Hazardous Area Classification in Oil & Gas Industry A Fire Prevention Tool
SFPE ENGINEERING TECHNOLOGY CONFERENCE Oct 4, 2010 New Orleans, LA
Overview
Oil and gas plants handle flammable materials
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Flammable Range
100% Air Too lean to burn Too rich to burn Flammable 0% UFL
LFL
LFL UFL
Lower Flammable Limit Upper Flammable Limit
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Flammable Range of Few Materials
Material Methane Ethane Propane Butane Hydrogen LFL (Vol %) 5 3 2 1.5 4 UFL (Vol %) 15 15.5 9.5 8.5 75.6
Flammable Range - Methane
100%
Too rich will not burn
UFL 15%
Flammable
LFL 5%
Lean will not burn
0%
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Source of Release
A point from which a flammable gas, vapor or liquid may be released into atmosphere. ex. flanges, instrument connections, pump seals, etc
Sources of Release
Flange Instrument Connection
Fire Triangle
Simultaneous occurrence of all three sources causes fire. Cutting off any one, extinguishes fire.
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Ignition Source
Electrical Apparatus
Aim of Area Classification
To avoid ignition of releases that may occur from time to time The approach is to reduce to an acceptable level the probability of coincidence of a flammable atmosphere and an electrical or other source of ignition.
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Hazardous Area
A three dimensional space in which a flammable atmosphere may be expected to be present at such frequencies as to require special precaution for the design and construction of equipment, and the control of potential ignition sources.
Leak Source
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Hazardous Area
Hazardous Area
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Extent of Hazardous Area
Direct Example Approach
limited to common facilities
Point Source Approach
release rates are dependent on process conditions
Risk-based Approach
an option methodology which may reduce the hazardous area determined by the point source approach
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Grade of Release
Continuous: A release that is continuous
or nearly so.
Primary: A release that is likely to occur
periodically or occasionally in normal operation. (Vents, Sample points, etc)
Secondary: A release that is unlikely to
occur in normal operation and, in any event, will do so only infrequently and for short periods. (Flanges, Instrument connections, etc)
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Subdivision of Hazardous Area
Zone 0: flammable atmosphere is
continuously present or present for long periods.
Zone 1: flammable atmosphere is likely to
occur in normal operation.
Zone 2: flammable atmosphere is not likely
to occur in normal operation and, if it occurs, will exist only for short period.
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Zone and Division
Continuous Release Zone 0
Primary Release Zone 1
Secondary Release Zone 2 Division 2
Codes and Standards IEC 60079, IP 15, API 505, NFPA 497 API 500, NEC Article 500, NFPA 497
Division 1
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Grade of Release and Zone (Division)
Under unrestricted open air conditions:
Continuous grade normally leads to Zone 0 (Division 1) Primary grade normally leads to Zone 1 (Division 1) Secondary grade normally leads to Zone 2 (Division 2)
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Effect of Ventilation
The term grade of release and zone are not synonymous. Poor ventilation may result in a more stringent zone while, with high ventilation provision, the converse will be true.
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Zone Classification
Cone Roof Storage Tank
Zone 1
Zone 0
Zone 2 Zone 1
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Zone Classification
Floating Roof Storage Tank
Zone 1 Zone 1
Zone 2
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Classification of Zone (Division)
Zone (Division) classification is based on the frequency of release. Each zone (division) is further classified into Groups and Temperature Class based on the properties of flammable material processed in that zone (division).
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Gas Group
Flammable materials are sub-divided into groups based on minimum ignition energy required for igniting them.
Typical Gas Hazard Acetylene Hydrogen Ethylene Propane
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NEC Article 500 A B C D
IEC IIC IIC IIB IIA
Auto-ignition Temperature (AIT)
Minimum temperature required to initiate or cause self-sustained combustion of the fluid independent of the heating.
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Temperature Class
Temperature Class is assigned to flammable material based on its autoignition temperature.
Temperature Class T1 T2 T3 T4 T5 T6
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Auto-ignition Temperature (o C) >450 >300 >200 >135 >100 >85
Auto-ignition Temperature (AIT)
Material Methane Ethane Propane Butane Pentane AIT (o C) 595 515 470 365 285 Temperature Class T1 T1 T1 T2 T3
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Area Classification
Zone 1 IIA T3 Zone 2 IIC T1
Zone 2 IIA T3
Zone 1 IIC T1
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Battery Room
Lead acid batteries emit H2 during charging and create hazardous area Battery rooms are classified as Zone 1 Group IIC Temperature Class T1
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Selection of Electrical Equipment
Factors to be considered: Zone in which the equipment will be used. Sensitivity to ignition of the material likely to be present, expressed as a gas group. Sensitivity of the material present to ignition by hot surfaces, expressed as a temperature class.
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Selection According to Zone Classification
Equipment suitable for Zone 0 can be used in Zones 0, 1 or 2. Equipment suitable for Zone 1 can be used in Zones 1 or 2. Equipment suitable for Zone 2 can be used only in Zone 2.
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Selection According to Gas Groups
Grouping becomes more severe in going from IIA to IIB to IIC. Group IIB equipment may be used in place of Group IIA equipment. Group IIC equipment can be used in place of equipment for both Group IIA and IIB.
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Selection According to Temperature Class
Temperature Class T1 T2 T3 T4 T5 T6 Maximum Surface Temperature (o C) 450 300 200 135 100 85
Equipment having a lower maximum surface temperature class may be used in place of that a higher maximum surface temperature (lower T class), but not conversely.
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Equipment Protection
Oil Immersed Protection
Heavy current switchgear and transformers
Pressurization or Continuous Dilution
Analyzers, control boxes, etc
Powder-filled Protection
Electronics, chokes, etc
Flame-proof Enclosure
Motors, lighting, junction boxes, etc
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Summary
Identify the flammable materials. Identify sources of release and determine grade of release (and hence Zone 0,1, 2 or Division 1, 2). Determine extent of hazardous area. Assign Gas Groups and Temperature Class. Select appropriate Electrical apparatus.
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Thank you
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