Hazardous Area Classification Guidelines

Hazardous Area Classification

Guidelines

John Kingsley
FollowJohn Kingsley
Business Development Manager at iFluids Engineering
The scope of this guide is to drawn the guidelines of several different Recommended

practice(s) for the Area Classification of a process plant. The area classification is

required for the installation of the electrical equipment with the related specific

protection kind within a process area.

The basic definition, and the following modifications is based mainly on the

NFPA 70, The national Electrical Code (NEC) and the API 505 Recommended Practice

(API RP 505). Once that a location has been classified, requirements for electrical

equipment and associated wiring should be determinate from applicable publications

(e.g. NFPA 70 and API Recommended Practice 14F (API RP 14F) and local regulations.

The final scope of the document is to achieve the classification of both permanently and

temporarily installed electrical equipment. The application is designed in relation to their

potential risk of ignition source in presence of an ignitable mixture of fuel, or a

flammable/ignitible substance, and Oxygen (Air) under normal atmospheric conditions.

Reference Atmospheric Conditions

Pressure 101.3 Kpa 14.7 Psia

Temperature 20C (293.15 K) 68F

The document provides that is no relevant changes related to the change of the

atmospheric conditions from the reference point. On the basis provided earlier, the

guide is developed on the recommended practice based on the petroleum facility zones

(where ignitable liquids, gases, and vapors are processed, handled and loaded).
References, Codes and Reference Standards:

Actually, there are many Reference standards and industrial codes as reference for the

plant area classification. Part of them are developed on the same basis, others are very

particular and applied in specific plant type (e.g. Drilling Facilities, Petroleum and petrol

chemical plants).

The Hazardous Area Classification presents in this guide is based on the following items

as reference:

API:

API RP 505 Recommended Practice for Classification of Locations for Electrical

Installation at Petroleum Facilities Classified as Class I, Zone 0, Zone 1 and Zone 2

(2002).
API RP 500 Recommended Practice for Classification of Locations for electrical

Installation at Petroleum Facilities Classified as Class I, Division 1 and Division 2.

IEC:

IEC 60079-10 Electrical Apparatus for explosive gas atmospheres- Part 10:

Classifications of hazardous Area.

IEC 60079-12 Classification of Mixtures of Gases or vapors with air according to their

maximum experimental Gaps (MEGs) and minimum ignition currents ratio (MIC).

IEC 60079-20 Electrical Apparatus for explosive gas atmospheres- Part 20: Data for

flammable gases and vapors, relating to the use of electrical apparatus.

NFPA: NFPA 30: Flammable and Combustible Liquids Code

NFPA 70: National Electrical Code

NFPA 325: Guide to fire Hazard Properties of Flammable Liquids, Gases, and volatile

Solids

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.

Basic Definitions:

The following list of definition is based on the reference codes and practice guideline

listed before. The reference standard is assigned to each definition.

Boiling Point The temperature of a liquid boiling at the reference atmospheric

conditions. (IEC 79-10, Mod.)

Area Classification See Further paragraph named (Area Classification and

Definition).

Class I, Zone 0 See Further paragraph named (Area Classification and Definition).

Class I, Zone 1 See Further paragraph named (Area Classification and Definition).

Class I, Zone 2 See Further paragraph named (Area Classification and Definition).

Combustible Liquid(s) See Flammable Liquid(s) definition.

Enclosed Area A three-dimensional space enclose by more than two-third (2/3) of the

possible projected plane surface area and of sufficient size to allow the entry of

personnel. For a common building, this would required two-third (2/3) of the walls,

ceiling, and/or floor be present.

Explosive gas atmosphere A mixture with air, under the reference atmospheric

conditions, of a flammable material in the form of gas or vapor which, after ignition,

combustion spreads throughout the unconsumed mixture. (API 505-3.2.20)

Flammable Capable of an easy ignition, burning intensely or spreading flame rapidly.

Flammable (Explosive) limit(s) The lower (LFL) and upper (UFL) percentages by

volume of concentration of gas in gas-air mixture that will form an ignitible

mixture. (NPFA 325)

Flammable Liquid(s) See Further paragraph named (Flammable liquid

Classification).

Flash Point The minimum temperature of a liquid at which sufficient vapor is give off

to form an ignitible mixture with air, near the surface of the liquid, or within the vessel

used, as determinate by the test procedure and apparatus specified in NFPA 30.

Grade of Release There are three basic grade of release, as listed below, in order of

decreasing likelihood of the explosive gas atmosphere being present.(1)

1- Continuous

2- Primary

3- Secondary

Other grades of release may be possible by combination of the basic ones listed.(IEC

79-10, Mod.)

(1) It is important to underline that there isnt any relationship with the type of release

discussed earlier like puff and plume.

Grade of Release: Continuous See Further paragraph named (Area Classification

and Definition).

