Hazardous Area Classification Training Course CD Version PDF

Hazardous Area Classification
Training Seminar
Instructor: Allan Bozek, P.Eng MBA
EngWorks Inc., Calgary, Alberta
www.EngWorks.ca
www.EngWorks.ca
Calgary - October 10, 2006

Edmonton – October 11, 2006
Calgary Oct 10, 2006

Edmonton Oct 11, 2006 Hazardous Area Classification 1
Premise for the Course
An area classification as designated by a Professional
Engineer is the area classification
Done under professional seal
Currently no definition of “competence”
www.EngWorks.ca

www.EngWorks.ca
The classification of facilities have become more
complex
Need for consistency in design approach and in
documentation
Decision to communicate these requirements to
industry via a set of Engineering Guidelines in the
appendix of the 2006 “Code for Electrical Installations
at Oil and Gas Facilities”

Learning Objectives
1. Provide you with the ability to analyze an oil, gas or chemical
processing facility and establish the degree and the extent of
a classified area.
2. Provide you with an overview of the various Codes and
www.EngWorks.ca
Recommended www.EngWorks.ca
Practices developed for area classification
3. Provide guidelines on how to properly document your analysis
and communicate it to third parties; who will rely on this
information for subsequent design, installation and operating
activities.
4. Provide you with an introduction to some of the various
options available to you for classifying a facility and when
they are appropriate for use.

Course Parameters
1. Will focus on Class I Hazardous Areas –
Class II and Class III areas are not covered
www.EngWorks.ca
2. Focus willwww.EngWorks.ca
be on the Zone method of area
classification
• Division method will be referenced where
differences exist
3. Primary focus will be on North American

Design and Construction Standards as
established by the CEC
Definition of a Hazardous
Location
“Hazardous location means premises,
buildings, or parts thereof in which
there exists the
www.EngWorks.cahazard
www.EngWorks.ca of fire or
explosion due to…”
Flammable gases and liquids
Combustible dust or flyings
Ignitable fibres and materials
CEC Section 0
Background History
Concept of a “Hazardous Location” was
first developed in the coal mining
www.EngWorks.ca
industry www.EngWorks.ca
Methane and coal dust the primary hazards
Light and power essential to mining
operations

The Davy Safety Lamp
www.EngWorks.ca
www.EngWorks.ca
Sir Humphrey Davy

Background History
Development of the motor led to the
introduction of ventilation into coal
mines reducing the hazard

www.EngWorks.ca
www.EngWorks.ca
Motors that were totally enclosed
contained the explosion
Led to the development of the XP
enclosure
Concept of intrinsic safety developed
Background History
1920 “Extra Hazardous Location” added to the NEC

UL labs were certifying equipment for use in hazardous locations
Class I and Class II designations added in 1931
www.EngWorks.ca

Class I Groupwww.EngWorks.ca
designations added in 1935
Concept of Division 1 and Division 2 added in 1947
Temperature code classification added in 1971
Zone Area classification option added in 1996

Purpose of an Area Classification
Historical
“Identify the possibility of an explosive atmosphere
being present and influencing the design of the plant
or facility to minimize the risk of ignition”
www.EngWorks.ca
www.EngWorks.ca
Based on normal operating conditions - does not deal
with the potential of catastrophic failures
Primarily used for establishing the type of electrical

equipment and wiring methods that can be used
within a hazardous area

Purpose of an Area Classification
Present and Future
ATEX Directive
Essential Health and Safety requirements with
respect to:
www.EngWorks.ca
Potential ignition sources from equipment in hazardous
locations
www.EngWorks.ca
Applies to non-electrical equipment
Alberta OH&S Requirements
Hazardous area classification is used as a basis for
implementation of the OH&S code
Regulates the work activities performed within a
classified location

What is Impacted by a Hazardous
Area Classification?
Cost of Ownership
Materials

www.EngWorks.ca
Overall installation Cost is 50% greater for Division 1
www.EngWorks.ca
locations when compared to Division 2
Cost difference is less between Zone 1 and Zone 2
Installation
Higher standard of care required for Zone 1 areas
Inspection requirements are greater
Maintenance
Ongoing maintenance costs are greater for Zone 1 areas
Safety
Defines the risk associated with the
performance of activities within an area

www.EngWorks.ca
www.EngWorks.ca
Defines (by code) the standard of care
required for installing, operating and
maintaining equipment within an area

Operations
Hot Work Permitting Requirements
Provides a basis for Restricted access

www.EngWorks.ca
Special procedures
www.EngWorks.ca
Requirement for sniffing the area for gas before performing
basic tasks
Shutdown of equipment components before inspection or
repair
All this may have an impact on the on-line performance

of a facility

Defining the Hazard
www.EngWorks.ca
www.EngWorks.ca

Edmonton Oct 11,
2006 Hazardous Area Classification 15
The Fire Triangle
For an explosion or
www.EngWorks.ca
I gn
fire to occur,www.EngWorks.ca
all
itio
el
three elements of
nS
Fu
ou
the fire triangle
rce
must be present
Oxygen

Probability of Events
Full House 1 in 500
Royal Flush 1 in 650,000
www.EngWorks.ca
Lotto 649 Win
www.EngWorks.ca
1 in 13,984,000
Dying 15 minutes after you bought your 1 in 14,000,000
649 ticket
Probability of an explosion from 1 gallon 1 in 59,000,000
of hydrocarbon
Probability of a simultaneous failure of 1 in 64,000,000
both process and electrical equipment
Relative risk of explosion within a
process area
100000
Tons of Hydrocarbon Release

10000
www.EngWorks.ca
1000
www.EngWorks.ca
100
10
1.0
0.1
100%
1.0%
0.01%
0.1%
10%
% Probability of Explosion
Probability of a Component Leak
(Source API 4615)
Minor Major
Leaks Leaks
Components 10 to 9999 >10,0000
Facility Type Screened No Leaks ppmv ppmv
www.EngWorks.ca
Light Crudewww.EngWorks.ca 48652 97.90% 1.11% 0.90%
Heavy Crude 13756 99.54% 0.43% 0.00%
Gas Production 40178 96.23% 2.15% 1.61%
Gas Plant 57126 96.28% 1.73% 1.97%

Offshore
Platform 45694 98.60% 0.81% 0.77%
Totals 205397 97.41% 1.39% 1.18%

Ignition Sources of Major Fires
Source: Factory Mutual Engineering Corp.
Source Percent of Accidents

Electrical 23
Smoking
Friction
www.EngWorks.ca
www.EngWorks.ca
10
18
Overheated Materials 8
Hot Surfaces 7
Burner Flames 7
Cutting, Welding, Mech. Sparks 6
Static Sparks 1
All Other 20
Rew and Spencer Model
Category Examples of Ignition Sources Ignition
(Strength of Potential
Source)
www.EngWorks.ca
Pilot Lights, Fired Heaters,Flares
Certain p=1
www.EngWorks.ca
Hot Work, Electrical Faults,
Strong Smoking p > 0.5
Vehicles, Substations, Unclassified
Medium electrical equipment, Engines, Hot 0.5 > p > 0.05
surfaces
Office Equipment, Electrical
Weak Appliances, Mechanical Sparks, p < 0.05
Static electricity
Intrinsically safe equipment,
Negligible Radio Frequency Sources p=0
Risk Assessment
Requires an understanding of process,
mechanical and electrical engineering
concepts

www.EngWorks.ca
www.EngWorks.ca
Requires an understanding of the various
codes and practices and knowing which one
is most suitable for a given situation
Must be carried out before the choice of

appropriately certified equipment is made

Risk Assessment
Subjective in nature and will be influenced by:
Standards and practices within an operating
company
www.EngWorks.ca
www.EngWorks.ca
Practices that vary between upstream, downstream
and offshore facilities
Size and complexity of a facility
Remote, unmanned or inaccessible facilities
Cold weather facilities
Operations Experience

Probability that an Explosive
Atmosphere will exist depends on:
Flammable Material Present
Source of Release
www.EngWorks.ca
Gradewww.EngWorks.ca
of Release
Continuous (>1000 hrs per year)
Primary (10-1000 hrs per year)
Secondary (1-10 hrs per year)
Rate of Release
Degree of Ventilation
Extent of a Hazardous Area
Classification depends on:
Properties of the flammable material
Concentration
Volatility

www.EngWorks.ca
Liquid temperature
Density
www.EngWorks.ca
Release rate
Geometry of the Source of Release
Release velocity
Ventilation
Climatic conditions
Topography
“Group Responsible” Concept
“final determinations of the classifications

should involve coordinated efforts between
www.EngWorks.ca
www.EngWorks.ca
process engineers, facility design engineers,
fire and safety specialists, instrument and
electrical engineers”
“should also include operations and

maintenance personnel”
Codes, Standards and
Recommended Practices
www.EngWorks.ca
www.EngWorks.ca

Edmonton Oct 11,
Canadian Electrical Code
CSA C22.1 Part 1
www.EngWorks.ca
www.EngWorks.ca

Canadian Electrical Code
Sets the minimum standards for
electrical installations in hazardous
www.EngWorks.ca
areas www.EngWorks.ca
All or portions of the code may be
mandated by law by the Authority having
Jurisdiction

CSA C22.1 (CEC)
Section 18 deals with Hazardous Locations
classified using the Zone Method
Zone Method of Classification is the required
www.EngWorks.ca
method for new installations
www.EngWorks.ca
Appendix B incorporates an extensive commentary
on Section 18 – well worth reading
Appendix J refers to locations where the

Division method of classification is used
Division method may be employed for existing
installations at the discretion of the Owner/User

CSA C22.1 (CEC)
CEC Section 20 provides guidance on area
classification for:
Commercial Garages
www.EngWorks.ca
www.EngWorks.ca
Aircraft Hangers
Motor Fuel Dispensing Facilities
Bulk Storage Plants
Paint Application Facilities

