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Hazardous Area Classification

Fundamentals & Cases


ATEX congres
Mei 2014, Dordrecht, Nederland

EX
Erik van de Kuilen Shell Global Solutions Inc.
Agenda
Fundamentals
Ignition Source Control
Standards & Practices
Area Classification: the Concept
Area Classification: a Multistep Process
Cases
Hot Surfaces
Management of Change – Gasgroup & Temperature class
Negligible Extent
Abnormal Operating Conditions - Temporary Zone 1
Management of Change – Release dispersion
Heat Exchanger Leakage
Ventilation
2

Q&A
Ignition Source Control…. or Not (?)

Hot
Surface

3
Ignition Source Control
Ignition Source Control is part of Process Safety Management
Ignition Source Control

Loss of
Containment

4
Proper Ignition Source Control reduces explosion risk 10-100x
Ignition Source Control
Ignition Source Control: # Ignition Sources
(EN 1127)
Permit to Work system (hot work)
1 Hot surfaces
‘No smoking’ areas 2 Flames & hot gases
3 Mechanical sparks
Traffic and vehicle control
4 Electrical apparatus
Hazardous Area Classification 5 Stray currents
Static Electricity control 6 Static electricity
7 Lightning
Etc. 8 Radio waves

Essentially covering all 13 ignition 9 High Frequency EM


waves
sources (ref. EN 1127) 10 Ionizing radiation
11 Ultrasonics
12 Adiabatic compression
Hazardous Area Classification is only
13 Exothermic reactions 5

a part of Ignition Source Control


Hazardous Area Classification: Stds & Practices
Area Classification is typically following industry stds & practices:
USA / North America:
API RP 500 – Recommended Practice for Classification of Locations for Electrical
Installation at Petroleum Facilities Classified as Class I, Division 1 and Division 2. –
North Americas and locations that have ANSI/NEMA designs
API RP 505 – Recommended Practice for Classification of Locations for Electrical
Installations at Petroleum Facilities Classified as Class 1, Zone 0, Zone 1, and
Zone 2 – North America and locations that have ANSI/NEMA designs

Europe (ATEX 137 since 2003) + rest of the world:


EU: IEC 60079-10 Classification of Hazardous Areas
UK: IP-15 – Energy Institute (previously Institute of Petroleum) Model Code
of Safe Practice, Part 15, 3rd edition, July 2005. – United Kingdom
Country local regulations, standards & practices 6
Hazardous Area Classification: the Concept
Hazardous Area Classification principle:
1.Determine likelihood and dimension of a flammable atmosphere
(zone) around certain leak and/or exposure points (LFL boundary)
2.Manage (design, maintain, operate) or eliminate ignition sources
within the zone

UFL LFL
LFL

7
Hazardous Area Classification: the Concept
Hazardous Area Classification scope:
Flammable fluids (Hydrocarbons, H2, CO, NH3, …)
‘Small’ release sources:
Flanges, pump seals, vents, drains
No catastrophic equipment failure
(Semi)permanent ignition sources*:
Equipment hot surfaces
Roads / plant vehicles
Machinery motors
Instrumentation

*Open flame equipment is typically excluded from Area Classification


and located outside the classified area 8
Hazardous Area Classification: A Multistep Process

1: Determine flammability properties for each fluid and/or


equipment item (in particular LFL, UFL, flashpoint, AIT)

Hydrocarbon
Auto Ignition
Temperature
(AIT)

9
Hazardous Area Classification: A Multistep Process

2: Determine Zone for all equipment items

a: Zone type (likelihood of flammable atmosphere):

Release Grade Equipment Zone Zone


(example) (ventilated) (confined/
non-
ventilated)
Continuous (>1000 Inside tank 0 0
b: Zone extension (dimensions of flammable atmosphere):
hr/yr)
Primary (10 - 1000 Sample 1 1/0
hr/yr) connection, pits
Secondary (< 10 Flange, pump 2 1
hr/yr) seal