Grade of Release: Primary See Further paragraph named (Area Classification and

Definition).
Grade of Release: Secondary See Further paragraph named (Area Classification

and Definition).

Gas Group(s) For the Classification, the ignitible gases or vapors are classified in

several different groups. The subdivision of the gases is related to the gases physical

and chemical properties.

Hazardous (classified) Location(s) A location where fire and explosion hazards may

exist due to flammable gases or vapors, flammable liquids, combustible dusts, or

ignitible fibers of flyings. (API 505-3.2.10.5)

Heavier-than-air Gases of Vapors Formally those gases of vapors with a relative

density above 1.2 as to be regarded as Heavier-than-air gases. (IEC 79-10, Mod.)

Highly volatile liquid(s) (HVL) See Further paragraph named (Flammable liquid

Classification).

Ignitible (Flammable) Mixture A gas-air mixture that is capable of being ignited by an

open flame, electric arc or spark, or device operating above the ignition temperature of

the gas-air mixture. (See Flammable (Explosive) Limits) (API 505-3.2.32)

Ignition (Auto ignition) Temperature (AIT) The lowest temperature of a heated

surface at which, under specific conditions, the ignition of a flammable substance, or

mixture in the form of gas or vapor will occur. (IEC 79-10, Mod.)

Lighter-than-air Gases or Vapors Formally those gases or vapor with a relative

density below 0.8 as to be regarded as Lighter-than-air substances. (IEC 79-10, Mod.)

Maximum Experimental Safe Gap (MESG) The maximum gap of the joint between

the two parts of the interior chamber of a test apparatus that, when the internal mixture

is ignited and under specific conditions, prevents the ignition of the external gas mixture

by propagating through a 25 mm (984 mils) long joint, for all concentrations of the tested

gas or vapor in air. (API 505-3.2.38)

Minimum Ignition Current (MIC) The minimum current that, in a specified spark test

apparatus and under specific condition, is capable of igniting the most easily ignitible

mixture. (API 505-3.2.39)

Minimum Ignition Current Ratio (MIC Ratio) The minimum energy required from a

capacitive spark discharge to ignite the most easily ignitible mixture of a gas or vapor

divided by the minimum current required from and inductive spark discharge to ignite

methane under the same test conditions. (NFPA 497)

Normal Operation(s) The situation when the equipment is operating within its design

parameters. (IEC 79-10, Mod.)

Protected Fire Vessel Any fired vessel that is provided with equipment (such flame

arresters, stack temperature shutdown, forced draft burners, with safety controls, and

spark arresters) designed to eliminate the air intake and exhaust as sources of ignition.

(API 505-3.2.48)

Release, Source of A point or location from which a flammable gas, vapor or liquid

may be released into the atmosphere such that an ignitible gas atmosphere could be

formed. (IEV 426-03.06, Mod.)

Release Rate The quantity of flammable gas or vapor emitted per unit time from the

source of release. (IEC 79-10, Mod.)

Vapor Pressure The pressure exerted when a solid or liquid is in equilibrium with its

own vapor. It is a substance properties linked to the environment condition and

determinate by ASTM D 323-82. (IEC 79-10, Mod.)

Vapor-tight Barrier Is a wall, or barrier that will not allow the passage of significant

quantities of gas or vapor at atmospheric pressure. (API 505-3.2.54)

Ventilation Natural or artificial movement of air and its replacement with fresh air.

Ventilation, Adequate Ventilation that is sufficient to prevent the accumulation of

enough quantities of an ignitible mixture into a specific location.

Volatile Flammable Liquid A flammable liquid whose temperature is above its flash

point, or a Class II combustible liquid having a vapor pressure not exceeding 276 Kpa

(40 Psia) at 37.8C(100F) whose temperature is above its flash point. (API 505-3.2.58)

Basic Condition for Fire(s) and Explosion(s):

As discussed earlier, to occur, a fire and/or and explosion needs three basic elements,

without any of them, or specific conditions for each of them, the event cannot occur. The

three main elements are: (1) A fuel, not necessary an common combustible (e.g. Dust,

or Mill Dust), (2) a combustible (e.g. Air or Oxygen). (3) An igniter source with enough

energy to ignite the flammable mixture (e.g. Electrical equipment, free flames, or hot

surfaces). Other than the presence of each of these elements, there are two additional

conditions needed to obtain a fire or an explosion: (4) The concentration of the fuel
within the mixture must be between its own Upper and Lower Flammable Limit. (5) The

three basic elements must be in same location, or they must have a position that allows

them to complete their own role.