CSA C22.1 (CEC Section 19)
www.EngWorks.ca
www.EngWorks.ca

Section 19 provides guidelines for
upstream oil and gas and drilling facilities
Does not apply to
www.EngWorks.ca

www.EngWorks.ca
Petroleum refineries
Petrochemical facilities
Gas distribution systems operated by a Utility
Fuel supply systems for equipment
Deleted from 2006 O&G Code
Not Mandated in all jurisdictions

Rule 19-100 (1)
Classifications of hazardous locations
established and documented by a
www.EngWorks.ca
www.EngWorks.ca
professional engineer under the engineer’s
seal and signature shall be the area
classification
Appendix D19
Engineering Guidelines for Determining
Area Classification
CEC Standata
www.EngWorks.ca
www.EngWorks.ca

CEC Standata
Code clarifications and updates
between formal code book updates
www.EngWorks.ca
Specific references to Section 18 and 19
www.EngWorks.ca
Available online at:
www.municipalaffairs.gov.ab.ca/mahome/ss/safety/electrical.cfm
On-line e-mail subscription is available

Alberta OHSA Requirements
www.EngWorks.ca
www.EngWorks.ca
http://www.hre.gov.ab.ca/documents/WHS/WHS-PUB_OHSC-1.pdf
Alberta OH&S Requirements
Part 10 Fire and Explosion Hazards
Section 162 – “Employers must insure that
flammable and combustible substances in the
workplace do not ignite”

www.EngWorks.ca
“No workerwww.EngWorks.ca
may enter an area where the
atmosphere LEL exceeds 20%”
Regulates placement of IC engines, fired
heaters and other equipment in hazardous
locations
Requirements for static control and hot work
permitting requirements

API RP 500 & RP 505
www.EngWorks.ca
www.EngWorks.ca

API RP 500
API 500 refers to Division Classified area as
defined in Article 500 of the NEC
Issued in 1955

www.EngWorks.ca
www.EngWorks.ca
Designed for petroleum refineries
Companion documents issued in 1966
RP500B – Production Facilities
RP500C – Gas Pipeline Transportation Facilities
Three documents recombined in 1991

API RP 505
API 505 refers to Zone Classified areas
as defined in Article 505 of the NEC
www.EngWorks.ca
Issued forwww.EngWorks.ca
general use in 1997
Incorporates several appendices not found
in RP 505
Current bases for CEC Section 18
Zone system adopted to improve safety,
reliability, maintainability and uniformity
API RP 500 & RP 505
Applicable to:
Refineries

www.EngWorks.ca
Drilling and production facilities
www.EngWorks.ca
Offshore drilling and production facilities
Pipeline facilities

API RP 500 & RP 505
Prescriptive in nature
if this is the situation – this is how you should classify the
area.
Does not attempt to describe the properties of
www.EngWorks.ca

flammable materials
www.EngWorks.ca
Makes reference to NFPA 325
Concepts are referenced from a variety of North
American and International publications
Incorporates more figures and diagrams than all
other API documents
The extent of the zones indicated on the figures are
based on experience

RP 505 Figure 20
www.EngWorks.ca
www.EngWorks.ca

RP 505 Table of Contents
1. Scope
2. References
3.
www.EngWorks.ca
Definitions
www.EngWorks.ca
4. Basic Conditions for a Fire or Explosion
5. Flammable and Combustible Liquids, Gases
and Vapors
6. Classification Criteria
7. Extent of a Classified Location
RP 505 Table of Contents
8. Recommendations for Common Applications
9. Recommendations for Petroleum Refineries
10. Recommendations for Drilling Rigs and Production
www.EngWorks.ca
Platforms www.EngWorks.ca
11. Recommendations for Offshore Drilling Platforms
12. Recommendations for Offshore Production
Platforms
13. Recommendations for Pipeline and Transportation
Facilities

API 505 Appendices
A. Sample Calculations to achieve adequate
ventilation by natural
B. Calculation of Minimum Air introduction to
www.EngWorks.ca
www.EngWorks.ca
achieve Adequate Ventilation using Fugitive
Emissions
C. Preferred Symbols
D. Alternative method for Area Classification
E. Procedure for classifying areas
F. Alternative Ventilation Criteria
NFPA 497
www.EngWorks.ca
www.EngWorks.ca

NFPA 497
Recommended Practice
Developed for the classification of
www.EngWorks.ca
chemical process plants
www.EngWorks.ca
The classification of chemical plants should
be less strict than for petrochemical
facilities
Appropriate for small to mid size chemical
plants
NFPA 497
Makes reference to both the Zone and Division
method of Classification
Incorporates an extensive list of Flammable and
www.EngWorks.ca
Combustible www.EngWorks.ca
materials c/w their physical properties
Size of a classified area is dependent on the volume,
pressure and flow rate within the process
Incorporates a list of point source diagrams to assist
the user in defining the extent of a classified area

NFPA 497 Figures
www.EngWorks.ca
www.EngWorks.ca

IEC 60079-10
www.EngWorks.ca
www.EngWorks.ca

ISA RP 12.24.01
(IEC 79-10 Mod)
www.EngWorks.ca
www.EngWorks.ca

ISA RP 12.24.01
Revision of IEC 79-10 to suit North American
standards and definitions
Recommended Practice

www.EngWorks.ca
www.EngWorks.ca
All revisions to IEC 79-10 are annotated
Incorporates the use of gas detection as a
means of classifying indoor areas Class 1
Zone 2

IP 15
Model Code of Safe Practice
www.EngWorks.ca
www.EngWorks.ca

IP 15
Model Code of Safe Practice
Essential reading when dealing with the
really difficult situations
Describeswww.EngWorks.ca
in detail three different

www.EngWorks.ca
approaches to area classification
Introduces the concept of the risk based
approach to area classification
First code to use dispersion modeling as a
basis for defining the extent of classified
areas
IGE/SR/25
Hazardous Area Classification for
Natural Gas Installations
www.EngWorks.ca
www.EngWorks.ca

IGE/SR/25
UK Guideline for establishing the area
classification for:

www.EngWorks.ca
Gas transmission and distribution facilities
www.EngWorks.ca
Gas Storage facilities
Complement IEC 60079-10 by providing

a detailed procedure with examples

Codes vrs Recommended
Practices
CEC are mandatory requirements
Set the minimum standards
Formal Variance is required to deviate from the CEC

www.EngWorks.ca
OH&S rules are mandatory requirements
www.EngWorks.ca
Vary from Province to Province
Code for Electrical Installations at Oil and Gas
Facilities are mandatory requirements in Alberta
Recommended practices are not mandatory –
Guidelines only
RP-505
ISA RP 12.24.01 (IEC 79-10 Mod)

NFPA 325
www.EngWorks.ca
www.EngWorks.ca

NFPA 325
Not a code, standard or recommended practice
Compilation of fire protection properties of
approximately 1500 materials and substances

www.EngWorks.ca
www.EngWorks.ca
Not originally intended for classifying facilities
Incomplete information
Referenced in RP 500, RP 505 and ISA 12.24.01 as

the reference for flammable and combustible
materials properties

IEC 60079-20
www.EngWorks.ca
www.EngWorks.ca

IEC 60079-20
Designed specifically for area
classification purposes

www.EngWorks.ca
Complete set of material properties
www.EngWorks.ca
Minor discrepancies in data between

IEC 79-20 and NFPA 325
Test methods are similar

WHMIS MSDS
Material Safety Data Sheets
Updated every three years
Extensive listing of chemicals at the
www.EngWorks.ca
CCOHS Website (Paid Subscription)
www.EngWorks.ca
http://www.ccohs.ca/
Completely describes the physical data
and the fire and explosion hazards for a
material

CAS Numbers
CAS No.
NFPA 497 www.EngWorks.ca

www.EngWorks.ca
CEC 2006
Appendix B
Refer to the Chemical Abstract Service Registry

Database (Subscription Service)
~ 30M Chemical Compounds listed
No info on LFL, UFL, AIT
Edmonton Oct 11, 2006
or MESG
Hazardous Area Classification 65
Area Classification
www.EngWorks.ca
www.EngWorks.ca
Definitions

Edmonton Oct 11,
Class I, Zone 2, Gp. IIA, TCode T2A
Class Definition of the Hazard
Zone
www.EngWorks.ca
Probability that a hazard may exist
www.EngWorks.ca
Group Characteristics of the Hazardous

Substance
Temp Maximum Surface Temperature
Code allowable in the area
Class – Definition of the Hazard
Class I – Flammable gases
Class II – Combustible Dusts

www.EngWorks.ca
www.EngWorks.ca
Class III – Ignitable Fibres or Flyings
Non-hazardous – Areas where Class I,II or III

substances are not expected to be present in
quantities as to require special precautions

Class I, Zone 0
(CEC 2006 Definition)
Class I locations shall be further divided into three

zones based on the frequency of occurrence and
duration of an explosive gas atmosphere as
follows:
a)
www.EngWorks.ca
www.EngWorks.ca
Zone 0, comprising Class I locations in which explosive gas
atmospheres are present continuously or are present for long
periods;
Greater than 1000 hrs/year

(10% of the time) Table 3 RP505

Class I Zone 1
b) Zone 1, comprising Class I locations in which:
i. Explosive gas atmospheres are likely to occur in normal
Delete from 2006 ii. www.EngWorks.ca

operation or;
www.EngWorks.ca
Explosive gas atmospheres may exist frequently because
CEC Definition
of repair or maintenance operations or because of
leakage; or
iii. The location is adjacent to a Class I, Zone 0 location, from
which explosive gas atmospheres could be communicated.
Greater than 10hrs/year and less than 1000hrs/year (0.1% – 10% of the time)
Table 3 RP 505
Class I Zone 2
c) Zone 2, comprising Class I locations in which:
i. Explosive gas atmospheres are not likely to occur in

normal operation and, if they do occur, they will exist for
www.EngWorks.ca
a short time only; or
www.EngWorks.ca
ii. Flammable volatile liquids, flammable gases, or vapours
are handled, processed, or used, but in which liquids,
gases, or vapours are normally confined within closed
Delete from 2006 containers or closed systems from which they can escape
CEC Definition
only as a result of accidental rupture or breakdown of the
containers or systems or the abnormal operation of the
equipment by which the liquids or gases are handled,
processed, or used; or

