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14-02-2018
1
A Pa ssion for S a f et y
UNDERSTANDING
HAZARDOUS AREA
CLASSIFICATION
Consultancy
Training
Testing
A Pa ssion for S a f et y
COURSE OBJECTIVES
On completion of the course you will learn:
 What are the Flammability Characteristics that are required to
carry out Hazardous Area Classification (HAC);
 How to conduct Hazardous Area Classification (HAC) & classify
workplace into various hazardous and non hazardous zones for
both vapors and dusts
 What equipment to select for identified hazardous zones.
14-02-2018
2
A Pa ssion for S a f et y
INTRODUCTION
SIGMA‐HSE (INDIA) PVT. LTD.
A Pa ssion for S a f et y
AREAS OF EXPERTISE
 We bring together our Indian and UK experts to provide our clients
with EHS services and appropriate engineering solutions.
 We undertake Laboratory testing in our UK laboratories to ISO, BSI
ASTM and VDI individual test standards.
Consultancy Testing Training
14-02-2018
3
A Pa ssion for S a f et y
OUR PRESENCE
 Technical Offices
 New Delhi, India
 Mumbai, India
 Hyderabad, India
 Winchester, UK
 Abu Dhabi, UAE
 Laboratories
 Process Safety Lab, Winchester, UK
 The Environmental Laboratory (ELAB), UK
A Pa ssion for S a f et y
CONSULTANCY SERVICES
Our Consultancy team provides a wide range of specialist technical knowledge
covering the following sectors:
 Process Safety Management (PSM) Implementation
 Industrial Fire & Explosion Hazards
 Electrostatic Hazard Assessment
 Process Hazard Analysis (PHA)
 Functional Safety
 Chemical Reaction Hazards
 Training Workshops
14-02-2018
4
A Pa ssion for S a f et y
LABORATORY TESTING
 Powder Fire & Explosion Properties
 Gas and Vapor Properties
 Electrostatic Properties
 Chemical Reaction Hazard Testing
A Pa ssion for S a f et y
PIPER ALPHA DISASTER
An explosion and the resulting oil and gas fires destroyed Piper Alpha Platform on 6 July
1988, killing 167 men, with only 61 survivor. The total insured loss was about £1.7
billion.
As per the investigation, deluge system was activated by gas leak. This resulted in
ingress of deluge water into a light fitting, which was no longer explosion proof. This
resulted in short circuiting and spark generation.
14-02-2018
5
A Pa ssion for S a f et y
DANVERS CHEMICAL PLANT EXPLOSION,
NOVEMBER 2006
CAI / Arnel Chemical Plant Explosion
Steam supply left on during night.
Overheating in the reactor led to
vaporization of reactor content,
forming confined vapor cloud.
No personnel on site during night.
Confined Vapor Cloud ignited by
non‐rated consumer‐type box fan.
10 Injured, and 24 Houses and Six
Businesses Destroyed
A Pa ssion for S a f et y
IMPERIAL SUGAR EXPLOSION, FEBRUARY
2008
Sugar Plant in Georgia USA
Dust explosion occurred in sugar silo
8 people dead in the workplace,
6 more died in hospital
42 people injured
14-02-2018
6
A Pa ssion for S a f et y
WHAT CONSTITUTES AN EXPLOSION
Oxidant
Confinement
Mixing
Fuel Ignition source
A Pa ssion for S a f et y
CONDITIONS FOR VAPOUR EXPLOSION
The liquid must be above its Flash Point temperature.
Concentration must be within flammability limits.
Flammable atmosphere need to support combustion.
Energy related to the ignition source must be sufficient.
14-02-2018
7
A Pa ssion for S a f et y
CONDITIONS FOR A DUST EXPLOSION
Dust must be flammable/ combustible and airborne to form a cloud.
Concentration must be within explosible limits.
Particle size distribution should be capable of propagating flame.
The atmosphere need to support combustion.
Energy related to the ignition source must be sufficient.