In classifying a particular location, the likelihood of the presence of a flammable gases

or vapor is a significant factor in determinate the zone classification (See Further

paragraph named Area Classification and Definition). Otherwise a distinction must be

made: the presence of the flammable mixture could be distinguished between normal

conditions and extraordinary condition. The term extraordinary condition doesnt

mean only a catastrophic event like a violent breakage of an item or similar, but also an

ordinary maintenance operation. There is obviously an objection: If an item, or a

location, needs a frequent maintenance, the act itself will go under the normal

condition. (API 505.4.2 refers to these condition adopting the phrase Normal and

Abnormal Condition).

As said, the mixture, to occur into an explosion and/or a fire, must have a concentration

within its range of flammability. It is quite important to know or to reach an

approximation of the quantities of flammable mixture are present inside the different

location, to determinate the extension of the area. As more the released quantities are

high, as more the area affected by the hazard is wide.

Another relevant parameter to take into account is the ventilation. The ventilation of a

specific location can reduce sensibly the hazard connected to a ignitible substance

release, even in major case. A good ventilation, natural and/or artificial), especially

inside enclosed location, is the fist measure to adopt to reduce the risk of Fires.
Especially for preliminary studies, even before the engineering starts, where the

knowledge of the plant and the area is almost unknown, found even and approximate

form of these parameters (Likelihood, Concentration, and Ventilation of a specific area)

could be really hard, and in the best case the approximation is totally aloof from reality.

In fact, the hazardous area classification is commonly made during the entire

development of the plant, from the first plot plan revised by the process company to the

final general plot plan of the engineering phase, reviewing continuously the data and the

area classification.

Safety Principles:

The area classification must be carried out when the initial process and instrument line

diagram (P&ID) are available and will be frequently updated till the start up of the plant.

Even during the life of the plant, the classification must be periodically updated, to take

into account potential changes to the original plat, or new release source(s).The

hazardous area classification, especially its first application, during the process design,

must be mainly affected from the inhertly design principles. To start the area

classification, it must be identified those area containing hazardous substance,

examining those area and identifying the potential sources or points of leakage. The first

question the operator should ask himself is Can these sources be replaced?, avoiding

source or any release point it could be the best strategy to adopt, especially when the

engineering of the plant even had started. If the source cannot be avoided, the rate of

the release, or its frequency, or its likelihood can be reduced? the hazard area related

to a release is as low as the quantity released, the time of the release and its likelihood

is low.
Flammable liquid(s) Classification:

Substances handled by any process facilities include flammable and combustible

liquids, flammable highly volatile liquids (HVLs) and flammable gases and vapors. When

classifying locations for electrical installations, the appropriate class and group(s)

should be determinate for all flammable substances. Each group, and class, is related

to the physical and chemical features of the substance. Refer to NFPA 325 or 497 for

the properties of specific flammable liquids, gases, vapors and volatile solids. The

volatility of flammable and combustible liquids is defined in NFPA 30.

Flammable (Class I) Liquids, such a gasoline, are defined as any liquid having a closed-

cup flash point below the threshold of 37.8C (100F) and a vapor pressure not

exceeding 276 Kpa (14 Psia). Combustible (Class II and III) liquids are defined as

liquids having a closed-cup flash point at or above the threshold of 37.8C (100F) and

below 60C (140F). Class III liquids are those liquids having a closed-cup flash point

above the threshold of 60C (140F).

Flammable and Combustible Liquid(s)

Class I II III

Flash Point Range(C) < 37.8 37.8 60 > 60

Vapor Pressure(Kpa) > 276 N.a. N.a

A common error is to confuse these classes and liquids group with the Classes of The

National Electrical Code, they are not synonymous.(NFPA 70).

Closed-Cup Flash Point and Auto ignition temperature:

Another spread error is to confuse the Flash point with the auto ignition temperature.

Flash Point The minimum temperature of a liquid at which sufficient vapor is give off

to form an ignitible mixture with air, near the surface of the liquid, or within the vessel

used, as determinate by the test procedure and apparatus specified in NFPA 30.

The auto-ignition temperature (AIT) instead, is the temperature, above the flash point,

which allow the ignition of the flammable mixture without any ignition source. Adopting

the definition of the IEC:

Ignition (Auto ignition) Temperature (AIT) The lowest temperature of a heated

surface at which, under specific conditions, the ignition of a flammable substance, or

mixture in the form of gas or vapor will occur. (IEC 79-10, Mod.)

The term Closed-Cup behind the flash point definition is referred to the standard

apparatus adopted for its assessment. There are two basic types of flash point

measurement: open cup and closed cup.

In open cup devices the sample is contained in an open cup which is heated, and at

intervals a flame is brought over the surface. The measured flash point will actually vary

with the height of the flame above the liquid surface, and at sufficient height the

measured flash point temperature will coincide with the fire point. The best known

example is the Cleveland open cup (COC).