Class I Zone 2
(CEC Definition)
c) Zone 2, comprising Class I locations in which:
Delete from 2006

iii. Explosive gas atmospheres are normally prevented by
adequate ventilation but may occur as a result of failure or
www.EngWorks.ca
CEC Definition
abnormalwww.EngWorks.ca
operation of the ventilation system; or
iv. The location is adjacent to a Class I, Zone 1 location from

which explosive gas atmospheres could be communicated,
unless such communication is prevented by adequate
positive-pressure ventilation from a source of clean air,
and effectively safeguards against ventilation failure are
provided
Less than 10hrs/year (<0.1% of the time)

Table 3 RP 505
Unclassified
Areas that are not classified Zone 0, 1 or 2
www.EngWorks.ca
www.EngWorks.ca
(Less than 1 hour per year (0.01% of the time)

Area Classification Shading
Conventions for Drawings
www.EngWorks.ca
www.EngWorks.ca

Division Classification System
Division 1
www.EngWorks.ca
www.EngWorks.ca
Risk
Division 2
Not Classified
1 hr/Year 10 Hr/Year 1000 Hr/Year
Duration of Time Gas Is

Present
Zone Classification System
Zone 0
Zone 1
www.EngWorks.ca
www.EngWorks.ca
Risk
Zone 2
Not Classified
1 Hr/Year 10 Hr/Year 1000 Hr/Year
Duration of Time Gas Is

Present
Zone vrs Divisions
Source: “Adapting to the Dual Area Classification System” , Paul Babiarz, Danny Liggett, Craig
Wellman, 1996 PCIC Conference Paper
Comparison of Zones and Divisions

Classified Area Time that Hazardous Gases Estimated % of Division Estimate % of Zone Areas
are Present in Ignitable Areas in North America in Europe
www.EngWorks.ca
Concentrations
www.EngWorks.ca
Zone 0 Continuously < 2%
Division 1 Normally Present < 5%

Occasionally in Normal
Zone 1 Operations > 60%
Zone 2 Division 2 Not Normally Present > 95% < 40%

“Normal” Operation
(ISA RP 12.24.01)
Normal operations is considered the situation when

facility equipment is operating within its design
parameters. Minor releases of flammable material
may be part of normal operations. Minor releases
www.EngWorks.ca
www.EngWorks.ca
include the releases from mechanical packings on
pumps.
Failures that involve repair or shutdown (such as the

breakdown of pump seats and flange gaskets, and
spillage caused by accidents) are not considered
normal operation.

“Abnormal” Operation
(API RP 505)
www.EngWorks.ca
www.EngWorks.ca

Abnormal Operations
Start-up and Shutdown
Plant maintenance activities
www.EngWorks.ca
www.EngWorks.ca
Reasonable to ignore if the activity is
expected to exist less than 1% of the
time (100hrs per year) and no
continuous or primary grade releases
expected

Group
Describes the Characteristics of the Hazardous Substance in terms of:
MESG – Maximum Experimental Safe Gap

The maximum gap between two parallel metal surfaces under specified test
www.EngWorks.ca

conditions that will prevent an explosion from propagating to an adjacent test
chamber www.EngWorks.ca
MIE – Minimum Ignition Current
The minimum energy required from a capacitive spark discharge to ignite the
gas or vapor
MIC – Minimum Ignition Current Ratio

The ratio of minimum inductive current required to ignite a gas or vapor as
compared to the minimum inductive current required to ignite methane

MESG Explained
Hot Gases are forced through

threaded connections and
fittings
www.EngWorks.ca
www.EngWorks.ca
Explosion
Sealing Compound
Gases must be cooled sufficiently to
prevent external atmosphere from being
ignited
MESG Test Apparatus
Westerburg Explosion Test Vessel
www.EngWorks.ca
www.EngWorks.ca

Group – Characteristics of the
Hazardous Substance
Group I Intended for describing atmospheres that contain
“firedamp” (Comprised mostly of methane)
Group IIA
www.EngWorks.ca
Flammable material having a MESG greater than
www.EngWorks.ca
0.90mm or a minimum MIC greater than 0.80
Group IIB Flammable material having a MESG greater than

0.50mm and less than 0.90mm or a minimum MIC
greater than 0.45 and less than 0.80
Group IIC Flammable material having a MESG greater than

0.50mm or a minimum MIC greater than 0.45

Comparison between Division and Zone
Methods for Group Classification
Division System Zone System

Group MESG MIC Group MESG MIC
www.EngWorks.ca
(mm)www.EngWorks.ca
Ratio (mm) Ratio
A Acetylene
IIC ≤0.50 ≤0.45
B ≤0.45 ≤0.40
>0.45 >0.40 >0.50 >0.45
C IIB
≤0.75 ≤0.80 ≤0.90 ≤0.80
D >0.75 >0.80 IIA >0.90 >0.80
Examples
Group Material MESG MIE MIC
(mm) (mJ) Ratio
Methane 1.12 0.28 1.0
Propane 0.97 0.28 0.97
www.EngWorks.ca
IIA www.EngWorks.ca
Butane 1.07 0.25 0.94
Heptane 0.91 0.24 0.88
Pentane 0.93 0.28 0.97
H2S 0.89 0.068 0.51
IIB
Ethylene 0.65 0.070 0.53
Hydrogen 0.28 0.019 0.25
IIC
Acetylene 0.25 0.017 0.25
MIE in Practical Terms
CH4/Air
H2/Air
10
Typical range of
spark discharge
energy from a
human body
www.EngWorks.ca
www.EngWorks.ca
Ignition Energy (mJ)
1.0
Stoichiometric
CH4/Air Mixture
0.1 0.274 mJ
Stoichiometric
Air/H2 Mixture
0.017 mJ
0
20 40 60 80
Edmonton Oct 11, 2006 Fuel (% Volume)
Temperature Code
Used to indicate the maximum temperature
allowed within a classified location to prevent
the auto-ignition of hazardous materials
www.EngWorks.ca
www.EngWorks.ca
Auto-ignition temperature (AIT) is the
temperature in which a material self-ignites
without any outside source of ignition

Temperature Codes
(NEC and CEC)
T1 - 450ºC T3A - 180ºC

T2 - 300ºC T3B - 165ºC
www.EngWorks.ca
T2A - 280ºC www.EngWorks.ca
T3C - 160ºC
T2B - 260ºC T4 - 135ºC
T2C - 230ºC T4A - 120ºC
T2D - 215ºC T5 - 100ºC
T3 - 200ºC T6 - 85ºC
Auto-Ignition Temperature
“The lowest temperature of a heat surface at which,
under specified conditions, the ignition of a
flammable substance in the form of a gas or vapor
mixture with air will occur”
www.EngWorks.ca
www.EngWorks.ca
API RP 505, IEC 79-10 - Mod
“The minimum temperature required to initiate or cause

self-sustained combustion of a solid, liquid or gas
independently of a heated or heating element.”
NFPA 497

ASTM 659 Test Method for AIT
www.EngWorks.ca
www.EngWorks.ca

Variables that affect AIT
Molecular structure of the hydrocarbon
mixture
% composition of the vapor in air mixture

www.EngWorks.ca
Hot surfacewww.EngWorks.ca
material
Type and reactivity of other materials present
Rate and duration of heating
Environmental Conditions
Initial temperature
Atmospheric pressure

Autoignition Temperature
www.EngWorks.ca
www.EngWorks.ca

AIT of Selected Materials
Material Auto-Ignition Temperature (ºC)
NFPA 325 NFPA 497 IEC79-20 CEC
Hydrogen 500 520 560 429
www.EngWorks.ca
Methane 537 630 537 537
Propane
www.EngWorks.ca
450 450 470 432
Butane 287 288 372 287
Ethane 452 472 515 472
H2S 260 260 270 260
Pentane 260 243 258 260
Crude Oil - - 560 -
Naphtha 232 288 290 288
Gasoline 280 280 - 280

Auto-Ignition Temperature
“Experimental studies, testing and practical experience
has shown that surface temperatures must often be
several hundreds of degrees higher than the
published minimum AIT to induce ignition”
www.EngWorks.ca
www.EngWorks.ca
“In general, ignition of hydrocarbons by hot surface
should not be assumed unless the surface
temperature is 360ºF (182ºC) above the accepted
AIT of the hydrocarbon involved”
API RP 2216 - Ignition Risks of Hot Surfaces

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Hazardous Materials

Edmonton Oct 11,
Hazardous Materials
NFPA Classification of Hazardous Materials
Flammable Gases
Flammable Liquids
www.EngWorks.ca

www.EngWorks.ca
Class IA, IB, IC
Combustible Liquids
Class II, Class III
Does not cover
Flammable Mists
Compressed Liquefied Gases
Cryogenic Flammable Liquids

Highly Volatile Liquids
Compressed Liquefied gases
Kept in a liquid state by pressure
When released behave like heavier than air gases
www.EngWorks.ca

www.EngWorks.ca
Example: Propane Storage Tanks
Cryogenic Flammable Liquids
Kept in a liquids state by temperature
Behave like flammable liquids when released
Example: LPG Terminals

Flammable Gases
Lighter than air (Vapor density < 1.0)
Seldom accumulate to form a hazardous mixture
except in enclosed area

www.EngWorks.ca
www.EngWorks.ca
Heavier than air (Vapor density > 1.0)
Fall to grade when released and can form an
ignitable mixture for extended periods of time
Gases with a vapor density between 0.8 and 1.2 may

exhibit characteristics of both

Flammable Vapors
Very similar to flammable gases except
that they are in the vapor phase.
www.EngWorks.ca
Exist at temperatures below their
www.EngWorks.ca
boiling point
Significant variance in persistence time