A Pa ssion for S a f et y
FLAMMABILITY DATA – HAC (VAPORS
AND GASES)
 For HAC the following data
are relevant
 Flash Point
 Flammability Limits
 Auto‐Ignition Temperature
 Gas Group
 Vapour Density *
* not flammability data
14-02-2018
8
A Pa ssion for S a f et y
FLAMMABILITY DATA – HAC (DUSTS)
 For HAC the following data are
relevant
 A/B Classification
 Minimum Explosible Concentration
 Particle Size
 Minimum Ignition Temperatures
⁻ MIT (cloud)
⁻ LIT (layer)
 Electrical Resistivity *
* not flammability data
A Pa ssion for S a f et y
SOME OF THE GUIDES FOR GAS/VAPOR
 EN 60079‐10
 essential but no guidance on zone extents
 identical to IEC 60079‐10
 Energy Institute; Model code of safe practice ‐ Part 15
 4th edition, 2015
 applies mainly to installations handling flammable liquids
 IS 5571 and IS 5572
 Mainly used for gases and vapors only
 And others
14-02-2018
9
A Pa ssion for S a f et y
PHILOSOPHY OF HAZARDOUS AREA
CLASSIFICATION
 Area classification assesses the probability of flammable atmospheres
occurring
 Once the probability is established, ignition sources can be prevented to
match this
 area classification does not specify the equipment
 Area classification does not take account of consequences
 these are covered as part of the general safety considerations
A Pa ssion for S a f et y
AREA CLASSIFICATION PROCEDURE
 Identify sources of release
 Consider ventilation and review
standard of housekeeping
 Determine the duration &
grade of release.
 Estimate zone size
 Assign zone numbers
 Report !
Where can it get out
Is there
ventilation
Housekeeping
Continuous Normal
Operation
Infrequently
Continuous
Zone 0/20
Primary Zone
1/21
Secondary
Zone 2/22
14-02-2018
10
A Pa ssion for S a f et y
ZONES DEFINITION
Zone 0/20
 An area in which an explosive gas/vapor/dust atmosphere is continuously
present, or present for long periods
Zone 1/21
 An area in which an explosive gas/vapor/dust atmosphere is likely to occur
during normal operation
Zone 2/22
 An area in which an explosive gas/vapor/dust atmosphere is not likely to
occur in normal operation, and if it occurs it will only exist for a short time
Note: Normal operation includes expected abnormal events, but not catastrophic failures
A Pa ssion for S a f et y
SOURCE OF RELEASE
Continuous grade
 continuously, or for long periods, or frequently
Primary grade
 periodically or occasionally during normal operation
Secondary grade
 not in normal operation
 only infrequently and for short periods
14-02-2018
11
A Pa ssion for S a f et y
GRADES OF RELEASE AND ZONES
Grade Duration Zone
Continuous
Primary
Secondary
>1000 hr/year
> 1 hr/shift
<1000 hr/year
> 10 hr/year
<10 hr/year
< 1 min/shift
0/20
1/21
2/22
A Pa ssion for S a f et y
EXTENT OF ZONES
 Use Example Approach.
 Use examples offered in guidance to develop own “rule of thumb”
guidance
 Or if not applicable then calculate individual zones
 Adjust size and shape
 But do not significantly reduce the size
14-02-2018
12
A Pa ssion for S a f et y
EXTENTS OF ZONES – DUSTS
 Depends upon the environment
creating the dusty atmosphere
 Can be affected by
 working procedures
 Ventilation, forced or natural
 Housekeeping (good or bad)
 Maintenance of equipment
HAS TO BE DETERMINED, CANNOT BE
CALCULATED!
A Pa ssion for S a f et y
VENTILATION
 Poor ventilation can lead to larger or more strict zone designation
 Also, high ventilation rates can be used to relax the classification,
sometimes even as far as “non‐hazardous” because zone is of “negligible
extent”
 Such high degree of ventilation is virtually only applicable to local artificial
ventilation
 Availability of ventilation is crucial
14-02-2018
13
A Pa ssion for S a f et y
EXAMPLES – GASES & VAPORS
 Continuous
 Surface of flammable liquid (e.g. in vessel)
 Exhaust from continuously emitting vent stack
 Primary
 Pump, valve seals or fittings where release normally expected
 Open handling of flammable liquids
 Sample points used as part of normal operation
 Open manway additions to vessels
 Secondary
 Pump or valve seals, release not normally expected
 Sample points not used in normal operation
 Relief valves, vents not normally active
 Flanges, connections, pipe fittings
A Pa ssion for S a f et y
EXAMPLES ‐ DUSTS
 Zone 20
 Normally inside dust handling equipment. For Eg. Mill, Silo, Dust Collector (Dirty
Side)
 Zone 21
 Inside some equipment
 Area outside equipment. For Example Around Dumping station, Vessel Charging
point
 Zone 22
 Wherever dust layers occur and where the powder can release because of any
leakages. For Ex. Clean Side of Dust Collector, Around Flange Joints in conveying
line.