There are two types of closed cup testers: non-equilibrium, such as Pensky-Martens

where the vapours above the liquid are not in temperature equilibrium with the liquid,
and equilibrium, such as Small Scale (commonly known as Setaflash) where the

vapours are deemed to be in temperature equilibrium with the liquid. In both these types

the cups are sealed with a lid through which the ignition source can be introduced.

Closed cup testers normally give lower values for the flash point than open cup

(typically 5-10 C) and are a better approximation to the temperature at which the vapor

pressure reaches the lower flammable limit (LFL).

The flash point is an empirical measurement rather than a fundamental physical

parameter. The measured value will vary with equipment and test protocol variations,

including temperature ramp rate (in automated testers), time allowed for the sample to

equilibrate, sample volume and whether the sample is stirred.

Methods for determining the flash point of a liquid are specified in many standards. For

example, testing by the Pensky-Martens closed cup method is detailed in ASTM D93,

IP34, ISO 2719, DIN 51758, JIS K2265 and AFNOR M07-019. Determination of flash

point by the Small Scale closed cup method is detailed in ASTM D3828 and D3278, EN

ISO 3679 and 3680, and IP 523 and 524.

Flash point, and auto-ignition temperature examples are reported above.For further

information about Flash point test, and data refer to NFPA 30.

Flammable Highly Volatile Liquid(s):

The HVLs such butane, propane, propylene, etc, are those flammable liquids of the first

class, with a vapor pressure exceeding 276 Kpa (40 Psia) at 37.8 C ( 100F).
Those liquids, have a high volatility and a low Flash point, allowing them to produce a

large volume of ignitible mixture. All the precautions must be taken if handled inside the

process plant, and they must be treated with ad over conservatively method. Usually the

mixture generated has a density lower than air, allowing quick movement and wide

distance covered. Those attitudes are the most dangerous and result into a wide

process area designed with strictly safety applications.

Class I Liquids:

Class I liquids, with the lowest Flash Point range, are usually handled at temperature

above the safety range, consequently can produce a flammable atmosphere. Especially

when released into the atmosphere, may produce a large volume of vapors (rarely

gases), especially near the source of release. Even if the Class I liquids are generally

related to the highest hazard, the less volatile liquids of this class release vapors slowly

and the ignition is possible only if the igniter (or the ignition source) is placed near the

liquid pool (See.Pool fire).

Class II Liquids:

With class II liquids, the likelihood of ignition is much lower than Class I liquids, due to

their higher flash point, only few of them are usually handled at temperature above their

flashpoint. The ignition of a liquid of the Class II usually is taken into account when

exposed to a fire, in this case the risk analysis is behind the common threshold of One

emergency only.
Even if they generate vapors, them usually are quite heavy and they cannot move to far

from the source. The transition state of the ignitible mixture from Heavier-than-air to

lighter-than-air is quite slow.

API RP 505 refers to the Class II liquids as Do not produce vapors of sufficient quantity

to be considered for electrical classification- (5.2.3.2)

Class III Liquids:

Similar to the Class II liquids, the Class III has a lower likelihood to produce an ignitible

atmosphere due to their highest flash point and lowest volatility. If heated beyond its

flash point, a Class III liquid produce a small amount of vapor, localized near the point of

release.

A partial list of flammable liquids, with the related Class, groups and category are

reported into the following pages (NFPA 497 1997).

Crude Oils:

A specific classification for the crude oils is impossible, its composition is too complex

and diversified that even its common physical properties are generic. However crude oil

is generally classified as Class I flammable liquid and its flash point range, generally

accepted, is -6.7 32.2 C (20-90F).

Gas Groups:

As done for the hazardous liquids, also the gases are divided into several different

groups and subclasses. The first subdivision is the classification into two groups: (1)
Group I Underground Gases and (2) Group II Aboveground Gases. The first class, is

referred to describe atmospheres containing firedamp (a mixture of gases, composed

mostly by methane, found usually in mines). For this reason the group I of flammable

gases are not used during the Hazardous area classification. The second group is use d

to describe all the gases found above ground and is subdivided into IIC; IIB and IIA

according to the nature of the gas or vapor. The last three categories of gases are

defined by two physical properties of the substance: Maximum experimental allowable

gap(s) (MEGS) and the Minimum Ignition Current ratio.

Maximum Experimental Allowable Gap:

The MESG is defined as follow:

Maximum Experimental Safe Gap (MESG) The maximum gap of the joint between

the two parts of the interior chamber of a test apparatus that, when the internal mixture

is ignited and under specific conditions, prevents the ignition of the external gas mixture
by propagating through a 25 mm (984 mils) long joint, for all concentrations of the tested

gas or vapor in air. (API 505-3.2.38)

The maximum experimental safe gap of flammable gases and vapors is the lowest

value of the safe gap measured according to IEC 60079-1-1 by varying the composition

of the mixture (flame propagation in the most ignitibie mixture).The safe gap is the gap

width at which in the case of a given mixture composition, a flashback just fails to occur.