Flashpoint vrs Boiling Point
Flash Point
Lowest temperature at which a flammable liquid
gives off enough vapor to form an ignitable

www.EngWorks.ca
mixture with air near the surface of the liquid
www.EngWorks.ca
Not precise physical quantities – particularly in the
case of mixtures
Boiling Point
Temperature at which the vapor pressure of the
liquid equals the surrounding atmospheric
pressure
Flashpoint Illustrated
Ignition can only occur when the material
is in the vapour state.
Liquids cannot burn
www.EngWorks.ca
www.EngWorks.ca
Transition area from liquid to vapour
Open Container

NFPA Definition
Class I Flammable Liquid
Any liquids with a flash point < 37.8°C
(100°F)
www.EngWorks.ca
When released at ambient temperature,
www.EngWorks.ca
will readily evaporate and form a gas-
vapor mixture
Tend to disperse rapidly to below their
LEL
Behave like heavier than air gases
Flammable Liquids
Classification
Class Flash point Boiling point Examples
IA Below Below Ethyl Ether

22.8°C 37.8°C
www.EngWorks.cawww.EngWorks.ca
(73°F) (100°F)
Pentane
IB Below Greater than Acetone

22.8°C 37.8°C Gasoline
(73°F) (100°F)
IC At or above Below Naphtha
22.8°C 37.8°C Xylene
(73°F) (100°F)
Combustible Liquids
Classification
Class Flash point Examples
II above 37.8°C Fuel Oil

(100°F) and below Kerosene
www.EngWorks.ca
www.EngWorks.ca
60°C (140°F)
IIIA above 60°C (140°F) Cresol
but below 93°C Ethylene
(200°F) Glycol
IIIB above 93°C (200°F) Asphalt
Transformer
Calgary Oct 10, 2006 Oil
Flammable / Explosive Limits
Range of composition of material in air
which will burn
www.EngWorks.ca
www.EngWorks.ca
UFL – Upper Flammable Limit
LFL – Lower Flammable Limit
UEL – Upper Explosive Limit
LEL – Lower Explosive Limit

Graphical Explanation of LEL and UEL
www.EngWorks.ca
Too Lean Explosive Range
www.EngWorks.ca Too Rich
0 LEL UEL 100%

Saturation
0% LEL 100% LEL

LEL and UEL Limits for Selected
Gases and Liquids
Flammable Substance LEL% UEL%
Methane 5.3 15
www.EngWorks.ca
Ethane www.EngWorks.ca 3 12.5
Propane 2.3 9.5
Hydrogen 4.0 75
H2S 4.0 46
Gasoline 1.3 6.9
Crude Oil 1 7
Flammability Relationships
IT
UPPER LIM
CONCENTRATION OF FUEL
AUTO
E
www.EngWorks.caUR
IGNITION
SS
www.EngWorks.ca
FLAMMABLE REGION
RE FLAMMABLE REGION
MIST
RP
PO
VA
LOWER LIM
IT
TEMPERATURE AIT
FLASH POINT AIT

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Properties of Hazardous Mixtures

Edmonton Oct 11,
Properties of Hazardous
Mixtures
Estimating the density of a mixture
Comparison to the density of air
MESG

www.EngWorks.ca
www.EngWorks.ca
Lead to Group Classification
LFL and UFL
AIT
Difficult to estimate – Must be determined
experimentally
Heavier than Air or
Lighter than Air?
Air has a molar weight of 28.96g/m at
0°C and Sea Level
www.EngWorks.ca
Calculate the molar weight of the
www.EngWorks.ca
mixture and divide by the molar weight
of air

Density Example
Material % by Molar %X
Volume Weight Mole Wt.
Methane 50% 16.04 8.02
www.EngWorks.ca
Ethane www.EngWorks.ca
10% 30.07 3.0
H2S 15% 34.08 5.11
Nitrogen 15% 28.02 4.2
Heptane 5% 100.2 5.0
Octane 5% 114.22 5.71
Total 100% 31.04
Density Example
Molar Weight of Material 31.04
= = 1.07
Molar Weight of Air 28.96
www.EngWorks.ca
www.EngWorks.ca
Material mixture is heavier than air
“For practical applications, a gas that has a relative

density below 0.8 is regarded as being lighter than air.
If the relative density is above 1.2, it is regarded as
being heavier than air. Between these values, both of
these possibilities should be considered”
RP-505
Calgary Oct 10, 20066.4.2.4
Buoyancy Considerations
Majority of releases are from
pressurized sources
www.EngWorks.ca
Shape of www.EngWorks.ca
a hazardous region is not
related to density but to angle of
release and how close the release point
is to the ground.

Calculating the MESG of
Mixtures
Application of Le Chatelier’s Principle
www.EngWorks.ca
www.EngWorks.ca
Where Xi denotes the % volume of the species i and

MESGi is the MESG of the species

Calculating the MESG of
Mixtures
Material % by Volume MESG (mm)
Ethylene 45 0.65
Propane 12 0.97
Nitrogen
Methane www.EngWorks.ca 20
www.EngWorks.ca
3
∞
1.12
Isopropyl Ether 17.5 0.94
Diethyl Ether 2.5 0.83
The relationship then becomes:

1
MESGmix = = 0.9442mm
0.45 + 0.12 + 0.20 + 0.03 + 0.175 + 0.025
0.65 0.97 ∞ 1.12 0.94 0.83
Determining the Group Classification
Division System Zone System

Group MESG MIC Group MESG MIC
www.EngWorks.ca
(mm) Ratio (mm) Ratio
A www.EngWorks.ca
Acetylene
IIC ≤0.50 ≤0.45
B ≤0.45 ≤0.40
>0.45 >0.40 >0.50 >0.45
C IIB
≤0.75 ≤0.80 ≤0.90 ≤0.80
D >0.75 >0.80 IIA >0.90 >0.80
Mixture has MESG of 0.9442 and is therefore Group IIA

Comparison between Le Chateliers
Approximation and Actual Tests
Source – NEC Group Classification of Mixtures, Edward M Briesch, UL Laboratories 1999
www.EngWorks.ca
www.EngWorks.ca

Approximating UFL and LFL of
a Mixture
Le Chatelier’s Principle applies again
Must use only the flammable limit
www.EngWorks.ca
components
www.EngWorks.ca

Approximating UFL and LFL
Applies only to mixtures with air
LFL is not influenced by pressure
www.EngWorks.ca
UFL www.EngWorks.ca
is influenced by pressure

UFL and LFL Mixture Example
Material % by Vol. % Vol % LFL % UFL
Combustible
Ethylene 48 60 2.3 36
Propane
Nitrogen
www.EngWorks.ca 12 15
www.EngWorks.ca
20 -
1.7
-
10.9
-
Methane 4 5 4.4 17
Isopropyl 16 20 0.4 7.9
Ether

UFL and LFL Mixture Example
1
UFLmix =
0.60 + 0.15 + 0.05 + 0.2
www.EngWorks.ca
36 10.9 17 7.9
www.EngWorks.ca
UFL = 17%mix
1
LFLmix =
0.60 + 0.15 + 0.05 + 0.2
2.3 1.7 4.4 0.4
LFLmix = 1.16%

Estimating the flammability of
a process stream
Rule of Thumb
If the total % combustibles in a mixture
www.EngWorks.ca
exceed the %LFL for the mixture, the
www.EngWorks.ca
mixture can be considered flammable

Mixture Flammable Test Example
Material % by Vol. Mole % LFL % UFL

Fraction
Ethylene 0.5 0.15 2.3 36
Hexane www.EngWorks.ca
www.EngWorks.ca
0.8 0.24 1.1 7.5
Methane 2 0.61 4.4 17
Total Combustibles 3.3
Air 97.7 2.37%
Total 100
Total Combustibles > %LFL - Mixture is Flammable

Estimating the AIT of a
Mixture
Material % Composition Published AIT
IsoButane 1% 460ºC (860ºF)

nButane 1% 287ºC (550ºF)
www.EngWorks.ca
www.EngWorks.ca
IsoPentane 53% 420ºC (788ºF)
nPentane 4% 260ºC (500ºF)
IsoHexane 23% 264ºC (507ºF)
nHexane 1% 225ºC (437ºF)
Cyclohexane 5% 245ºC (473ºF)
DiMethylButanes 11% 405ºC (761ºF)
Gasoline Tipate 280ºC (536ºF)
(88 Octane)
Estimating the AIT of a
Mixture
The only certain method of ascertaining
the AIT of a mixture is by lab testing
www.EngWorks.ca
www.EngWorks.ca
My personal ROT
Use the lowest AIT whose composition
exceeds 5% of the mixture

AIT Mixture Example
Material % by Vol. AIT ºC
Ethylene 45 450
Propane www.EngWorks.ca
12
www.EngWorks.ca 450
Nitrogen 20 -
Methane 3 537
Isopropyl Ether 17.5 443 AIT
Diethyl Ether 2.5 180

Exercise #1
Define the Material Properties
Calculate the density relative to air
Calculate the LFL
www.EngWorks.ca
Calculate www.EngWorks.ca
the MESG
Estimate the AIT

Mixture Rules of Thumb
For H2S, Group IIB classification requires
>25% H2S by composition (RP 505)

www.EngWorks.ca
www.EngWorks.ca
For Hydrogen, Group IIC requires >30%
Hydrogen by composition (IP15)

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Ventilation

Edmonton Oct 11,
Ventilation (RP-505)
Adequate Ventilation (RP-505)
Ventilation (natural or artificial) that is sufficient to prevent the
accumulation of significant quantities of vapor-air or gas-air
mixtures in concentrations above 25% of their lower flammable
www.EngWorks.ca
(explosive) limit.
www.EngWorks.ca
Inadequate Ventilation (RP-505)
Ventilation that is less than adequate
Enclosed areas are considered adequately ventilated if:

“1.0 cubic foot of air volume flow per minute per square foot of
floor area but at least 6 ACPH on a continuous basis”

