Hazardous Area Classification

Standard

Global Operations

June 2016

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 Document Title Hazardous Area Classification
Document Number 0101-000-11-001
Document Type Standard
Status Endorsed by Global Operational Leadership Team
Date June 2016
Version 2.0
Project Name Vopak Standards
Owner Royal Vopak – Global Operations

Confidentiality and Distribution

Vopak Global Operations Standards contain confidential information regarding Vopak and its relevant
subsidiaries and have been prepared with a view to inform and instruct Vopak employees. For that
reason none of these Standards - whether in original or copies, including but not limited to any
medium including paper or electronic formats like file copies, word documents, pdf files, on electronic
storage devices or by email - is to be shown, given or loaned to any third party, including external
companies and persons not directly employed by Vopak. No exceptions are permitted without the
written authorisation of the Director Corporate Global Operational.

This document has only been made available to Vopak employees who have agreed to return it to
Vopak immediately upon first request, together with any copies and any other information that was
provided. Persons who are not employed by Vopak and who have nevertheless received this
document must be aware that it is likely they have received it in breach of a confidentiality obligation.
Such persons may not rely on, use, duplicate or disclose any information contained in this document
and should forthwith return it, together with any copies if any, to Vopak.

This copy is not controlled, for the latest revision check on Vopak Intranet.

June 2016 2.0 Updated. Non electrical equipment added. Definition of duration for
zoning adapted.
Sept. 2008 1.0 Endorsed by Operational Excellence Leadership Team
Date: Version: Description:
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TABLE OF CONTENT

Page

1 STANDARD REQUIREMENT 5

2 BACKGROUND AND INTRODUCTION 6

2.1 Exclusions 7
2.2 Non electrical equipment 7
2.3 Management of Change 7

3 AREA CLASSIFICATION PROCESS 8

3.1 Nature of Flammable Material Releases 8
3.2 Ventilation 8
3.3 Information Required 8
3.3.1 Local Rules and Regulations 9
3.3.2 List of Equipment for Area Classification (LEAC) 9
3.3.3 Properties of Materials (POM) 10
3.3.4 Plant Layout Drawings 10
3.3.5 10
3.4 Review meetings 11
3.5 Area Classification Layout 12
3.6 Drawing Updates 12

4 TYPICAL AREA CLASSIFICATION FOR COMMON FACILITIES IN OPEN AREAS 13

4.1 Bunded Tanks Cone or Domed Roofs 13
4.2 Bunded Tank, Floating Roof 14
4.3 Composite area classification drawing for bottom loading road tanker during loading in
the event of a spillage 15
4.4 Composite area classification drawing for top loading road tanker during loading in the
event of a spillage – Classes I, II and III 16
4.5 Typical hazardous area classification of a road tanker during unloading 17
4.6 Jetties – Loading Facilities Only 18
4.7 Jetties – Unloading 20
4.8 Drum Filling in the Open Air 22
4.9 Typical Hazardous Area Around Tank Vents 23
4.10 Liquid Pool due to Spillage 24
4.11 Open Sump – zoning for primary grade release 25
4.12 Pump Area Classification 26
4.13 Drainage System – Open Drain Channel 27
4.14 Relief Valves 27
4.15 Sample Points 27
4.16 Pipe, Equipment, Joints and Valves 28
4.17 Water Drain Point 29
4.19 LPG Installations 31
4.20 Typical composite hazardous area classification around LPG road tanker during
unloading 32

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5 DEFINITIONS 33

6 REFERENCES 38

APPENDIX 1 – EL CODE, PART 15, CALCULATION OF RISK LEVEL 39

APPENDIX 2 – EXAMPLE LEAC SHEET 42

APPENDIX 3 – EXAMPLE POM SHEET 43

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1 Standard Requirement
Every Vopak Terminal handling flammable or combustible products shall undertake a Hazardous Area
Assessment.

That assessment shall follow the steps set out in this guidance or equivalent local regulations or
guidance.

The assessment shall be fully documented and shall reference and justify the guidance used.

The outcome of the assessment shall be recorded as zone classification drawings covering the entire
terminal facility.

The zone classification drawings shall be used as the basis of mechanical and electrical equipment
selection, and for establishment of maintenance plans at the terminal.

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2 Background and Introduction
Terminals handling flammable liquids will always have some risk of fire.

Common causes of fire result from sparking or heat produced in electrical or non-electrical (see
section 2.2 for details) equipment.

Electrical and non-electrical equipment shall be based on the area classification designed to minimise
or eliminate this risk.

The choice of equipment to use in any area is dictated by the possibility that a flammable (or
explosive) atmosphere will exist.