The test procedure and its parameters are fully describe in IEC 60079-1-1.

Gas Group IIB:

Atmospheres containing acetaldehyde, hydrogen, of flammable gas, flammable liquid

produced vapor, or combustible liquid produced vapor mixed with air that may burn or

explode having either a maximum experimental safe gape (MESG) greater than to 0.50

mm (20 mils) and less than or equal to 0.90 mm (35 mils) or a minimum igniting current

ratio (MIC Ratio) greater than 0.45 and less than or equal to 0.80 (NFPA 497).

Gas Group IIC:

Atmospheres containing acetylene, hydrogen, of flammable gas, flammable liquid

produced vapor, or combustible liquid produced vapor mixed with air that may burn or

explode having either a maximum experimental safe gape (MESG) greater than or

equal to 0.50 mm (20 mils) ora minimum igniting current ratio (MIC Ratio) less than 0.45

(NFPA 497)
For the most gases and vapours it is sufficient to make only one determination between

the MESG and MIC Ratio to relate the gas to its own group. There are some cases

which both determination are required:

a) When MIC Ratio is within the range 0.8 0.9.

b) When MIC Ratio is within the range 0.45 0.5.

c) When MESG is within the range 0.5 0.55

In those cases, the second parameter will classify the gas and its group. The IEC

provides a complete list of common substances with their own group and properties

inside the IEC 600 79-12 (1978).

Hazardous Area Classification

General Criteria:

The choice of classify an area is based on the assumption that flammable gas(es),

vapor(s) or ignitible liquid(s) may be present. The choice starts from two basic

assumption:

a) There is an Hazardous Substance.

b) There is a potential Source of Release.

Possible source of release include: vents, flanges, control valves, pump and

compressor sealing, fittings, and floating roof seals. It is obvious that the presence of

those elements inside a process plat is so spread and wide that usually not each of

them must be considered during the area classification as a potential source of ignitible,

o generally, hazardous substances. The following paragraphs will explain which of them

are significant and have a relevance inside the classification study. Once that the

substances are identified and the potential source localized, before the area

classification, other factors must be taken in account like the grade of release, grade of

ventilation and the topography of the plant.

Commonly, the grade or release is distinguished into three different category:

Continuous.

Primary.

Secondary

Each of these categories leads naturally to one specific kind of location, but there is no

firm rules (see Classification Precautions 9.10.VI). However the grade of release is

strictly connected to the time of release:

Once that the type of release has been indentified, the ventilation assessment of the

specific area is required. The ventilation assessment is the last step to classify a

specific area. To evaluate the extension of a specific area a great number of information

must be gathered, especially:

Volatility of the flammable liquid

Flash point

Liquid Temperature at release

LFL and UFL

Vapor and liquid density

Geometry of the source of release

Quantity Released

Potential Release Rate

Concentration and starting conditions

Ventilation

Process Plant Topography

Climatic Conditions
Looking at the great number of information required, it is simply notice that have an

accurate estimate of the hazardous area is really hard to get. Many codes and

Recommended practice suggest several different examples and suggestions to achieve

a correct safety levels, not underestimating the potential hazard (API RP 505 or NFPA

497).

Area Classification and Definition:

The area classification, especially the area definition, is the same for several different

codes and standards like: API; IEC. NFPA. National Electrical Code (NFPA 70), etc.

The following paragraph is developed on the API RP 505 basis, and the area definition

are reported from it.

Class I, Zone 0:

Class I, Zone 0 presents the following features:

(1) Is a location in which a presence of ignitable concentration, or flammable gases, or

combustible liquids is continuous;

Or

(2) In which an ignitible concentration, or flammable gases, or combustible liquids is

present for a long time.

This locations usually includes locations inside vented tanks or vessels containing

volatile flammable liquids; the volume between the inner and the outer roof section of a

floating roof tank containing volatile flammable liquids; inside open vessels, tanks and
pits; and inside inadequately ventilated enclosures containing normally venting

instruments utilizing or analyzing flammable fluids and venting the inside of enclosures.

Class I, Zone 1:

Class I, Zone 1 presents the following features:

(1) Is a location in which a presence of ignitible concentration, or flammable gases, or

combustible liquids are likely to exist under normal operating conditions;

Or

(2) in which an ignitible concentration, or flammable gases, or combustible liquids

may exists frequently because of repair or repair maintenance operations or because of

leakage;

Or

(3) In which equipment is operated or process carried on, of such nature that

equipment breakdown or faulty operations could result in the release of ignitible

concentrations of flammable gases or vapors and also cause simultaneous failure of

electrical equipment in a mode to cause the electrical equipment to become source of

ignition.