Ventilation (IEC 79-10 Mod)
“the likelyhood of an explosive gas atmosphere,
and hence the zone designation depends
mainly on the grade of release and the
www.EngWorks.ca
ventilation”www.EngWorks.ca
High, Medium, Low
Availability of Ventilation
Good, Fair Poor

Grade of Release
Continuous
A release that is continuous and is expected to
occur for long periods.

www.EngWorks.ca
Primary www.EngWorks.ca
A release that can be expected to occur
periodically or occasionally during normal
operation
Secondary
A release that is not expected to occur in normal
operation and if it does occur, is likely to do so
infrequently and for short periods

Influence of Ventilation on
Type of Zone
Degree
High Medium Low
Grade of
Release www.EngWorks.ca
Availability
www.EngWorks.ca
Good Fair Poor Good Fair Poor Good,
Fair or
Poor
Non Zone Zone 1 Zone 0 Zone 0 Zone 0 + Zone 0
Continuous
Haz. 2 +Zone 2 Zone 1
Non Zone Zone 2 Zone 1 Zone 1 + Zone 1 or Zone 1 or
Primary
Haz. 2 Zone 2 Zone 0 Zone 0
Non Non Zone 2 Zone 2 Zone 2 Zone 2 Zone 1 or
Secondary Haz. Haz. Zone 0
High Ventilation
Can reduce the concentration at the source of
www.EngWorks.ca
release, virtually instantaneously, resulting in
www.EngWorks.ca
a concentration below the LEL
Examples:
Dilution ventilation on acoustic hoods on
gas turbines
May be up to 60 ACPH

Medium Ventilation
Can control the concentration, resulting
in a stablewww.EngWorks.ca
situation in which the
www.EngWorks.ca
concentration beyond the zone is below
the LEL
Examples:
Building evacuation fans exchanging air at
6 ACPH

Why 6 ACPH?
www.EngWorks.ca
www.EngWorks.ca
Combustible Build-up Curve, General Ventilation: Continuous Release

Source NFPA 69
Why 6 ACPH?
www.EngWorks.ca
www.EngWorks.ca
Combustible Decay Curve, General Ventilation: Instantaneous Release

Source NFPA 69
Low Ventilation
Cannot control the release while the
www.EngWorks.ca
release iswww.EngWorks.ca
in progress and cannot
prevent undue persistence of a
flammable atmosphere after the release
has stopped
Anything less than 6 ACPH

Availability of Ventilation
Good
Ventilation is available continuously
Fair
www.EngWorks.ca
Ventilation iswww.EngWorks.ca
expected to be present during normal
operation. Discontinuities are permitted provided
they occur infrequently and for short periods.
Poor
Ventilation that does not meet the standard of fair or
good, but discontinuities are not expected to occur
for long periods

Influence of Ventilation on
Type of Zone
Degree
High Medium Low
www.EngWorks.ca
Grade of
Release www.EngWorks.ca
Availability
Fair or
Poor
Continuous
Haz. 2 +Zone 2 Zone 1
Primary
Haz. 2 Zone 2 Zone 0 Zone 0
Buoyancy Considerations
Majority of releases are from
pressurized sources
www.EngWorks.ca
Shape of www.EngWorks.ca
a hazardous region is not
related to density but to angle of
release and how close the release point
is to the ground.

CFD Analysis CH4 Release
Geometry of Release
UFL = 17%
www.EngWorks.ca
www.EngWorks.ca
CH4
LFL = 5.3%

Different Release Rates
2 kg/sec 8 kg/sec 32 kg/sec
www.EngWorks.ca
www.EngWorks.ca

Different Release Directions
www.EngWorks.ca
www.EngWorks.ca

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Application of the Principles

Edmonton Oct 11,
Four Approaches to Area
Classification
1. Classification by Direct Example
• NEC/CEC
• API RP 500/505
•
•www.EngWorks.ca
NFPA 497
IP15 www.EngWorks.ca
2. Source of Hazard Method (Point Source

Concept)
• Appendix D RP 505
• IEC 79-10 Mod
• IP 15

Four Approaches to Area
Classification
3. Hybrid Approach
• Use direct example where appropriate
• www.EngWorks.ca
Modify classifications
www.EngWorks.cabased on fugitive
emissions studies, use of gas detection, vapor
barriers ect.
4. Risk Based Approach
• IP 15
• Applicable to situations where the release rate
may be an unknown, unspecified and variable
quantity

Classification by Direct Example
Most commonly used method of area classification in
North America
Easiest to use
www.EngWorks.ca

www.EngWorks.ca
Requires a judgment be made on the basis of what
hazardous materials might be present and the
probability of the containment systems leaking
Extent of an area classification is made by

referencing the figures and diagrams published in
established codes and standards
Classification by Direct Example Work Process
Based on Appendix E API 505
Step 1 – Determine the need

www.EngWorks.ca
Step 2 – Assignment of the Classification
www.EngWorks.ca
Based on the probability of a hazardous material
being present in ignitable quantities
Are the hazardous materials heavier or lighter
than air

Classification by Example Work Process
Based on Appendix E API 505
Step 3 – Determine the extent of the hazardous area

based on the figures provided in CEC, RP505 and the
Code for Electrical Installations at Oil and Gas
Facilities

www.EngWorks.ca
www.EngWorks.ca
Step 4 – Assign the Group and the temperature code
based on the materials present
Reference NFPA 325
Step 5 Document the Hazardous Locations

Area Classification Drawing Plan View and cross sections
where applicable

Gas Station Example
www.EngWorks.ca
www.EngWorks.ca

Gas Station Pump
CEC 20-004
www.EngWorks.ca
www.EngWorks.ca

Gas Station Storage Tank
(CEC 20-004)
www.EngWorks.ca
www.EngWorks.ca

Gas Station Garage
(CEC 20-102 )
www.EngWorks.ca
www.EngWorks.ca

NFPA 325 Materials Data
www.EngWorks.ca
www.EngWorks.ca

Group and Temperature Classification
Refer to CEC Appendix B Temperature

and Gas Groups Table
www.EngWorks.ca
Gasoline www.EngWorks.ca
Group IIA
AIT of 280°C
T2A temperature code

Resulting Area Classification
www.EngWorks.ca
www.EngWorks.ca

Drilling Rig Example
www.EngWorks.ca
www.EngWorks.ca

Drilling Rig Classification
Challenges
Materials vary in composition
Crude Oil
Gas/Condensate

www.EngWorks.ca
www.EngWorks.ca
Large number of potential ignition sources
Combustion engines
Tools
Large variety of configurations

Enclosed, partially enclosed and open type derricks

Drilling Rig Classification
Challenges
Unconventional release sources
Dissolved gas in under balance drilling operations
Pressure kicks
www.EngWorks.ca

www.EngWorks.ca
Fugitive emissions from residual mud on drilling equipment
Stuffing box emissions
Vapours present in oily water drainage systems
High risk of personnel being within the classified area
Area classification is not typically reviewed by a

Professional Engineer

Code for Electrical Installation
at Oil and Gas Facilities
www.EngWorks.ca
www.EngWorks.ca

API RP 505 Drilling Rig
www.EngWorks.ca
www.EngWorks.ca

IP 15 Drilling Rig
www.EngWorks.ca
www.EngWorks.ca

Inherent Problems with the Classification by
Example Work Method
Subject to abuse and incorrect use
User does not have to fully understand the process; Only required
to apply the recommendations stated in the code or practice
Application figures are only a guideline and require the application
www.EngWorks.ca
of sound engineering judgment
www.EngWorks.ca
Does not dwell on the group or temperature classification
The user is required to reference recommended practices for
complete definition
Tend to over classify facilities
Leads to inconsistencies between users and applications

Diagrams are frequently misinterpreted

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Hybrid Method

Edmonton Oct 11,
Hybrid Method
Uses the guidelines provided by the
Classification by Direct Example publications
where appropriate
www.EngWorks.ca
www.EngWorks.ca
Incorporates concepts related to material

properties, ventilation, fugitive emissions and
other methods of determining hazard radii as
referenced by a variety of publications

Hybrid Method Work Process
1. Review of Government Regulations and
selection of Industry Codes and References
Assemblewww.EngWorks.ca
Project Data
2.
3.
www.EngWorks.ca
List all Hazardous Materials and Material
Properties
4. Identify all Material Release Sources
5. Assign an Area Classification
6. Document the Area Classification
Classification of an Upstream Facility
by Direct Example
www.EngWorks.ca
www.EngWorks.ca

Typical Process Building
RP 505
www.EngWorks.ca
www.EngWorks.ca

Tank Farm RP 505
www.EngWorks.ca
www.EngWorks.ca

Pig Launcher RP 505
www.EngWorks.ca
www.EngWorks.ca

Pump (RP 505)
www.EngWorks.ca
www.EngWorks.ca

Resulting Classification
www.EngWorks.ca
www.EngWorks.ca

Hybrid Approach
Data Requirements
Process Descriptions
www.EngWorks.ca
PFDs www.EngWorks.ca
P&IDs
Material Balance Sheets
Equipment List
Plot Plan
Overview of the Process
www.EngWorks.ca
www.EngWorks.ca

Flammable Materials Data Sheet
www.EngWorks.ca
www.EngWorks.ca

Mixture Analysis
www.EngWorks.ca
www.EngWorks.ca

Potential Sources of Release
Process Equipment
Rotating Equipment
Piping Connections
www.EngWorks.ca

Flanges www.EngWorks.ca
Pumps
Valves
Tank Fugitive Emissions
Sample Connections
Pig Launchers
Analyzer Emissions
www.EngWorks.ca
www.EngWorks.ca

Pig Launcher - Tank Farm
www.EngWorks.ca
www.EngWorks.ca

www.EngWorks.ca
www.EngWorks.ca

Dehy Building
Enclosed areas are considered adequately ventilated if:
“1.0 cubic foot of air volume flow per minute per
square foot of floor area but at least 6 ACPH on a
continuous basis” RP 505
www.EngWorks.ca
www.EngWorks.ca
Outside Dimensions
14’W X 24’L X 12’H
Volume 4032 ft3
Area 336 ft2
Air flow required for “Adequate Ventilation”