This documents sets out the process of determining the correct Hazardous area classification to guide
the selection and maintenance of electrical and mechanical equipment for use at terminals handling
hazardous substances.

It has been based upon:

 IEC60079-10: 2008 - Electrical apparatus for explosive gas atmospheres. Classification of
hazardous areas,
 IP-15, Energy Institute (EI) Model code of safe practice Part 15: The Area classification code
for installations handling flammable fluids.

There are other codes giving similar guidance in other parts of Europe and in the rest of the world.
For example:

1
USA 40 CFR 191.307, NFPA 70 (National Electrical Code)
Netherlands NPR 7910
Germany TrbF20 (G)

Metric units have been used in this code, although it is accepted that in some location imperial units
are still required.

In common with other Vopak standards, where a local code is applicable this should be initially used
in preference to this standard. However if this standard has a more stringent outcome, this standard
shall be applied. It is believed that all the different standards give similar results.

The EI Code is based upon risk; this requires a level to be established for use with the secondary
releases which are accidental and not well documented. For the Vopak sites, a Level I has been
allowed.

Please see: Appendix 1 - EI Code Part 15 Calculation of risk level

Catastrophic failures are not covered by area classification, i.e. vessel failures etc. These should be
covered as part of hazard studies.

°
The EI code part 15 anticipates an ambient temperature of maximum 30 C.

1
The NEC uses hazardous Divisions instead of hazardous Zones as used in the IEC / ATEX. NEC
Division 1 matches ATEX / IEC zone 0 and 1, while NEC division 2 matches ATEX / IEC zone 2.

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 Where higher ambient temperatures are experienced, some adjustments to the recommendations of
this code will be required.

Where zones created by adjacent sources of release overlap and are of different zone classification,
the higher risk classification will apply.
Usually if zones of the same type overlap, then this zone type is adopted for this area, however if the
area has many sources of release, the zone rating may be increased; a history of flammable releases
in this area may be helpful in determining this.

2.1 Exclusions

Dust hazards have not been covered as part of this procedure as this is not part of Vopak’s normal
business; however guidance is available in :
 IEC 60079-10-2 Explosive atmospheres. Classification of areas. Combustible dust
atmospheres

2.2 Non electrical equipment

This applies for any non-electrical system which can create sufficient energy for ignition. Please be
aware that the it is only applicable for equipment in zoned area, where the fire triangle (oxygen, fuel
and ignition source) are available, Typical examples for Vopak are
 Mechanical equipment, which can create hot surfaces or sparks due to friction, e.g. pump,
compressors, ventilators, belt driven systems, seals in pumps/ ventilators etc;
 Systems which can create static charge, e.g. hoses or injectors;
 Rest area housing, where e.g. sliding doors can create sparks due to metal to metal contact;

If you take the example for a product pump installed inside a zone 1 bunt wall. The pump housing
itself does not have to be certified, the seal / bearing system and e-motor do have to certified. In the
pump housing fuel (product) and an ignition source are available, but no oxygen because the house is
liquid full.

We are aware that certified equipment is not available everywhere. Please prepare a risk analysis and
contact Division (possibly followed by Global Operations) to discuss alternatives.

2.3 Management of Change

It must be recognised that changes to the products stored and changes to the installation at a terminal
can have an influence on area classification; some are obvious such as changing of tanks from non-
flammable to flammable service. Others may be less obvious such as in the above tank change, this
may also change the classification of the jetty.

Such changes must be taken into account in a formal management of change process, as described
in the Vopak Fundamental standard.

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3 Area Classification Process

3.1 Nature of Flammable Material Releases

In assessing flammable gas or vapour escape, the relative vapour density should be reviewed.

If the gas or vapour is heavier than air then it will take longer to disperse to below its flammable limit
than a gas which is lighter than air. Additionally if the heavier than air gas or vapour is in an area of
limited ventilation, for example a below ground level pump room, or deep pipe culverts, then the
release will remain within its flammable limits longer than if it is in an area of open ventilation.

For lighter than air gas or vapour releases, potential for build up under roofs should be reviewed and
the effect of the vapour/gas being present for longer periods plus the spread within a roof-space
should be accounted for.

Heavier than air gases or vapours can be released at high or low velocities, at high velocities the jet
mixing effect of the discharge mixing with air may reduce the distance over which the material is
flammable.

A low velocity discharge may flow over a long distance over the ground as it will not have the mixing
effect of atmospheric diffusion.

Where a potential jet of release hits an obstacle, it will then change to a low velocity release, so for
example flange guard rings may sometimes help to reduce the velocity and so the extent of the
affected area.