10
Hazardous Area Classification: A Multistep Process

2: Determine Zone for all equipment items

b: Zone extension (dimensions of flammable atmosphere):

IP 15: Direct Example Approach

11
IP 15: Point Source Approach
Hazardous Area Classification: A Multistep Process

3: Determine fluid ignition parameters (ref. Literature)


a: the Gasgroup for the released fluid*
b: the Temperature Class for the released fluid
Fluid (typical) Gas Released Ignition Gasgroup Auto Ignition T
group fluid Energy Temperature class
(mIE) (AIT) (deg C)
Alkanes II A
Ethylene, EO, CO II B Methane 0.28 I /II A 525 T1
Ethane 0.24 II A 510 T1
Hydrogen II C
Propane 0.25 II A 460 T1
T Temperature
class (deg C) Hexane 0.24 II A 230 T3
1 450
Ethylene 0.07 II B 425 T2
2 300
Hydrogen 0.01 II C 560 T1
3 200
4 135 Benzene 0.2 II A 498 T1
5 100 Ethylene 0.06 II B 429 T2
6 85 Oxide
12

* Also ‘apparatus’ group or ‘explosion’ group; a parameter related to the sensitivity for ignition
Hazardous Area Classification: A Multistep Process
4: Complete the Hazardous Area Classification Design Basis
and develop the drawings….

13
Hazardous Area Classification: A Multistep Process

///// Zone 2
14
Hazardous Area Classification: A Multistep Process
Hazardous Area Classification: A Multistep Process
5: Implement and/or verify in the field:
(incl. selected explosion protection: ia, ib, d, e, n,...)
equipment nameplates NAME PLATE:
hot surfaces Universal Supplies Ltd,
roads & vehicles CE 0999
Trans type 100
II G
6: Risk assess and/or modify any EEX ib IIC T4
deviations from the required area 40 C < Ta < 70 C
ACB 00 ATEX 9999
classification Apparatus parameters
Serial No. 991234

(Ignition Hazard Analysis)

7: Document !
(Area Classification Design Basis,
Explosion Protection Document)
Copyright of Shell Projects & Technology RESTRICTED October 2012 16
Hazardous Area Classification – Some Cases

1. Hot Surfaces
2. Management of Change – Gasgroup & Temperature class
3. Negligible Extent
4. Abnormal Operating Conditions - Temporary Zone 1 operation
5. Management of Change – Release dispersion
6. Heat Exchanger Leakage
7. Ventilation

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Hot Surfaces
Hot equipment surfaces can be an ignition source, if the surface
temperature exceeds the Auto Ignition Temperature (AIT) of the
released fluid:
Operating temperature > Gasoline AIT

Copyright of Shell Projects & Technology RESTRICTED October 2012 18


Hot Surfaces
Risk Considerations (Ignition Hazard Analysis):
What is the actual Heating Medium line surface temperature? Is the line
insulated or could it be ? Is the insulation gas tight? Are there any flanges?
Will the Gasoline indeed reach the Heating Medium line and heat up to AIT?
Could any Gasoline leak points perhaps be eliminated or relocated?
Could the Heating Medium line be rerouted/shielded off?
API RP 2216-03:
Ignition Risk of Hydrocarbon Liquids and Vapors by Hot Surfaces in Open Air:
“ignition of hydrocarbons by a hot surface should not be assumed unless the
surface temperature is approximately 360 °F (182°C) above the accepted
minimum ignition temperature of the hydrocarbon involved.”
Consider ignition due to hot surface*:
Zone 0 & Zone 1: fluid AIT
Zone 2: fluid AIT + 180 °C.
* EN1127 indicates 80% of AIT for Zone 0 and 1 and AIT for
Copyright of Shell Projects & Technology
Zone 2
RESTRICTED October 2012 19
Hot Surfaces
A new insulated Steam line (Operating Temperature > 300 C) into
an existing pipe track (conservatively) classified as Zone 1 with
fluids AITs < 250 C: New steam line