Or

(4) Is adjacent to a Class I, Zone 0 location which ignitible concentrations of vapors

could be communicated, unless communication is prevented by adequate positive

pressure ventilation form sources of clean air and effective safeguards against

ventilation failure has been taken.

This classification usually includes locations where flammable liquids or liquefied

flammable gases are transferred from one container to another; inadequately ventilated

pump rooms for flammable gas or for volatile flammable liquids; the interior of

refrigerators and freezers in which volatile flammable materials are stored in the open,

lightly stoppered, or easily ruptured containers; and other locations where ignitible

concentrations of flammable vapors and gases are likely to occur in the course of

normal operation but not classified as zone 0.

Class I, Zone 2:

Class I, Zone 2 presents the following features:

(1) Is a location in which a presence of ignitible concentration, or flammable gases, or

combustible liquids are not likely to occur under normal operating conditions and if the

do occur will exists for a short period of time;

Or

(2) in which an ignitible concentration, or flammable gases, or combustible liquids

are handled ,loaded, unloaded, processed, or used, but in which the liquids, gases, or

vapors normally are confined within closed containers of closed system from which they

can escape ONLY as a result of accidental rupture or breakdown of the containers or

system, or as result of the abnormal operation of the equipment with which the

substances are handled or processed;

Or

(3) In which ignitible concentrations of flammable gases or vapors normally are

prevented by positive mechanical ventilation, but which may become hazardous as a

result of failure or abnormal operation of the ventilation equipment;

Or

(4) Is adjacent to a Class I, Zone 1 location which ignitible concentrations of vapors

could be communicated, unless communication is prevented by adequate positive

pressure ventilation form sources of clean air and effective safeguards against

ventilation failure has been taken.

The zone 2 classification usually includes locations where volatile liquids, or flammable

gases or vapors are used, but that would become hazardous only in case of an accident

or of some unusual operating condition.

Zone Considerations:

The word Normal are commonly used inside the zone definitions, but is not

synonymous of everything is working properly. For instance, a process may be so

sensitive to control that the activation of safety valves or other pressure relief

equipment, o generally safety equipment, is frequently, and that should be considered

normal.

The frequency of the maintenance or repair is relevant to define the normal and

abnormal situation: if the maintenance is required frequently the operations are to

evaluate as Normal, however if the maintenance frequency is low, its operations are

included into the abnormal category.

Zone 1 location are usually placed as border line of each Zone 0 location; to

separate Zone 0 and Zone 2 locations (Called Transition zone(s)). To prevent the

extension of an Zone 1 location as border of the Zone 0 location, it can be used a

vapor-tight barrier (see definitions) to avoid the spreading of the hazardous

substances.

Class I, Zone 2 locations are those area when abnormal conditions will generate a

release. For instance, a leakage from a sealing is quite rare, and can be considered

abnormal. Also the simultaneous rupture of the equipment and the electrical installation

is quite rare.

Zone 2 location are usually placed as border line of each Zone 1 location (Called

Transition zone(s)). To prevent the extension of an Zone 2 location as border of the

Zone 1 location, it can be used a vapor-tight barrier (see definitions) to avoid the

spreading of the hazardous substances.

Classification Precautions:

There is a natural relationship between the grade of release and the type of zone.

Zone Flammable Mixture presence

(Hour/year) Grade of Release 0

Continuous1 1000 or more

10 1000

Primary2 1 10

SecondaryUnclass. Less than 1

The grade of release, and the kind of zone are not synonymous, in fact a continuous

grade of release naturally leads to a constant presence of the flammable mixture in the

area. But a specific assessment should be taken for each specific place.

Unclassified Zones:

Many process plant locations may remains unclassified at the end of the classification,

why? Because the experience has shown that, regardless the grade of ventilation of the

location, the likelihood of an accidental leakage and the consequent release of

hazardous material are quite rare.

In those area category are included:

1) Locations where flammable substances are contained in all-welded closed piping

systems without valves, flanges or similar device.

2) Locations where flammable substances are contained in continuous metallic tubing

without valves, flanges or similar device.

3) Adequate ventilated location surrounded by process items with continuous flame

sources (e.g. flare tips)

4) Locations with any non-electric ignition sources (flare tips, free flame, etc) .
Ventilation:

In the major part of the cases, the ventilation is one of the most important parameter for

the classification of an area. Eventually gas or vapors leaked to the atmosphere can be

diluted by dispersion or diffusion into the air dropping their concentration below the LFL

concentration threshold. The ventilation, natural or artificial, leads to the continuous

replacement of the air of a specific zone with fresh air. The fresh air must come from

an unclassified or Zone 2 location to be efficient and positive.

Suitable ventilation rates can also avoid persistence of an explosive gas atmosphere,

thus influencing the type of zone (IEC 600 79-10. Mod.).