Where a product is released in liquid form but above its boiling point, it will flash off creating a large
vapour cloud, giving an appreciable hazard radius.

Examples of this would be where a liquid has been heated by the process and is contained under
pressure to maintain it in a liquid state, or an LPG release.
In the case of an LPG release the associated vapour cloud will be cold, the vapour is denser than air
and it will spread over an appreciable distance.

Many products may not be above their flashpoint, however upon a pressurised release the product
may form a flammable mist.
The hazard radius this gives is difficult to predict and needs special consideration.

3.2 Ventilation

For the Vopak sites, it is anticipated that most equipment is in the open air so only well ventilated
scenarios are anticipated, this is reflected with the classifications given in this procedure.

Where limited ventilated areas exist, i.e. inside buildings, ventilation rates will need to be assessed
against potential leak rates and adjustments made to the hazard radius as required. Further guidance
can be gained from IEC60079-10.

3.3 Information Required

To carry out an area classification review, the following information needs to be available:
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 1. Local Rules and Regulations
2. List of Equipment for Area Classification
3. Properties of Material
4. Plant Layout drawings

In the following section details are given on this information

3.3.1 Local Rules and Regulations

Any local licensing authority rules and other statutory requirements, such as the Dangerous
Substances and Explosive Atmospheres Regulations (DSEAR).

3.3.2 List of Equipment for Area Classification (LEAC)

All equipment on the plant should be listed, even if it does not handle potentially flammable materials,
this ensures that no potential sources are overlooked.

The equipment is taken from a plant mechanical asset register, supplemented by information from
operations and/or the process engineer.

Additional items which may not be contained on the plant mechanical asset register, which should be
added to the LEAC include:
 Sample Points
 Vent points for process vents and relief valves
 Process drain points
 Plant Drains

This schedule is known as a List of Equipment for Area classification (LEAC).

Please see: Appendix 2 - Example LEAC Sheet

In this example, columns 1 to 7 are completed prior to the review meeting.

One of the columns requires to indicate the Grade of Release. The grade of release can be either
continuous, primary or secondary.
A continuous grade of release is:
 the release product is continuous or nearly so. This is typical 10% or more of the operation or
2
duration of an activity .
A primary grade of release is:
 the release of product which is either regularly or at random times during operation. This is
typical between 0,1% and 10% of the operation or duration of the activity.
A secondary grade of release is:
 the release of product which is unlikely to happen in normal operation and in any event will
be of limited duration. This is typical less than 0,1% of the operation or duration of the
activity;
 Locations where deposited dust is present would be considered as secondary grades of
release.

2
Example: If a system is only used 100 hours per year and the release is 50 hours per year, the
system should comply with zone 0.

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3.3.3 Properties of Materials (POM)

All products (materials) handled on the site should be listed on this schedule, known as the Properties
of Materials Sheets (POM).

Please see: Appendix 3 - Example Properties of Materials sheet (POM).

3.3.4 Plant Layout Drawings

Layout: A Plant layout drawing is required, showing locations of all equipment shown on the LEACs
with respect to plant boundaries, roadways, bunds etc.

To ensure that surrounding plants do not have hazardous areas impinging onto the area to be
reviewed, this should be checked before the meeting and the zones added to the layout drawing
under review.

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3.4 Review meetings

The following representatives should be present at an area classification review meeting:

- Project Engineer
- Process Engineer (Optional)
- Maintenance Manager
- Instrument or Electrical Engineer
- Safety manager
- Operations Manager

Ventilation extents and grades need to be established, this procedure has been written on the basis of
well ventilated areas, with good availability of that ventilation.

During the review meetings, each piece of equipment handling materials on the plant is analysed and
given an individual classification, these are added to columns 8 to 13 on the LEAC sheets. The extent
of the radii is marked on the drawing and the overall area classification picture builds up as the
individual classifications are added.

Once all of the radii are shown on the drawings, a decision is made on the adopted extents of the
area classification often this is an easily identified boundary, i.e. up to a pathway on the plant. An
example area classification drawing is shown in the appendices, this indicates not only the individual
radii but also the adopted extent of the area classification.

Please see: Appendix 4 - Example Area Classification Drawing

The decisions made in the area classification review meeting should be recorded for reference,
usually in the form of meeting minutes.