14’ X 24’ = 336 ft3/min
6 ACPH = 6 X 4032/60 = 403 ft3/min
403 ft3/min or 6 ACPH is required by API 505
Heating Requirements
To maintain the interior temperature at a
nominal 50ºF under ambient conditions of
-45ºF would require 15kW of supplemental heat
www.EngWorks.ca
www.EngWorks.ca
May be a problem with local freeze-up on

certain lines requiring the addition of heat
trace as a precautionary measure

API 505 Fugitive Emissions
Calculation
Adequate Ventilation (RP-505)
Ventilation (natural or artificial) that is sufficient to
prevent the accumulation of significant quantities of
vapor-air or gas-air mixtures in concentrations above
www.EngWorks.ca
25% of theirwww.EngWorks.ca
lower flammable (explosive) limit.
A fugitive emissions calculation estimates the amount

of hazardous material likely to be present in an
enclosed area under normal operating conditions
The results are used for to calculating the amount of

air movement required to achieve the definition of
“adequate” ventilation
www.EngWorks.ca
www.EngWorks.ca

API 4615 Background
Summarizes the results of several studies
conducted by API and published in 1993
185,000 components in 20 different facilities
www.EngWorks.ca
A total of 4796
leaking
components were found to be
www.EngWorks.ca
Intent was to support the EPA clean air act of

1990
Not originally intended for area classification
purposes

API 4638
Explains a variety of
methods for
performing fugitive
www.EngWorks.ca
www.EngWorks.ca
emission calculations
Provides background
definitions, step by
step procedures and
working examples

Aussie Equivalent
www.EngWorks.ca
www.EngWorks.ca
http://www.npi.gov.au/handbooks/approved_handbooks/foilgas.html
Component Definitions
(as per API 4615)
Connections Open ended devices
Threaded connections sample connections
Tubing fittings Drains
Valve connections Bleed valves
www.EngWorks.ca
Flanges
www.EngWorks.ca
Other
compressor seals
pressure relief valves
Pumps and pump Hatches
seals dump lever arms
polished rod stuffing
boxes
Valves Instruments
Excludes check valves sight glasses

Stream Types
Gas
Heavy Oil
www.EngWorks.ca
Light Oil www.EngWorks.ca
Water/Oil

EPA Average Emission Factors
(lb/Component/day)
Heavy Oil Light Oil Water/Oil
Gas (<20 API (≥20 API (Water Content
Gravity) Gravity) 50% - 99%)
www.EngWorks.ca
Valve 2.4E-01 4.4E-04 1.3E-01 5.2E-03
www.EngWorks.ca
Connector 1.1E-02 4.0E-04 1.1E-02 5.8E-03
Flange 2.1E-02 2.1E-05 5.8E-03 1.5E-04
Open-End 1.1E-01 7.4E-03 7.4E-02 1.3E-02
Other 4.7E-01 1.7E-03 4.0E-01 7.4E-01
Pump 1.3E-01 Not 6.9E-01 1.3E-03

Available
Fugitive Emission Factors
Abnormal Operation (Gas Service)
(lbs/component/day)
Component Normal Abnormal Emissions

Increase
Connections 1.1E-02 1.4 127 X
Flanges
www.EngWorks.ca
www.EngWorks.ca
2.1E-02 4.3 204 X
Pumps and pump seals 1.3E-01 3.9 30 X

Valves 2.4E-01 5.2 21 X
Open ended devices 1.1E-01 2.9 26 X
Other 4.7E-01 4.7 10 X

Variables effecting Emission
Rates
• Fluid phase • Batch/continuous
• Valve type/ process

packing/configuration • Equipment size
Pressure • Pump seal type
www.EngWorks.ca
•
www.EngWorks.ca
• Fluid
• Gasket type
• Temperature toxicity/corrosiveness
• Pump rpm
• Flange type
• Service life
• Flange bolting
procedures • Compressor seal type
• Unit type
• Inspection frequency

Methods for Estimating
Components
1. Physical Count
2. Estimate from P&IDs
3. API 4638 Approximation

www.EngWorks.ca
www.EngWorks.ca
Count the number of valves
Number of flanges = number of valves
Number of connectors = 3 X number of valves
Number of open ended devices = 10% of the
number of valves
Number of “other” components = 5% of the
number of valves
Fugitive Emissions Calculation
RP 505 Appendix B
Calculation determines what ventilation rate is
required to ensure that the fugitive emissions do not
exceed 25% of the LEL of the hazardous material
present.
www.EngWorks.ca
www.EngWorks.ca
Based on perfect mixing
Safety factor of 4 is applied
All calculations are done using imperial

measurements
Use care when converting to metric values

Fugitive Emissions – Dehy
Building
Component No. HC Emission Total
Type (lbs/Component/day) Emissions
(lbs/day)
www.EngWorks.ca
Valve
Connector
42
www.EngWorks.ca
126 1.1E-02 1.38
2.4E-01 10.08
Flange 42 2.1E-02 0.882

Open-End 6 1.1E-01 0.66
Other 3 4.7E-01 1.41
Pump 0 1.3E-01 0
Total 14.4
Fugitive Emissions Calculations
Cont’d
Convert lbs/day to lbs/hour
14.4 lbs/day / 24 = 0.6 lbs/hour
www.EngWorks.ca
www.EngWorks.ca
Calculate the mole weight of the
Hydrocarbon Emission
24.46 (from mixture analysis)

Calculate the cubic feet/pound-mole
weight of the Hydrocarbon mixture
Assumption: volume of one pound-mole of
ideal gas = 359 ft3 at standard temperature-
pressure (32ºF at 14.7 psia)

www.EngWorks.ca
www.EngWorks.ca
Ideal gas law (PV=nRT)
Charles’ Gas Law (V1T2 = V2T1)

Volume varies proportionately to the
temperature in degrees Rankin (Fº +

460)
Volume of ideal gas at 90ºF
At 90ºF and 14.7 psia, 359 ft3 would
occupy:
www.EngWorks.ca
www.EngWorks.ca
(359)(460 + 90)/(460 +32) = 401ft3

Calculate the Hydrocarbon Leak
Rate
(E)(V)
G=
60(mw)
www.EngWorks.ca
Where: www.EngWorks.ca
G = Leak rate,cfm
E = Emission rate, lbs/hour
V = Volume, ft3/lb-mole
mw = average mole weight
60 = 60 minutes per hour

Hydrocarbon Leak Rate
E = 0.6 lbs/hour
V = 401 ft3/lb-mole
mw = 24.46
www.EngWorks.ca
60 = 60 www.EngWorks.ca
minutes per hour
(0.6)(401)
G= = 0.1639 ft3/min
60(24.46)

Hydrocarbon Concentration
(as per NFPA 69)
C = (G/Q) (1-e-kn)
or
C = (G/Q)
www.EngWorks.ca
(1 – e-kn approaches www.EngWorks.ca
1 after steady state conditions)
Where:
C = Concentration of hydrocarbon in air, percent (in decimal
format)
G = Leak rate
Q = Fresh air introduction rate
N = number of air changes
K = quality factor
Required Fresh Air Introduction
Rate
100% LEL (from mixture analysis = 3.31%)
Required to maintain a 25% LEL
www.EngWorks.ca
www.EngWorks.ca
Required fresh air introduction rate
0.1639 ft3/min
Q= = 21.15 ft3/min
(0.25 X 0.031)

Application of Safety Factor
Safety factor of 4 is applied (as per RP 505
6.6.2.4.8)
www.EngWorks.ca
www.EngWorks.ca
Required ventilation rate = 4 X 21.15 ft3/min
= 84.61 ft3/min
Volume of Dehy building =4032 ft3
Equivalent to 84.61 ft3/min X 60 min/hr /

4032ft3 = 1.25 ACPH
Application of the Results
The Dehy building ventilated at 1.25 ACPH is
considered adequately ventilated
Typical value for an upstream process building is between
www.EngWorks.ca
0.5 and 2 ACPH

www.EngWorks.ca
Industry recommended bathroom fan sizing criteria – 8
ACPH
For ventilated areas < 3 ACPH, RP 505 recommends

continuous monitoring by fixed gas detectors to
assure the LEL remains at the 25% level or below
Generally tied in with ventilation fans sized at 12 ACPH

Design of the HVAC System
Degree
High Medium Low
Grade of
Release
www.EngWorks.ca
www.EngWorks.ca
Availability
Fair or
Poor
Continuous Haz. 2 +Zone 2 Zone 1
Primary Haz. 2 Zone 2 Zone 0 Zone 0
Design of the HVAC System
Must provide a good quality of ventilation
good mixing
no stagnant areas

www.EngWorks.ca
Must be reliable and provide good availability
www.EngWorks.ca
99% availability target
Designed to extract fugitive emissions
Heavier than air releases
Lighter than air releases
Must be capable of stabilizing an abnormal release
Consistent with the IEC definition of a Medium degree of
ventilation

Ventilation Strategies
Natural Ventilation
Artificial Ventilation
www.EngWorks.ca
www.EngWorks.ca
Recirculation Ventilation

Natural Ventilation
www.EngWorks.ca
www.EngWorks.ca
Wind Driven Flow Stack Driven Flow

Mechanical Extract Ventilation
Gravity
Louvers
www.EngWorks.ca
www.EngWorks.ca Air Movement
XP Fan
Air Movement
Gravity XP Fan
Louvers
Crossflow Ventilation Crossflow Ventilation

Lighter than Air Density Materials Heavier than Air Density Materials

Mechanical Supply Ventilation
www.EngWorks.ca
www.EngWorks.ca

Turbine Ventilator
www.EngWorks.ca
www.EngWorks.ca
Dehy Building requires 85 CFM

Dehy Building
HVAC Design Option #1
Turbine Ventilator
Wind (>2mph)
www.EngWorks.ca
www.EngWorks.ca GD GD
I
Gravity
Louvers
Air Movement XP Fan
12 ACPH
Stack
Effect
Fixed Fixed
Louvers Louvers