Existing pipe track

Zone 1

Alternative: installing a new 2 km pipe rack

Risk Considerations (Ignition Hazard Analysis):


API 2216 not applicable for Zone 1 (only for well ventilated systems)
What is the Steam line surface temperature? What about flanges?
Where are the Hydrocarbon leak sources? Close to Steam line hot points?
Could the Steam line be shielded/segregated from the Hydrocarbon lines?
Copyright of Shell Projects & Technology RESTRICTED October 2012 20
Management of Change – Gasgroup and T Class
Installing new equipment in
existing facility New IIA-T2 equipment / zone
New IIC-T2 equipment / zone (max surface temp. 300 ̊C)
(max surface temp. 300 ̊C)
Existing / Replaced IIA-T3
Equipment / zone
(max surface temp. 200 ̊C)

Existing IIA-T3 and


T2 equipment IIC-T3 Equipment /
in T3 zone zone (max surface
temp. 200 ̊C)
IIA equipment in
IIC zone

New IIA-T2 equipment / zone


(max surface temp. 300 ̊C)
Zone with Negligible Extent (NE)
During facility decommissioning
residual Hydrocarbons at low/no
pressure may retain inside and
dictate need for Area
Classification .

EN 60079-10-1 has introduced


the concept of Zone with
Negligible Extend (NE).
Zone 2 NE is accepted by the UK
Health and Safety Executive
(HSE) and does not require
control of ignition sources within
it.

Approach is being considered for Good High


de-commissioning of platforms in Ventilation
Normal outside
North Sea: required
conditions
Abnormal Operating Conditions (Drilling WHCP)
Platform Well Head Control Panel (WHCP)
cabinet (ca. 3 m3) is located in Zone 2 and
internally classified Zone 1. Zone 2 is
based on normal production.

During HAZOP it was found that for 3-6


months every 3-4 yrs, the platform is also
used to drill new wells.
This would require 3 m radius Zone 1
conditions extending over the WHCP.

Relocate/renew the cabinet for Zone 0 ?

Alternative? During Zone 1 operation:


Provide gas detection in/near the cabinet to indicate
increased gas concentration inside/outside the cabinet.
Install ventilation on the cabinet to maintain Zone 1 inside
Management of Change – Standards & Dispersion
New filter unit for FCC product
Distance from proposed location to
nearby road: 7.5 m
Zone radius/distance to road
according local standard: 15 m

This would require closure or


major rerouting of main access
road to Control Room and Unit….

Physical Effect Modeling:


Dispersion analysis shows max release IP 15 Point Source
size 4.5 m from filter unit leak points
Supported by IP 15 Area Classification
point source method
Heat Exchanger Leakage (Cooling Water Return)
Leaking Heat Exchanger(s)
resulting in Hydrocarbon in open
Cooling Water Returns and may
be ignited
(CW Return not classified).

To reduce the risk:


Zone 1/2 for the CW Return?
Install gas / Hydrocarbon
detection in CW Return +
Close off the road in case of gas
detection to prevent ignition by
passing vehicle
A similar case:
Heat Exchanger Leakage (Cooling Water Return)
New designs would have closed CW return lines, classified
CW towers and Hydrocarbon vent in the return line:
CW tower fire Hydrocarbon Vent Line

CW Return Line

Ref. API 505


Ventilation (Winterizing)
During winter, some plants are ‘sheltered’ to prevent freezing
problems. This could impact the natural ventilation and the Zoning.
Ventilation (Winterizing)
Design and locate the screens such that (natural) ventilation is still
adequate:
50% LEL for secondary grade release
25% LEL for continuous & primary grade release
(ref. IEC 60079-10 ventilation calcs)
Winterizing screens

Zone 2 facility
Open area
for
ventilation

If not adequate, then need to consider artificial ventilation and/or


gas detection
Q&A

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