In addition to reviewing the equipment on the LEAC sheet, the following points should also be
addressed during the meeting:

- The presence of any flammable dusts;

- Sample Points;
- Fired heaters, i.e. process heaters or boilers etc.;
- Limited ventilation areas;
- Relief valve and Process Vents;
- Process Drain Points;
- Compressors, including their ancillary parts such as seal oil tanks and any building or
enclosure fitted;
- Any piece of plant, which is regularly serviced, leading to flammable releases, i.e. filter
change-outs;
- Analyser houses and their ventilation;
- Mechanical equipment, which can develop hot surfaces;
- Oil/Water decanters and separators;
- Manual decanting of flammables inside stores etc.;
- Vapour systems with open flames, e.g. incinerators or flares;

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3.5 Area Classification Layout

Following the meeting, the area classification layout drawing should be completed, this needs to show
the entire boundary of the zones discussed above, along with the following information:

- Legend – zoning shading styles

- Plant agreed temperature class and gas group as a minimum for the hazard area equipment.
- Elevations where deemed to be useful, i.e. tank elevations, structure elevations etc.
- References to other documents
- Locations of signage (optional)

Any zoning, which extends outside of the plant will need to be addressed, this may involve:

- Informing a neighbouring plant that the zone extends into their area.
- Inform local authorities that the zoning extends beyond the plant boundaries.
- Looking for legitimate reasons to reduce the area classification, perhaps using additional
means of limiting potential leaks, plant re-design or relocation.

Zoning that extends across access ways and roadways needs to be reviewed as this may place
restrictions on personnel and traffic flow.

Air intakes to buildings should be reviewed once the area classification layout has been agreed, this is
to ensure that the air supplied to offices, control rooms, analyser houses etc is not likely to contain
flammable gases or vapours.
If there is not an alternative point to draw air from other than the zoned area, then additional mitigation
may be required, i.e. gas detection, auto shut-off of electrical supplies etc.

Note: Some very small zone 1 areas may exist, these can possible be covered by notes on the
drawings, with reference to the note adjacent to that piece of equipment on the layout.

3.6 Drawing Updates

It is important that once the area classification has been decided and documented, all interested
parties are aware of its content, these would normally include:

- Terminal Manager
- Operations Manager
- Safety Officer and Manager
- Permit Issuer
- Maintenance staff

Following the review, the completed documents should be updated in the formal records and re-
issued to relevant users.

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4 Typical Area Classification for Common Facilities in Open Areas
nd
The information in this chapter is based on IP15 (2 edition) and might deviate from local code.
Please check availability of local code.

The following patterns are used for the zoning

Zone Pattern
0

4.1 Bunded Tanks Cone or Domed Roofs

The above figure is applicable to:

- Tanks handling materials above their flashpoint, but below their boiling point.
- Tanks that vent to atmosphere.
- Tanks that have sufficient protection against over-fill to ensure that the bund will not be filled
with flammable liquid. If this is not the case, a further zone 2 hazard radius should extend
from the bunds, in line with section 4.10.
- Tanks both with and without internal floating roofs.
For materials which are not above their flashpoint, but may form flammable mists due to spray effects
etc (i.e. diesel, kerosene etc), the ullage space should still be regarded as zone 0, with a zone 1 of 3m
for filling rates up to 500m3/hr.

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4.2 Bunded Tank, Floating Roof

The above figure is applicable to:

- Tanks handling materials above their flashpoint, but below their boiling point.
- Tanks that have sufficient protection against over-fill to ensure that the bund will be filled with
flammable liquid. If this is not the case, a further zone 2 hazard radius should extent from the
bunds, in line with section 4.10.
- Operating regimes where the roof will not be grounded on its legs during the operation cycle,
since the spare space so created below the roof would draw in air an create the possibility of
ignition cause by friction.
- Roofs should only be landed for inspection, cleaning and maintenance under carefully
supervised work permit control. Any vapour space below the roof or between the primary and
secondary seals should be treated as zone 0.
- Please be aware that some local codes indicate that the area in the tank and above the
floating roof is zone 0 (instead of zone 1).

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4.3 Composite area classification drawing for bottom loading road tanker during
loading in the event of a spillage

The above figure applies to road tanker filling facilities, handling material above its flashpoint but
below its boiling point, the tanker vent piped to a closed system, that is either back to the supply tank
ullage space or to a vent remote from the gantry.

The large zone 2 area shown is to cover potential spillages, to quantify this, the potential spillage area
needs to be identified and it should then be classified in line with section 4.13.

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 4.4 Composite area classification drawing for top loading road tanker during
loading in the event of a spillage – Classes I, II and III

Notes:

1 If weather roofing is provided, all space above the zone 1 area will be zone 2 up to the roof.
2 Spillage areas should be assessed and classified in accordance with section 4.13.
3 Areas filled in as shown.