 Around a non‐confined Zone 21 due to fine dust or dust layers
Note : Practical considerations can make it necessary to classify a whole area
14-02-2018
14
A Pa ssion for S a f et y
RECOMMENDED ZONE MARKINGS
 Show zones on a site plan
 Make side views as required
 If possible include the gas
group and temperature class
 Report contains all data used
and assumptions made for the
classification
 Heights and shapes of zones to
be mentioned in report
A Pa ssion for S a f et y
DRAWINGS AND REPORT
 Show zones on a site plan
 Make side views as required
 If possible include the relevant
dust data
 Report contains all data used
and assumptions made for the
classification
 Heights and shapes of zones to
be mentioned in report
Recommended zone markings
Zone 20
Zone 21
Zone 22
14-02-2018
15
A Pa ssion for S a f et y A Pa ssion for S a f et y
AREA CLASSIFICATION REVIEWS
 Responsibility for area classification rests with project manager or site
manager
 New plant
 review during design
 review during start up
 review in use
 General reviews
 when changes are made
 at least every two years
 results may indicate the frequency needed
14-02-2018
16
A Pa ssion for S a f et y
TYPES OF PROTECTION ‐ ELECTRICAL
APPARATUS
 Flameproof Ex d
 Increased safety Ex e
 Purged or
pressurised Ex p
 Oil filled Ex o
Sand or powder
(quartz) filled Ex q
 Encapsulated Ex m
 Intrinsically safe Ex ia/ Ex ib
 Non‐incendive Ex n
 Special protection Ex s
 Protection by EX t
Enclosure
A Pa ssion for S a f et y
SELECTION OF ELECTRICAL APPARATUS
 Zone 0
 Ex ia
 Ex s (specially certified)
 Zone 1
 any suitable for Zone 0
 Ex d ‐ Ex p
 Ex q ‐ Ex o
 Ex e ‐ Ex ib
 Ex m
 Zone 2
 any suitable for Zone 0 or 1
 Ex n (Ex N)
 Zone 20
 Ex ta
 Zone 21
 Ex tb
 Zone 21
 Ex tc
 In addition the maximum surface
temperature must be considered
 determined by AIT
 usually as temperature classes
14-02-2018
17
A Pa ssion for S a f et y
INGRESS PROTECTION
A Pa ssion for S a f et y
INGRESS PROTECTION
 Zone 20
 Use Dust tight enclosure (IP 6X)
 Zone 21
 Use Dust tight enclosure (IP 6X)
 Zone 22
 Use Dust tight enclosures (IP 6X) ‐ Zone 22 (If powder is conductive)
 Use Dust protected enclosures (IP 5X) ‐ Zone 22 (If powder is non‐
conductive)
14-02-2018
18
A Pa ssion for S a f et y
TEMPERATURE CLASS FOR VAPOURS
AND GASES
Maximum surface
temperature
(°C)
AIT
(°C)
T1 450 °C >450 °C
T2 300 °C >300 °C (450 °C)
T3 200 °C >200 °C (300 °C)
T4 135 °C >135 °C (200 °C)
T5 100 °C >100 °C (135 °C)
T6 85 °C >85 °C (100 °C)
A Pa ssion for S a f et y
EQUIPMENT MARKING
1180 II 2 G D
Ex d II C T4 IPXX
ATEX Marking
BS‐EN Marking
14-02-2018
19
A Pa ssion for S a f et y
HAZARDOUS AREAS EXAMPLE
A Pa ssion for S a f et y
THANK YOU!