Fan Affinity Law – Fan output CFM is
directly proportional to fan speed
www.EngWorks.ca
Required HP vary with the fan speed
www.EngWorks.ca
cubed

Dehy Building
HVAC Design #2
Fan Affinity Law – Fan output CFM is directly proportional to fan speed
www.EngWorks.ca
www.EngWorks.ca GD GD I VFD
Gravity
Louvers
XP Fan
Fan sized for 12 ACPH
Air Movement 2 ACPH Normal Conditions
12 ACPH on Gas Detection
Fixed Fixed
Louvers Louvers

Plan Layout
Insure no Stagnant Air Pockets
Fixed
Louver
www.EngWorks.ca
1 ACPH
U/
www.EngWorks.ca
H
H
U/
Recirculated Air
Gravity
Louver Exhaust Fan
12 ACPH
Air Flow
H
U/
U/
H
Fixed
Louver
1 ACPH

Fan Recirculation Options
HM Control Soleniod
T Thermostat
Heat Medium Supply
www.EngWorks.ca
www.EngWorks.ca
Air Flow Fan Motor MS Motor Starter Switch
Heat Medium Return

Classification around Ventilation
Openings
www.EngWorks.ca
www.EngWorks.ca

Naturally Ventilated Enclosed
Areas
Method for naturally ventilating enclosed areas by
means of the stack effect is provided in RP-505
6.6.2.4.5with a working example in Appendix B

www.EngWorks.ca
www.EngWorks.ca
Provides 12 ACPH of ventilation (one complete air
change each five minutes)
Method for calculating adequate ventilation is only

applicable to building with volumes of 1000 ft3 or less

Natural Ventilation
RP 505 Appendix A
www.EngWorks.ca
www.EngWorks.ca

Stack Effect
Sizing Ventilation Louvres
V
A=
1200 h( Ti – To )/ Ti
www.EngWorks.ca
www.EngWorks.ca
Where:
A – Free Area of inlet (or outlet) opening(s) (includes a
50% effectiveness factor)
V – Volume of building to be ventilated, in cubic feet
h – height from the center of the louver opening to the Neutral
Pressure Level (in feet)
Ti – temperature of indoor air (degrees Rankin)
To – temperature of outdoor air (degrees Rankin)
Calculating the Height to the
Neutral Pressure Level
H
h=
1 + [(A1/A2)2(Ti/To)]
Where:
www.EngWorks.ca
www.EngWorks.ca
h – height from the center of the louver opening to the Neutral
Pressure Level (in feet)
A1 – free area of lower opening, in square feet
A2 – free area of upper opening in square feet
H – Vertical distance (center to center) between A1 and A2 in feet
Ti – temperature of indoor air (degrees Rankin)
To – temperature of outdoor air (degrees Rankin)
Note: If Ti < To the ration Ti/To should be inverted

Application to the Inlet Separator Building
Dimensions of Inlet Separator Building
12’L X 10’W X 8’H
Volume of Building - 960 ft3
www.EngWorks.ca
Ti - 110ºF or (110 + 460 = ) 570ºR
www.EngWorks.ca
To 95ºF or (95 + 460 = ) 555ºR
-
H – (distance between A1 and A2) – 7ft

Assume A1 = A2
7
h=
1 + [(570/555)]

h = 3.45 ft
Sizing Ventilation Louvers for the
Inlet Separator Bldg
V = 960 ft3
h = 3.45 ft
Ti = 110ºF or (110 + 460 = ) 570ºR
www.EngWorks.ca
To = 95ºF orwww.EngWorks.ca
(95 + 460 = ) 555ºR
960
A=
1200 3.45(570 – 555)/ 570
A = 2.65 ft2 for inlet and outlet

Sizing Louvers
Outlet Louver consists of a roof vent that
extends along length of building
www.EngWorks.ca
Size of ventwww.EngWorks.ca
opening is 10ft X 0.5ft
Total area = 5ft2
Inlet Louvers
4 – 10” X 10” louvers for an effective area of
2.75ft2
Ventilation Considerations
Beware of Operator intervention
Document the air change requirements
onwww.EngWorks.ca
the area classification drawings
www.EngWorks.ca
Be careful with the conversions

www.EngWorks.ca
www.EngWorks.ca

Analyzer/Custody Transfer
Building
Building is inadequately ventilated
Sources of release include emissions from the
analyzer and the custody transfer meter run

www.EngWorks.ca
Analyzer is certified
locations
for use in Class 1 Zone 2
www.EngWorks.ca
Number of small sample lines that may be prone to

freeze-up
Use of gas detection may be an appropriate strategy for

classifying the building

Use of Combustible Gas Equipment as a
basis for Area Classification
(RP-505)
Gas detectors must be of stationary type
Adequate number must be installed

www.EngWorks.ca
www.EngWorks.ca
Gas detectors must be calibrated a minimum of every
three months or as specified by the equipment
manufacturer
The temperature code of electrically operated

equipment does not exceed 80% of the AIT for the
flammable materials present in the building

Combustible Gas Detection for Use in
Hazardous Locations
(CEC Appendix H)
Provides suggestions for use of combustible gas
detectors as supplementary protection for equipment
not approved for the Zone

www.EngWorks.ca
Effectively allows you to place non-hazardous
www.EngWorks.ca
equipment in Zone 2 locations and Zone 2 equipment
in Zone 1 locations
Does not change the area classification as per RP-
505
Recommends that all essential services such as lighting,
process instrumentation and gas detection be approved for
the Class Group and Zone of the area

Use of Combustible Gas Detection
Analyzer Approved for use in Zone 2 Locations
www.EngWorks.ca
www.EngWorks.ca
CEC Appendix H RP-505
Audible and visible alarm is actuated when LEL reaches 20%

Equipment is disconnected when LEL reaches 40%
Equipment is de-energized in the failure of gas detection equipment

Gas Detection Application
Considerations
Density of the gases being detected
Location of gas detectors
Redundant heads

www.EngWorks.ca
www.EngWorks.ca
Effects of ventilation flow
Adverse environments
Temperature
Airborne particles
Contaminants
Corrosive compounds
Vibration
Accessibility for calibration and maintenance
Gas Detection Technology
Catalytic Bead
Platinum coil embedded in a
catalyst
Flammable gas reacts with
www.EngWorks.ca
the catalyst creating heat
www.EngWorks.ca
which changes the resistance
in the platinum coil which is
monitored
Sensitive to contamination
and “poisoning”
Halogens
Sulphur compounds

Gas Detection Technology
Infrared
Measurement is based
on the absorption of IR
radiation as it passes
through a volume of
gas www.EngWorks.ca
www.EngWorks.ca
Immune to all chemical
poisons Open Path IR Gas Detector
Does not need oxygen or

air to detect gas
Lower maintenance than
catalytic bead
Will not detect hydrogen
Point Source IR Gas Detector

Maintenance of Gas Detection
Equipment
“Combustible gas detection instruments should never
be used as a substitute for safe electrical design”
Appendix H H.1.3 CEC
Consideration must be given to environmental

www.EngWorks.ca
conditions www.EngWorks.ca
Temperature
Airborne particles
Contaminants
Corrosive compounds
Gas detectors must be adjusted to detect all gases
that may be encountered
State what gases the gas detectors must be calibrated for
on the area class drawings

Gas Detector Calibration
Combustible Gas Correction factor for Correction factor for
Sensors Calibrated Sensors Calibrated on
on Propane Methane
Methane
Propane
www.EngWorks.ca
1.0
0.55
www.EngWorks.ca
1.82
1.0
Butane 1.0 1.82

Pentane 1.22 2.22
Hexane
Heptane
Gasoline 0.85 1.54

Gas Detector Location
Guidelines
Locate the detector near the hydrocarbon release
source
Locate the detector where gas emissions are likely to

www.EngWorks.ca
accumulate www.EngWorks.ca
Take into account the density of the gas
May need to place detectors in high and low locations
Outdoor applications require special consideration
Environmental contamination of detector heads
Topography and wind direction play a role
Open path IR detectors better suited to outdoor applications

Gas Detector Location
Guidelines
Intake or exhaust duct placement in
mechanical ventilation systems requires
special attention

www.EngWorks.ca
LEL alarmwww.EngWorks.ca
set point should be set as low as
reasonably practical
Locate gas heads with calibration
maintenance activities in mind
Incorporate redundancy into the design
Document the rational for placement of the
gas heads

Gas Detection Maintenance
CEC Appendix H5 recommends that the
installation be calibrated in accordance
www.EngWorks.ca
with the manufacturer’s
www.EngWorks.ca instructions
Paragraph 4.8.2(f) of RP 500 (1991
or
Editions)
Paragraph 6.8.2 (f) in RP 505
Gas detectors calibrated at least every
three months
www.EngWorks.ca
www.EngWorks.ca

www.EngWorks.ca
www.EngWorks.ca

Use of Vapour-tight Barriers
Effective way of locating non-hazardous
rated equipment adjacent hazardous
www.EngWorks.ca
areas www.EngWorks.ca
Benefits include
Reduced on-site wiring costs
Allows equipment to be pre-commissioned

Use of Vapour-tight Barrier
www.EngWorks.ca
www.EngWorks.ca

Definition of a
Vapour-tight Barrier
“a barrier that will not allow the passage

of www.EngWorks.ca
significant quantities of gas or vapor
www.EngWorks.ca
at atmospheric pressure”
RP 500/505

Compressor/Pump Building
www.EngWorks.ca
www.EngWorks.ca
Cable Transit Detail
Location of vapour-tight walls should be specified

on the area class drawings
Fired Heaters/Flare Stack
www.EngWorks.ca
www.EngWorks.ca