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4.5 Typical hazardous area classification of a road tanker during unloading

The above figure applies to:

- Road tanker off-loading facilities, handling material above its flashpoint but below its boiling
point.
- The road tanker being parked in a designated location as close as reasonably practicable to
the tank fill points, which are installed in adequately ventilated positions in open areas; and
- Hose runs being confined to a designated ‘corridor with the minimum No of hoses used, to
reduce the couplings required.

The following zones apply:

Zone 1 of nominal 1m radius around the road tanker bottom loading adaptors, which extends down to
ground level.

Zone 1 of nominal 1m height above ground and 1m radius either side of the hose corridor required
from the tanker unloading position to the storage tanks.

Zone 2 of 4m radius from the tanker unloading connections, to a height of 1m to cover any small
spillages of up to about 2.5 litres that may occur during the disconnection of hoses.

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4.6 Jetties – Loading Facilities Only

Notes:

The above figure applies to loading a ship with materials above their flashpoint but below

Notes:

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 1. The above figure applies to loading a ship with materials above their flashpoint but below its
boiling point.
2. Distance may be reduced to 15 m for vessels with loading or unloading rates of 10m3/min or
less.
3. The hazardous area should extend 20 m above the coupling points. This may be reduced to
15 m for loading rates of 10m3/min or less.
4. If non-segregated ballasting or gas freeing is carried out, then the jetty must be classified for
loading.

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4.7 Jetties – Unloading

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Notes:

1. The hazardous area for each piece of equipment on the jetty should be evaluated.
2. If non-segregated ballasting or gas freeing is carried out, then the jetty must be classed as for
loading.
3. This above figure applies to unloading a ship with materials above their flashpoint but below
its boiling point.
4. The height of the hazardous area should be 20 m above the coupling point. For a category C
material, this is equivalent to a 5 mm diameter hole in the coupling. If larger hole sizes are
possible reference should be made to Table C9(a) for the equivalent hazard radius.

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4.8 Drum Filling in the Open Air

Notes:

The dimensions of L are controlled by means of spillage containment such as good contours, kerbs
and drains, the full extent of the zone 2 hazard radius should be assessed in accordance with section
4.10.

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4.9 Typical Hazardous Area Around Tank Vents

Vent pipe opening should have at least R1 metres of free space around it in all directions to allow
dispersal of vapour, and be away from open windows, doors etc.

For road tanker to delivery systems the height of a vent above the working level should be greater that
the possible liquid level in the road tanker to prevent overspill and in no case less than 5m above
working level.

To avoid placing a working platform in a zone 1 area, h should be measured from any working level
within R1 metres of the vent stack

In (c), R1 for zone 1 should be for the primary grade release and R1 for zone 2 should be for the
secondary grade release.

Table of hazard radius (R1) from tank vent for materials above their flashpoint and below their boiling
point:

Vent Rate Vent Diameter (mm)

Nm3/Hr 50 80 100 250
250 2 2 2 3
500 3 3 3 4
1000 3 4 4 6
2500 4 5 5 6

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4.10 Liquid Pool due to Spillage

R1 Is the extent of the hazard radius from the edge of the pool in the same direction.

L Is the equivalent diameter of the pool

h Depends on the temperature of release and the volatility of the material released. For materials
above their flashpoint and below their boiling point, h is nominally 1m for volatile fluids or at elevated
temperatures, a nominal height of at least 3m should be applied. However, it is recommended that
this height is verified by calculation.

Table of hazardous area from liquid pool:

Equivalent Diameter of Pool, L (m) Hazard Radius R1 (m)

Less than 5 3
5 to less than 10 7.5
10 or greater 15

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4.11 Open Sump – zoning for primary grade release

Notes:

The zone 2 is applicable where there is a possibility of a secondary grade release and the hazard
radius R1 for the primary grade release is less than 15m.
h depends on the temperature of release and the volatility of the material released. For materials
above their flashpoint and below their boiling point, h is nominally 1m for volatile fluids or at elevated
temperatures, a nominal height of at least 3m should be applied. However, it is recommended that
this height is verified by calculation.
For a secondary release, the areas shown as zones 0 and 1 would be zone 1 and 2 respectively.