An Adequate Ventilation is defined as ventilation (natural or artificial) that is sufficient

to prevent the accumulation of a concentration of flammable substances over

the twenty-five percent (25%) of the concentration LFL threshold. Refer to NFPA 30 for

additional details.

Ventilation Assessment:

The assessment of the ventilation system(s) can be done evaluating the hypothetical

volume released and the time of residency of the same. The following analytical method

is subject to several limitations, but adopting suitable safety factors, the error resulted is

on the side of safety.

To start the assessment, it must be know the maximum release rate of the substance

(G)
The first step is to evaluate the minimum volumetric flow of fresh air (Vair) needed to

dilute the hazardous mixture:

Where:

k = 0.25 (Safety Factor) for primary and continuous grade of release, 0.50 for secondary

grade of release.

LFL = Lower Flammable limit of the mixture

T = Ambient Temperature (in Kelvins)

Generally LFL are expressed as (Vol%), to convert it to (Kg/m3) use the following

formula:

Where:

MW = Molecular Mass of the substance (Kg/mol).

Now we need to set the number of cycles of change, for the air, per time unit C (S-1),

and the potential hazardous volume around the source can be estimated:

Where:

Vz = Potential Hazardous Volume near the release source (m3).

f = is an additional safety (and quality) factor equal to 1 5 that denotes the quality of

the ventilation system. The greatest value (5) means that the air flow is not fresh or is

impeded.
Once that Vz is estimated, it identify the volume within the ignitible mixture

concentration is at least 25 or 50 % (related to the k value adopted) of its own LFL.

For an Enclosed Area (which 2/3 of the outside surface of the volume is covered) the

number of cycles of changes of air per unit of time is defined by the following formula:

Vtot = is the total volume of the air flow rate.

Vo = is the total volume of the enclosed area.

In an open air situation, even with the lowest wind speed, the number of cycles of

change air are high. Usually is adopted a C equal to 0.03 s-1 (related to a wind speed of

0.5 m/s). However, this method is quite conservative, over-sizing the hazardous area.

Once that the hazardous volume has been defined, the next step to estimate the grade

of ventilation is to achieve the Persistence Time (t) of the flammable mixture. The time

required for the average concentration to fall from the starting value of Xo to the LFL

multiplied by k after the release has stopped can be estimated from:

t is estimated in the same time unit of C. A particular attention must be adopted for the

Xo value: inside the hazardous volume, the concentration of the flammable substance

vary sensibly between the 100% (in the whole area near the source of release) and the

25% of the LFL. However the proper value of Xo should be estimated for each case.

The residence time estimated, isnt a quantitative value for the area classification, it

gives additional information about the abnormal process, and must be compared to the

time scale of the specific process.An acceptable time of dispersion depends by the time

and frequency of the release.

The volume Vz can be used to provide a means of rating the ventilation as: High,

Medium, or low. The persistence time can be used to provide a means of rating the

ventilation required to comply with the definition of Area 0, 1 or 2.

In particular ventilation can be rated as:

High when Vz is small, almost negligible.

Medium when the Vz volume can be controlled.

Low when the Vz volume cannot be controlled.

The code IEC 600 79-10 relate the value of Vz to the rate of the ventilation:

2) Low Ventilation cannot occur in open space cases.

With High Ventilation Grade, the ventilation is so efficient that the Hazardous volume

can be considered negligible and the related area my remain unclassified. An high

grade of Ventilation can be assigned only in cases of Artificial Ventilation, into small

enclosed area.

Another relevant parameter to consider is the Ventilation availability. The availability

needs to be taken into account during the area classification the type of zone. The level

of availability are the following:

A Good Ventilation is present virtually continuously.

B Fair Ventilation is present during normal operation.

C Poor Doesnt met the feature of good and Fair, but discontinuities are not to be

expected to occur for long periods of time.

In open space cases, the wind action is included under the Good category even at the

lowest speed (0.5 m/s). The effect of the ventilation to the area classification is

summarized in the following table.

The Zone definition NE indicates a theoretical zone that would be negligible extent

under normal operating conditions. The symbol + adopted means Surrounded by.

Multiple source:
An enclosed area, o in general, a specific zone could have several different release

sources. How can I assess the ventilation? IEC 600 79-10 presents a simple method to

evaluate the ventilation in a multi-source zone. The value of to adopt, during the

calculation, depends from the grade of release. The following table shows the value to

adopt for each grade of release category.

9.11.III Calculation Examples:

Example N1:
Minimum volumetric flow rate of fresh air:

Estimation of Hypothetical Volume Vz:

Time of persistence t:

Conclusion: The hypothetical volume Vz is significant but it can be controlled. The

degree of ventilation Is considered as medium with regard to the source based on this

criterion. With a persistence time of 0.26 h, the concept of Class I, Zone 1 may not be

met if the operation is repeated frequently.