For Queries, contact our Process Safety Expert on +91 9599 024327
or write to him on hchichra@sigma‐hse.com
CONSULTANCY
 Hazardous Area Classification
 Electrostatic Hazard Assessment
 Process Safety Assessment
 Dust Explosion Risk Assessment
 ATEX assessment
And OTHERS
PROCESS SAFETY TESTING
 Electrostatic Properties
 Powder Fire & Explosion Properties
 Gas and Vapor Properties
 Chemical Reaction Hazard Testing
DETAILED TRAININGS

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Understanding HAC Webinar v1.pdf

  • 1. 14-02-2018 1 A Pa ssion for S a f et y UNDERSTANDING HAZARDOUS AREA CLASSIFICATION Consultancy Training Testing A Pa ssion for S a f et y COURSE OBJECTIVES On completion of the course you will learn:  What are the Flammability Characteristics that are required to carry out Hazardous Area Classification (HAC);  How to conduct Hazardous Area Classification (HAC) & classify workplace into various hazardous and non hazardous zones for both vapors and dusts  What equipment to select for identified hazardous zones.
  • 2. 14-02-2018 2 A Pa ssion for S a f et y INTRODUCTION SIGMA‐HSE (INDIA) PVT. LTD. A Pa ssion for S a f et y AREAS OF EXPERTISE  We bring together our Indian and UK experts to provide our clients with EHS services and appropriate engineering solutions.  We undertake Laboratory testing in our UK laboratories to ISO, BSI ASTM and VDI individual test standards. Consultancy Testing Training
  • 3. 14-02-2018 3 A Pa ssion for S a f et y OUR PRESENCE  Technical Offices  New Delhi, India  Mumbai, India  Hyderabad, India  Winchester, UK  Abu Dhabi, UAE  Laboratories  Process Safety Lab, Winchester, UK  The Environmental Laboratory (ELAB), UK A Pa ssion for S a f et y CONSULTANCY SERVICES Our Consultancy team provides a wide range of specialist technical knowledge covering the following sectors:  Process Safety Management (PSM) Implementation  Industrial Fire & Explosion Hazards  Electrostatic Hazard Assessment  Process Hazard Analysis (PHA)  Functional Safety  Chemical Reaction Hazards  Training Workshops
  • 4. 14-02-2018 4 A Pa ssion for S a f et y LABORATORY TESTING  Powder Fire & Explosion Properties  Gas and Vapor Properties  Electrostatic Properties  Chemical Reaction Hazard Testing A Pa ssion for S a f et y PIPER ALPHA DISASTER An explosion and the resulting oil and gas fires destroyed Piper Alpha Platform on 6 July 1988, killing 167 men, with only 61 survivor. The total insured loss was about £1.7 billion. As per the investigation, deluge system was activated by gas leak. This resulted in ingress of deluge water into a light fitting, which was no longer explosion proof. This resulted in short circuiting and spark generation.
  • 5. 14-02-2018 5 A Pa ssion for S a f et y DANVERS CHEMICAL PLANT EXPLOSION, NOVEMBER 2006 CAI / Arnel Chemical Plant Explosion Steam supply left on during night. Overheating in the reactor led to vaporization of reactor content, forming confined vapor cloud. No personnel on site during night. Confined Vapor Cloud ignited by non‐rated consumer‐type box fan. 10 Injured, and 24 Houses and Six Businesses Destroyed A Pa ssion for S a f et y IMPERIAL SUGAR EXPLOSION, FEBRUARY 2008 Sugar Plant in Georgia USA Dust explosion occurred in sugar silo 8 people dead in the workplace, 6 more died in hospital 42 people injured
  • 6. 14-02-2018 6 A Pa ssion for S a f et y WHAT CONSTITUTES AN EXPLOSION Oxidant Confinement Mixing Fuel Ignition source A Pa ssion for S a f et y CONDITIONS FOR VAPOUR EXPLOSION The liquid must be above its Flash Point temperature. Concentration must be within flammability limits. Flammable atmosphere need to support combustion. Energy related to the ignition source must be sufficient.