Table of hazardous area from liquid pool:

Equivalent Diameter of Pool, L (m) Hazard Radius R1 (m)

Less than 5 3
5 to less than 10 7.5
10 or greater 15

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4.12 Pump Area Classification

The above figure is to be used with materials above their flashpoint but below their boiling point, the
distances below are based upon a pump installed at a height greater less 1m above the ground with a
discharge pressure of 10bara, a shaft diameter of 25mm:

Pump Seal Shaft Size (mm) Hole size (mm) R1 (m) R2 (m)

Pumps without 25 5.75 10 10

throttle bushes
50 11.5 15 >40
75 17.25 Consult Consult
Manufacturer. Manufacturer.
100 23 Consult Consult
Manufacturer. Manufacturer.
Pumps with 25 2.5 5 5
throttle bushes
50 5 8 5
75 7.5 12 >40
100 10 14 Consult
Manufacturer.
High integrity 25 2 4 4.5
seals
50 2 4 4.5
75 2 4 4.5
100 2 4 4.5

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 The above classifications are designed to be onerous and are calculated in the absence of specific
manufacturer’s data for an installation or operating experience. If this is available, then the following
tables can be used:

Hole size R1 (m) R2 (m)

(mm)
1 2 2
2 4 4
5 8 16
10 14 40

4.13 Drainage System – Open Drain Channel

Notes:

The above classification allows for the drainage system only having flammable liquid within it for brief
periods, the drain being graded and liquid contents draining to a remote point. However as the drain is
an area of limited ventilation it still given a zone 1 classification, with 3m of zone 2 around it.

4.14 Relief Valves

Based upon Vopak being storage only, i.e. no processes, the relief valves will only be on thermal
expansion and fire relief. Bearing this in mind, the relief valve vents shall be classified in accordance
with an infrequent release tank vent, see section 4.9.

4.15 Sample Points

Samples taken from tank systems should be at minimal pressures, typically the head of liquid in the
tank. The taking of a sample should be under controlled conditions, i.e. spillage should be controlled.

The above classification is based upon abnormal occurrence, i.e. a valve jamming open and a
spillage occurring. The actual size of the hazardous area is dictated by the likely wetted area from a
spillage and the associated zone 2 around it, this should be assessed by the plant engineers and
classified in accordance with section 4.10. If the sample point is used more than once per day, then it

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 should be classified zone 1 in its local area, where venting may happen, i.e. 1.5m around the sample
point.

4.16 Pipe, Equipment, Joints and Valves

Piping systems designed and constructed to ANSI/ASME B31.3 (ISO 15649) Standard or equivalent
and without valves, instruments or significant flanges should not be considered as sources of release.

Flanges would only normally be classified as a secondary hazard risk unless they are broken in once
per day or more and material is released.

The figure above shows the hazard risk dimensions, this is based upon a liquid handled above its
flashpoint but below its boiling point and a pressure of up to 10bara and an equivalent leak of hole
size 1mm diameter.

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4.17 Water Drain Point

This Water drain classification applies to materials handled above their flashpoint but below their
boiling point.

A water drain point pipe on a vessel (tank) is usually of larger bore diameter than a sample point, in
the case of a flammable material break through, the material which escapes will create a much larger
hazard risk.

The EI code lists examples up to 100bara with a large hazard risk from them, the table has been
replicated below. As the water drain points at Vopak should operate at a much lower pressure, i.e.
the tank head pressure, the plant engineer should evaluate the likely wetted area from a spillage and
use section 4.10 to derive the hazard radius.

IP Code hazard radii for drain (and liquid sample) points (table 5.2 – part):

Hazard Radius R1 (m)

Pressure Bar Diameter Diameter Diameter
Absolute 2mm 5mm 10 mm
100 5 11 22

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4.18 Tanks with Outer Protective Wall

The above figure is applicable to:

- Tanks handling materials above their flashpoint, but below their boiling point.
- The classifications shown above are in addition to the classifications shown in chapter 4.

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4.19 LPG Installations

Notes:

The above figure applies to an LPG installation.

The main sources of release are considered to be ullage level indicators and loading/unloading
connections, which are provided with self sealing valves.

These points should have nominal zone 1 area of radius 1.5m and 3m respectively, which correspond
to the loss of materials from a nominal 1mm diameter hole.

Any depressions within the zone 2 should be classified as zone 1, with a surrounding zone 2, the size
of which is determined in section 4.10.

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4.20 Typical composite hazardous area classification around LPG road tanker
during unloading

The above figure accounts for the following sources of release:

- Discharge pump, this should be a high integrity pump and will give an associated zone 2 of
4m.
- Hose and connection points are given a zone 2 of 1.5m.
- The relief valve on the tanker of 0.5m if it has a soft seat, otherwise it would be 2.5m.
- The ullage level indicator would be classified zone 1 for 1.5m.

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5 Definitions
Item Description

Abnormal In the context of “abnormal” operation, the

untoward, irregular though not necessarily
wholly unexpected, deviation from “normal”
operation (see normal).

Apparatus Group (or sub-group) Certain equipment for use in a hazardous area
is allocated to a group or sub-group depending
upon its suitability for use with certain gases.

