embedded in zone Classification. * Continuous grade, normally but not necessarily, leads to Zone 0 Primary Grade, normally but not necessarily, leads to zone 1 Secondary grade, normally but not necessarily, leads to zone 2 3.6 Fluid category is very difficult to interpret from the above code for non-chemical engineers. So, we interpret it from a product classification code called Apparatus & Enclosure subgrouping to be covered as a separate topic.

3.7 A means to relate the classification to safety standards to be followed is also now available through another guideline called ATEX 100a and will be covered in other topics. 3.1 Area Classification Drawings will show Area Classification symbols as given below. The area bounded by a cloud denotes extent and area boundary.

3.2 3.3 4

Zone 0

Zone 1

Zone 2

Non-hazardous

So Zone and Gas group must be specified in data sheet as a minimum as per this standard. AMERICAN STANDARD OF AREA CLASSIFICATION The American Petroleum Institute API has two standards - API RP 500 and RP 505. These originate from or traceable to other previous U.S. national standards such as National Electric Code or NEC, National Fire Protection association or NFPA etc. API RP 500: Recommended Practice for Classification of Locations for Electrical Installations at Petroleum facilities classified as Class 1, Division 1 and Division 2 (Nov. 1997) API RP 505: Recommended practice for classification of locations for Electrical installations at Petroleum facilities classified as Class1, Zone 0, Zone 1and Zone 2.(Nov. 1997)

4.1

API RP 505 is normalized to IEC and thus the link between two broad standards of Area Classification is established.

4.2
4.2.1

API RP 500 Classification tables Table 1 Class Description Table 2 Division Description Table 3 Gas (as per Representativ NEC) & Fluid e Gas Group Group Atmospheres Description Group A Acetylene

Class

Division

Class 1

Flammable gases or vapors are or may be present to form explosive or ignitable mixtures

Division 1

Division 2

Unclassified or NonHazardous

Areas not classified as Division 1 or Division 2

Flammable gas or vapor is expected to exist under normal operating conditions or under faulty operation or faulty electrical equipment Flammable gas or vapor may be present but is contained within closed system or not allowed to accumulate by proper ventilation

Group B Group C Group D Liquid- Class 1 Petroleum Liquid- Class 2 Petroleum Liquid- Class 3 petroleum Crude oilMostly planned as Class 1

Hydrogen series Di-ethyl ether Gasoline Class for liquids is based on flash point

4.2.2 4.2.3

Class 2 Combustible Dust atmospheres and Class 3- Combustible Fibers and Flyings are not in above table for clarity and is outside the scope of this article. Area Classification Drawings will show Area Classification symbols as given below. The area bounded by a cloud denotes extent and area boundary.

Division 1 Division 2 Special Division 1 So Class, Division and Gas group must be specified in data sheet as a minimum, as per this standard.

4.3 4.3.1

API RP 505 Classification Table Class detail is as per API RP 500. Zone detail is essentially as per IP 15. Division detail is not required as it is covered by Zone detail. Fluid categorization i.e. Gas grouping is as per IEC 70-10 (but Flammable Liquid Categorization is same as in IP 15 or API RP 500). Gas Grouping Class I Description Remarks

II A

II B II C

Not used but denotes underground gas such as fire damp (Methane) Atmospheres containing acetone, ammonia, ethyl alcohol, gasoline, methane, propane etc. Atmospheres containing acetaldehyde, ethylene etc. Atmospheres acetylene, Hydrogen etc.

MSEG- Max. Experimental Safe gap and MIC Max. igniting current ratio values decide gas grouping

4.3.2

Area Classification Drawings will show Area Classification symbols as given below The area bounded by a cloud denotes extent and area boundary.

Zone 0

Zone 1

Zone 2

Unclassified

So Class, Zone and Gas group must be specified in data sheet as a minimum as per this standard. Class is implied as Class 1 if not specified explicitly.

WHAT HAPPENS IF YOU IGNORE AREA CLASSIFICATION ?

8 Courtesy: MIT Web site