  • 7. 14-02-2018 7 A Pa ssion for S a f et y CONDITIONS FOR A DUST EXPLOSION Dust must be flammable/ combustible and airborne to form a cloud. Concentration must be within explosible limits. Particle size distribution should be capable of propagating flame. The atmosphere need to support combustion. Energy related to the ignition source must be sufficient. A Pa ssion for S a f et y FLAMMABILITY DATA – HAC (VAPORS AND GASES)  For HAC the following data are relevant  Flash Point  Flammability Limits  Auto‐Ignition Temperature  Gas Group  Vapour Density * * not flammability data
  • 8. 14-02-2018 8 A Pa ssion for S a f et y FLAMMABILITY DATA – HAC (DUSTS)  For HAC the following data are relevant  A/B Classification  Minimum Explosible Concentration  Particle Size  Minimum Ignition Temperatures ⁻ MIT (cloud) ⁻ LIT (layer)  Electrical Resistivity * * not flammability data A Pa ssion for S a f et y SOME OF THE GUIDES FOR GAS/VAPOR  EN 60079‐10  essential but no guidance on zone extents  identical to IEC 60079‐10  Energy Institute; Model code of safe practice ‐ Part 15  4th edition, 2015  applies mainly to installations handling flammable liquids  IS 5571 and IS 5572  Mainly used for gases and vapors only  And others
  • 9. 14-02-2018 9 A Pa ssion for S a f et y PHILOSOPHY OF HAZARDOUS AREA CLASSIFICATION  Area classification assesses the probability of flammable atmospheres occurring  Once the probability is established, ignition sources can be prevented to match this  area classification does not specify the equipment  Area classification does not take account of consequences  these are covered as part of the general safety considerations A Pa ssion for S a f et y AREA CLASSIFICATION PROCEDURE  Identify sources of release  Consider ventilation and review standard of housekeeping  Determine the duration & grade of release.  Estimate zone size  Assign zone numbers  Report ! Where can it get out Is there ventilation Housekeeping Continuous Normal Operation Infrequently Continuous Zone 0/20 Primary Zone 1/21 Secondary Zone 2/22
  • 10. 14-02-2018 10 A Pa ssion for S a f et y ZONES DEFINITION Zone 0/20  An area in which an explosive gas/vapor/dust atmosphere is continuously present, or present for long periods Zone 1/21  An area in which an explosive gas/vapor/dust atmosphere is likely to occur during normal operation Zone 2/22  An area in which an explosive gas/vapor/dust atmosphere is not likely to occur in normal operation, and if it occurs it will only exist for a short time Note: Normal operation includes expected abnormal events, but not catastrophic failures A Pa ssion for S a f et y SOURCE OF RELEASE Continuous grade  continuously, or for long periods, or frequently Primary grade  periodically or occasionally during normal operation Secondary grade  not in normal operation  only infrequently and for short periods
  • 11. 14-02-2018 11 A Pa ssion for S a f et y GRADES OF RELEASE AND ZONES Grade Duration Zone Continuous Primary Secondary >1000 hr/year > 1 hr/shift <1000 hr/year > 10 hr/year <10 hr/year < 1 min/shift 0/20 1/21 2/22 A Pa ssion for S a f et y EXTENT OF ZONES  Use Example Approach.  Use examples offered in guidance to develop own “rule of thumb” guidance  Or if not applicable then calculate individual zones  Adjust size and shape  But do not significantly reduce the size
  • 12. 14-02-2018 12 A Pa ssion for S a f et y EXTENTS OF ZONES – DUSTS  Depends upon the environment creating the dusty atmosphere  Can be affected by  working procedures  Ventilation, forced or natural  Housekeeping (good or bad)  Maintenance of equipment HAS TO BE DETERMINED, CANNOT BE CALCULATED! A Pa ssion for S a f et y VENTILATION  Poor ventilation can lead to larger or more strict zone designation  Also, high ventilation rates can be used to relax the classification, sometimes even as far as “non‐hazardous” because zone is of “negligible extent”  Such high degree of ventilation is virtually only applicable to local artificial ventilation  Availability of ventilation is crucial