Continuous grade of release A grade of release in which the release product

is continuous or nearly so.
This is typical 10% or more of the operation or
duration of an activity
Example: If a system is only used 100 hours per
year and the release is 50 hours per year, the
system should comply with zone 0

Explosive Atmosphere Mixture with air, under atmospheric conditions,

of flammable substances in the form of gas,
vapour, mist or dust, in which after ignition,
combustion spreads throughout the
unconsumed mixture.

Extent of zone The distance in any direction from the source of

release to the point where the gas/air mixture or
dust cloud has been diluted by air to a value
below the lower explosive limit and in the case
of dusts where there is insufficient deposited
dust to form an explosive cloud if disturbed

Flammable dust A dust capable of ignition when mixed with air in

certain proportions as a dust cloud, or capable
of ignition as a dust layer.

Flammable Gas or Vapour A gas or vapour capable of ignition when mixed

with air in certain proportions.

Flammable liquid A liquid capable of forming a flammable mist or

vapour.

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 Flammable Material Material which is flammable of itself, or is
capable of producing a flammable gas, vapour
or mist.

Flammable Mist Droplets of flammable liquid, dispersed in air so

as to form an explosive atmosphere.

Flammable range (Explosive range) The range bounded by the upper and lower
flammable limits.

Flash Point Lowest liquid temperature at which, under

certain standardised conditions, a liquid gives
off vapours in a quantity such as to be capable
of forming an ignitable vapour/air mixture.

Gas or vapour relative density The density of gas or vapour compared with the
density of dry air at the same temperature and
pressure. It is calculated as the ratio of the
molecular weight of the gas or vapour
compared with the average molecular weight of
air.

Hazard Radius
The largest horizontal extent of the hazardous
area, independent of ground effects, that is
generated by the source when situated in an
open area under unrestricted natural ventilation.
This is the distance at which the concentration
of flammable vapour in air has fallen to the
lower flammable limit.

Hazardous area An area in which explosive gas/air mixtures,

dust clouds or layers are, or may be expected to
be, present in quantities such as to require
special precautions for the construction and use
of electrical and mechanical equipment.

Ignition Temperature of an explosive Lowest temperature of a heated surface at

gas atmosphere which, under specified conditions, the ignition of
a flammable substance in the form of a gas or a
vapour mixture with air will occur.

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 Indoor situation An area, which is substantially enclosed,
through which the flow of air is restricted and
which, therefore, does not meet the
requirements of a well ventilated situation.

Initial boiling point (IBP) The lowest temperature at which a liquid or

liquid mixture commences to boil under
prescribed test conditions.

Liquefied flammable gas A flammable material which is stored or handled

as a liquid and which at 17.5°C and
atmospheric pressure is a flammable gas.

Lower flammable limit (Lower explosive The smallest concentration of flammable gas,
limit) vapour, mist or dust which, when mixed with air,
is capable of ignition and subsequent flame
propagation under prescribed test conditions.

Non-hazardous area An area in which explosive gas/air mixtures,

dust clouds or layers are not expected to be
present in quantities such as to require special
precautions for the construction and use of
electrical and mechanical equipment.

Normal In the context of “normal operation”, the actual,

real, expected day-to-day conditions taking into
account the achieved standards of design,
maintenance and production practice.

Primary grade of release A grade of release in which the release of

product which is either regularly or at random
times during operation.
This is typical between 0,1% and 10% of the
operation or duration of the activity.

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 Secondary grade of release A grade of release in which the release of
product is unlikely to happen in normal
operation and in any event will be of limited
duration.
This is typical less than 0,1% of the operation or
duration of the activity;
Locations where deposited dust is present
would be considered as secondary grades of
release.

Source of release A point from which a flammable gas, vapour,

liquid or dust may be released into the
atmosphere.

Temperature Class (T class) One of six values of temperature allocated to

equipment derived from a system of
classification according to the maximum surface
temperature of the apparatus.

Upper flammable limit The largest concentration of flammable gas,

vapour, mist or dust which, when mixed with air,
is capable of ignition and subsequent flame-
propagation under prescribed test conditions.

Vapour relative density See gas or vapour relative density.

Well-ventilated situation An area or building substantially open where

there is little or no restriction to the natural
passage of air through it. (A compressor shelter
with a large roof ventilator and with the sides
open sufficient to allow free passage of air
through all parts of the building is considered to
be well ventilated).

Zone 0 Zone in which an explosive gas/air mixture or

dust cloud is continuously present or present for
long periods of time and for dusts where
deposited dust may be present in thick layers.