Example N2:
Minimum volumetric flow rate of fresh air:

Estimation of Hypothetical Volume Vz:

Time of persistence t:

Conclusion: The hypothetical volume Vz is negligible. However the items adjacent to the

valve should be classified as Zone 2.

Example N3:
Minimum volumetric flow rate of fresh air:

Estimation of Hypothetical Volume Vz:

Time of persistence t:

The time of persistence cannot be estimate for continuous release. Conclusion: The

hypothetical volume Vz is negligible. However the items adjacent to the flange should

be classified as Zone 2.

Adjacent Area:

For the area adjacent to the classified one, particular attention must be adopted. There

three different cases:

1) A non closed adequately ventilated area that is adjacent to a classified area, and

that is NOT separated from the classified area by vapor tight-barrier, should be

classified to the extent designated.

2) A enclosed area that is adjacent to a classified area, that is separated from the

classified area by a vapor tight-barrier, is unclassified, considering only the external

sources.

3) An enclosed area that is adjacent to a classified area, and that is NOT

separated from the classified area by the vapor tight-barrier, should be classified the

same as the highest classification included. (API RP 505).

Extent of the hazardous area:

The extent of a particular zone, is function of several factors and parameters. The API

RP 505 suggests the extent of area generated by different potential release sources

(e.g. Vents, Rupture disk, etc.).

Refer to API RP 505, NFPA 497 for the single source. In those cases, the extent of the

single area is determined only by the location of potential sources of release of

flammable liquids, gases or vapors, and not by the location of the igniters (electrical and

non-electrical).

To estimate the extent of the specific area, especially for particular cases not revised by

the common standards, there are many dispersion model, even software suitable.

An alternative method for the area Classification:

API RP 505 suggests an alternative method for the area classification. The method is

based on the concept of Point Source, involving the creation of specific boundaries for

each individual source. At the end of the specific classification, an extended area

classification is made by the composition of the adjacent different area.

The extent of the area is related to: 1) the grade and velocity of the release 2) and the

volatility of the single substances. ( the volatility of a mixture is equal to the highest

volatility of its components).

The Hazard Radius is a direct function of volatility and rate of release, that means that

as one of the last parameter is reduced, the extent of the hazardous area tend to be

reduced.

The rate or the speed of the release (the quantity released) is divided into three different

categories: High, Medium and Low.

A release with High speed flow has a greater hazard radius due to the misting

transition. A mist, or spray, has usually a density lighter-than-air, that means that even at

low wind speed the dispersion is quick and cover a wide area.

The second parameter adopted in this method is the substance volatility. The volatility of

the most common flammable liquids and flammable gases or vapors, are present into
NFPA 30: Flammable and combustible liquid Code. The process groups all hazardous

substances into five different volatility categories.

Category G: Flammable substances handled and processed as Gases and vapors.

Category 1: Materials, including LPGs, with a vapor pressure, at the operating

temperature, above 70 psia (0.483 MPa). Those material, once released, vaporize in a

very short time, even if processed liquefied.

Category 2: Materials are all Class 1A Flammable liquids with a vapor pressure of or

less than 70 psia and all other flammable and combustible liquids with a vapor pressure

between 14.7 psia and 70 psia at operating conditions.

Category 3: Materials are all Class 1B Flammable liquids with a vapor pressure of or

less than 14.7 psia and all other flammable and combustible liquids with a vapor

pressure less than 14.7 psia when the operating conditions are above their own flash

point.

Category 4: Materials of Class II and heavier materials that are operated below their

flash point

For further information about the volatility, and flash point refer to NFPA 30, 325 and 497

Once that the material category has been found, its hazard radius is only function of the

material release rate and the dispersion rate of gases and vapors.

Application to Non-Enclosed adequately ventilated locations containing Heavier-

than-air gases or vapor:

The extent of the hazard radius, for each potential source, can be estimated by the

following matrix. Those method, based on API RP experience, is usually adopted for

those type of source usually not revised by the standards and codes.

For each substance category (G 4), and for a specific rate of release, the radius can

be estimated. The application of those radius shall be done with the following

precautions. Where the extent of an hazard radius has been indentified, it must be

revised by the good engineering safety judgment. The presence of physical barrier,

inside the hazard radius estimated, shall be considered to modify the area extent. In

many particular cases, the dispersion, especially for mixtures, must be evaluated using

suitable software or models. In those cases, which the dispersion isnt subject at any

external influence (e.g. Wind, Internal ventilation, etc.) the cloud dispersion is to be

considered symmetric and uniformly.

For example, a category 2 fluid, with a mass release of 13 gal(US)/min (0.82 litri/s), the

hazard radius is estimated within the range of 5-25 ft (1.5 7.6 m), with an adequate

knowledge of the source, and its area, the specific value can be estimated.