  • 13. 14-02-2018 13 A Pa ssion for S a f et y EXAMPLES – GASES & VAPORS  Continuous  Surface of flammable liquid (e.g. in vessel)  Exhaust from continuously emitting vent stack  Primary  Pump, valve seals or fittings where release normally expected  Open handling of flammable liquids  Sample points used as part of normal operation  Open manway additions to vessels  Secondary  Pump or valve seals, release not normally expected  Sample points not used in normal operation  Relief valves, vents not normally active  Flanges, connections, pipe fittings A Pa ssion for S a f et y EXAMPLES ‐ DUSTS  Zone 20  Normally inside dust handling equipment. For Eg. Mill, Silo, Dust Collector (Dirty Side)  Zone 21  Inside some equipment  Area outside equipment. For Example Around Dumping station, Vessel Charging point  Zone 22  Wherever dust layers occur and where the powder can release because of any leakages. For Ex. Clean Side of Dust Collector, Around Flange Joints in conveying line.  Around a non‐confined Zone 21 due to fine dust or dust layers Note : Practical considerations can make it necessary to classify a whole area
  • 14. 14-02-2018 14 A Pa ssion for S a f et y RECOMMENDED ZONE MARKINGS  Show zones on a site plan  Make side views as required  If possible include the gas group and temperature class  Report contains all data used and assumptions made for the classification  Heights and shapes of zones to be mentioned in report A Pa ssion for S a f et y DRAWINGS AND REPORT  Show zones on a site plan  Make side views as required  If possible include the relevant dust data  Report contains all data used and assumptions made for the classification  Heights and shapes of zones to be mentioned in report Recommended zone markings Zone 20 Zone 21 Zone 22
  • 15. 14-02-2018 15 A Pa ssion for S a f et y A Pa ssion for S a f et y AREA CLASSIFICATION REVIEWS  Responsibility for area classification rests with project manager or site manager  New plant  review during design  review during start up  review in use  General reviews  when changes are made  at least every two years  results may indicate the frequency needed
  • 16. 14-02-2018 16 A Pa ssion for S a f et y TYPES OF PROTECTION ‐ ELECTRICAL APPARATUS  Flameproof Ex d  Increased safety Ex e  Purged or pressurised Ex p  Oil filled Ex o Sand or powder (quartz) filled Ex q  Encapsulated Ex m  Intrinsically safe Ex ia/ Ex ib  Non‐incendive Ex n  Special protection Ex s  Protection by EX t Enclosure A Pa ssion for S a f et y SELECTION OF ELECTRICAL APPARATUS  Zone 0  Ex ia  Ex s (specially certified)  Zone 1  any suitable for Zone 0  Ex d ‐ Ex p  Ex q ‐ Ex o  Ex e ‐ Ex ib  Ex m  Zone 2  any suitable for Zone 0 or 1  Ex n (Ex N)  Zone 20  Ex ta  Zone 21  Ex tb  Zone 21  Ex tc  In addition the maximum surface temperature must be considered  determined by AIT  usually as temperature classes
  • 17. 14-02-2018 17 A Pa ssion for S a f et y INGRESS PROTECTION A Pa ssion for S a f et y INGRESS PROTECTION  Zone 20  Use Dust tight enclosure (IP 6X)  Zone 21  Use Dust tight enclosure (IP 6X)  Zone 22  Use Dust tight enclosures (IP 6X) ‐ Zone 22 (If powder is conductive)  Use Dust protected enclosures (IP 5X) ‐ Zone 22 (If powder is non‐ conductive)
  • 18. 14-02-2018 18 A Pa ssion for S a f et y TEMPERATURE CLASS FOR VAPOURS AND GASES Maximum surface temperature (°C) AIT (°C) T1 450 °C >450 °C T2 300 °C >300 °C (450 °C) T3 200 °C >200 °C (300 °C) T4 135 °C >135 °C (200 °C) T5 100 °C >100 °C (135 °C) T6 85 °C >85 °C (100 °C) A Pa ssion for S a f et y EQUIPMENT MARKING 1180 II 2 G D Ex d II C T4 IPXX ATEX Marking BS‐EN Marking
  • 19. 14-02-2018 19 A Pa ssion for S a f et y HAZARDOUS AREAS EXAMPLE A Pa ssion for S a f et y THANK YOU! For Queries, contact our Process Safety Expert on +91 9599 024327 or write to him on hchichra@sigma‐hse.com CONSULTANCY  Hazardous Area Classification  Electrostatic Hazard Assessment  Process Safety Assessment  Dust Explosion Risk Assessment  ATEX assessment And OTHERS PROCESS SAFETY TESTING  Electrostatic Properties  Powder Fire & Explosion Properties  Gas and Vapor Properties  Chemical Reaction Hazard Testing DETAILED TRAININGS