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 Zone 0, 1 and 2 In a hazardous area three types of zone are
recognised, in sequence of decreasing
probability of explosive gas/air mixtures, dust
clouds or dust layers being present during
operation

Zone 1 Zone in which an explosive gas/air mixture or

dust cloud is likely to occur in normal operation.

Zone 2 Zone in which an explosive gas/air mixture or

dust cloud is not likely to occur in normal
operation and if it does it will exist only for a
short time, and for dusts where deposited dust
is present in sufficient quantity to form a
flammable dust cloud if disturbed.

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6 References

- IEC 60079-10-1: Explosive atmospheres – Part 10-1: Classification of areas – Explosive gas
atmospheres

- IP Model code of safe practice part 15: Area classification code for installations handling
flammable fluids.

- DSEAR 2002 Regulation 7

- HSG176 – The storage of flammable materials in tanks

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Appendix 1 – El Code, part 15, Calculation of Risk Level
In line with appendix C of the EI Code, the classifications applied are based on the probability of risk
to individuals from contact with hazardous sources, as opposed to being purely prescriptive. The
appropriate release frequency LEVEL (I, II or III) determines the hazard radii for the classification
zones. It is the general intent to assign the ‘level’ to an installation as a whole rather than determine
the ‘level’ for each individual point source.

Calculations
The determination of the level is a ratio of the exposure to potential ignition sources against the
probability of ignition.

Exposure
The exposure must first be calculated by considering the probability of occupancy (Pocc) and the
calculation of number of secondary grade release sources within range (Nrange). This will allow the calculation
of the parameter known as Exposure (Exp), where:

Exp = PoccxNrange

The probability of occupancy is calculated by estimating the proportion of time the individual spends
on site exposed to at least one potential release source (i.e. within a hazardous area). This is simply
the number of hours the individual spends in the hazardous area per year divided by the number of
hours in a year. 40 hours multiplied by 48 weeks = 1920 hours/year. Therefore, the maximum P occ is
1920 divided by 8760 = 22%.
For simplicity, there are four values of Pocc for zone 2 based on this assumption:

Average hours per day in hazardous zone Pocc Pocc (%)

8 (100% of time) 0.22 22

5 0.13 13
2 0.055 5.5
1 0.028 2.8

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The calculation of number of secondary grade release sources within range varies depending on the
type of plant in question and the nature of the work the individual is performing.
To this end a calculation must be made based on the average number of release sources that could
affect the individual (taken as the average number of zone 2 radii which the individual is within during
their time in the hazardous area).
Again, for simplicity the average values are as follows:

Av. No. of
release
Activity Description
sources in
range
Hazard radius from flanges/valves is typically
General patrol in 1.5-3.0m and therefore only large radius
release sources (E.g. Standard pumps) will 1
“open” plant
affect worker for large proportion of time.
As above, however allows for congestion and
General patrol in proximity to multiple release sources. 5
“congested” plant

Inspection of items of equipment such as

Inspection of pumps, compressors, manifolds etc.
areas with many observation of typical onshore plant shows 30
release sources groups of 30 release sources (within 3metre
range) to be typical.

Probability of ignition at the zone 2 outer boundary

Although ignition sources are controlled within the zone 2 boundary, beyond this point it is acceptable
to locate any source of ignition. The probability of ignition (P ign) is therefore calculated on the types
and number of ignition sources. A more general guide indicates the following probabilities:

Probability of
Ignition
Description ignition, given
source
release
Where control of ignition sources extends beyond zone 2
Controlled (E.g. on offshore facilities where ignition sources are linked to 0.003
fire and gas detection systems).
Weak Ignition sources within zone 2 0.01
Ignitions due to road traffic, substations, buildings,
Medium unclassified electrical equipment, engines and hot surfaces 0.1
etc.
Continuous strong ignition sources such as fired heaters and
Strong flares etc. 1

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Determination of level

The level assigned to a particular section/plant can be determined from the relation between the
Exposure and the probability of ignition. This relation can be plotted on the graph within the area
classification guidelines to establish the level.

Results

The results for the release frequency level for this plant as a whole are based on the following
calculations:

Parameter Assumption/calculation Value

Pocc Average of 5 hours per day in hazardous zone 0.13

Nrange General patrol in “congested” plant 5

Exp Pocc x Nrange 0.65
Pign Medium 0.1
Level 0.1 against 0.65 I

Conclusion

It can therefore be assumed, based on the above figures that this plant as a whole can be considered
a LEVEL I area. This will become particularly prevalent when classifying areas with a number of
pumps and flanges. For this reason, all such zone 2 boundaries for this type of equipment have been
classified in relation to a level I area.

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Appendix 2 – Example LEAC Sheet

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Appendix 3 – Example POM Sheet

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