Fired Heater Considerations
Occupational Health and Safety Code Part 10
www.EngWorks.ca
www.EngWorks.ca

Flares
Typical Detail for a Flare
www.EngWorks.ca (Historical)
www.EngWorks.ca

Flares
www.EngWorks.ca
www.EngWorks.ca
Typical Detail for a Flarestack
(Makes more Sense)
600mm
15m

Other Potential Sources of Release
Generator Buildings
RP505
www.EngWorks.ca
www.EngWorks.ca

Batteries
Certain battery designs liberate hydrogen
during the recharge cycle
Lead Acid
www.EngWorks.ca

www.EngWorks.ca
Lead Calcium
Lead Antimony
Battery design that do not liberate hydrogen
Nickel cadmium
Nickel hydride

Batteries RP505
www.EngWorks.ca
www.EngWorks.ca
Valve-regulated lead acid (VRLA) batteries are also known as sealed lead acid
Batteries Continued
VRLA Batteries incorporate a catalyst to
recombine oxygen and hydrogen into
water

www.EngWorks.ca
www.EngWorks.ca
Overcharging can cause the battery to
liberate hydrogen through a safety vent
Typical UPS is designed to prevent
overcharging
Equalization charge cycle can cause a battery
to liberate hydrogen

CEC Appendix B
Notes on Rules
www.EngWorks.ca
www.EngWorks.ca

Battery Rooms
Locations surrounding VRLA batteries
are generally unclassified provided:

www.EngWorks.ca
Installedwww.EngWorks.ca
in open type racks
Ventilation is present > 1 ACPH
Battery rooms incorporating open type
lead calcium batteries required special
attention (Refer to RP505 Section 8.2.6)

Vendor Skid Packages
Responsibility for the Area Classification
of a skid package building often blurred
www.EngWorks.ca
Some contracts require the skid vendor
www.EngWorks.ca
to perform the area class study
Client defines the area classification and
then rely on the vendor to sign and stamp
the drawings
Most skid vendors subcontract the task
Vendor Skid Building
Area Classification Problems
Skid vendor does not have access to
the process parameters
Documentation by the skid vendor is

www.EngWorks.ca
www.EngWorks.ca
often lacking
Number of ACPH required
Gas detection operating parameters
Signing and stamping the drawings are
often an issue.
Options
Specify in detail what is required by the
vendor
Documentation requirements
www.EngWorks.ca

www.EngWorks.ca
Design details on drawings
Performance verifications
Have the Client’s Consultant perform the area
class study
Ventilation and gas detection requirements are
defined during the vendor drawing review stage
Single source of responsibility
Remote Locations
CEC 2006 Appendix B
Note on rule 18-006
www.EngWorks.ca
www.EngWorks.ca
Related to the Definition of a Zone 2 location (<10hrs per Year)

Additional Considerations
Open and Closed Drains
Natural Barriers and depressions
www.EngWorks.ca
“abnormal” www.EngWorks.ca
operation of equipment
Manned and Unmanned facilities
Locating electrical equipment outside of
classified areas when-ever possible

Posting of area classifications on building
entrances or plant areas
www.EngWorks.ca
Training ofwww.EngWorks.ca
plant and construction personnel
Area classification may change over the life of

the facility based on operating and
maintenance experience
Reviews should be carried out throughout the life
of the facility

Area classification may change over the life of
the facility based on operating and
www.EngWorks.ca
www.EngWorks.ca
Reviews should
of the facility
be carried out throughout the life
New or modified equipment

Changes in installation protection
Operations experience
Changes in operational procedures
Actual measurements
Area Classification Worksheet
www.EngWorks.ca
www.EngWorks.ca

www.EngWorks.ca
www.EngWorks.ca

Area Classification Study
Codes and Recommended Practices Used
Conditions where the study is valid
Hazardous Materials Worksheet
Source of Release Worksheet
www.EngWorks.ca

www.EngWorks.ca
List of assumptions
Fugitive Emission Calculations
Ventilation Calculations
List of recommendations
Installation and operations
Rational for gas detector placement
Area Classification Drawings
Plan view and cross sections
Professional Engineering Stamp

Drawing requirements
Area Classifications Information
Class
Zone

www.EngWorks.ca
Provide a legend consistent IEC recommendations
www.EngWorks.ca
Group Classification
May be more than one Group for a facility
AIT
Indicate a Maximum temperature and what material it is
based on rather than a Temperature Code
Cross section drawing details where
appropriate

Notes to the Drawings
Assumptions
Reference the Area Classification Study
Document www.EngWorks.ca

www.EngWorks.ca
Indicate ventilation requirements for each
building
Indicate gas detection and equipment
operating requirements
Indicate walls are required to be vapour-tite

Refinery Application
www.EngWorks.ca
www.EngWorks.ca

Refinery Plot Plan
www.EngWorks.ca
www.EngWorks.ca

RP 505 Figure 20
www.EngWorks.ca
www.EngWorks.ca

Area Classification Example 3 -
Upgrader
www.EngWorks.ca
www.EngWorks.ca

Area Classification Worksheet for a Refinery
www.EngWorks.ca
www.EngWorks.ca

Area Classification - Upgrader
www.EngWorks.ca
www.EngWorks.ca

Area Classification Section Details
www.EngWorks.ca
www.EngWorks.ca

Considerations for Refinery
Facilities
Natural barriers and the use of elevation as
means to define an area classification
Drains

www.EngWorks.ca
www.EngWorks.ca
Gas Detection
Process areas
Unclassified buildings
Locating electrical equipment outside of
classified areas when-ever possible

Considerations for Refinery
Facilities
Vehicles – Road and Rail Traffic
Fixed combustion engines
www.EngWorks.ca
Gas www.EngWorks.ca
turbine drives
Hot surfaces

Area Classification
www.EngWorks.ca
www.EngWorks.ca
Alternate Methods

Edmonton Oct 11,
NFPA 497
www.EngWorks.ca
www.EngWorks.ca

HTA Liquid at Grade
(NFPA 497)
www.EngWorks.ca
www.EngWorks.ca

HTA Liquid at Grade
(NFPA 497)
www.EngWorks.ca
www.EngWorks.ca

Adequately Ventilated Indoor
Location (NFPA 497)
www.EngWorks.ca
www.EngWorks.ca

API Alternative Method
Appendix D RP 505
Incorporates the results of extensive
dispersion modeling
Requires www.EngWorks.ca
additional engineering skill and

www.EngWorks.ca
equipment knowledge
Suitable for well-ventilated outdoor
locations
Loosely based on the methods
described in IP15 - 2002
RP-505 Appendix D
Point Source Concept
Involves determining the “hazard radius” of
all potential release sources
Volatility of release sources
www.EngWorks.ca

www.EngWorks.ca
Quantity of release materials
Nature of the release
Velocity of the materials being released
Release source boundaries are plotted on an
area diagram which is then simplified to form
the overall area classification
Example Pump Application
Pump #1 #2
Pump #2
(Pentane)
Product Butane Pentane
Motor
Seal Low Low
www.EngWorks.ca
Vertical
Emission Emission
Pump #1
(Butane) www.EngWorks.ca Type Seal Seal
P-suc 94 110
(psig)
Material Oper Vapor
Temp Pressure P-dis 130 950
(ºF) (psig)
(psia)
P-Pump 150 319
Seal
Butane 110 60
(psig)
Pentane 180 56
Flow 90 350
Edmonton Oct 11, 2006 Hazardous Area Classification rate gpm gpm 286
RP 505 Figure 20
www.EngWorks.ca
www.EngWorks.ca

15m
15m
Pump #2
www.EngWorks.ca
(Pentane)
15m 15m
www.EngWorks.ca Motor
15m
Vertical
Pump #1
(Butane)
15m
Transient Vapour Zone 15m

Classification Procedure
1. Determine the volatility classification based
on Figure D-1
2. Estimate the mass release rate

www.EngWorks.ca
www.EngWorks.ca
May be estimated using the guidelines provided:
Table D-1 for pumps, D-4 for flanges and valves
3. Determine the hazard radius
Figure D-3 for heavier than air
Figure D-4 for lighter than air

Vapor Pressure – Temperature
Volatility Chart
Category 1 – Materials

that almost immediately

flash to atmosphere
www.EngWorks.ca
www.EngWorks.ca
Category 2 – Class 1A
Flammable Liquids
Category 3 – Class 1B
Flammable Liquids
Category 4 – Class II
and heavier materials

1. Determine the Volatility
Classification
Butane
Category 1
Pentane Volatility
Category 2
Volatility
www.EngWorks.ca
www.EngWorks.ca

Edmonton Oct 11, 2006 Butane Operating TempHazardous
110ºF Pentane Operating Temp 180ºF
Area Classification 291
2. Estimate the mass release
rate
www.EngWorks.ca
www.EngWorks.ca

Guidelines for Predicting Release Rates
www.EngWorks.ca
www.EngWorks.ca
Butane Pump #1
Pentane Pump #2
Category 1 Volatility
Category 2 Volatility
Flow rate = 90 gpm
Flow rate = 350 gpm
Discharge Pressure
= 150 psig 293
Discharge Pressure = 319 psig
3. Determine the Hazard
Radius
www.EngWorks.ca
www.EngWorks.ca
Pentane Pump #2
Butane Pump #1

3.04m
www.EngWorks.ca
www.EngWorks.ca 3.04m
Pump #2
3.04m
(Pentane)
Motor
3.04m 3.04m
Vertical 1.52m
Pump #1
(Butane)
3.04m
Transient Vapour Zone

Problems with the Point Source
Concept
Requires the release rate from various
sources be determined
Maywww.EngWorks.ca
reduce the extent of the area
www.EngWorks.ca
classification but the extent may be
difficult to communicate

Application to a Refinery
www.EngWorks.ca
www.EngWorks.ca

Fuel Gas Manifold Building
As per RP 505
PSV
www.EngWorks.ca
Process
www.EngWorks.ca Vent
MV
Regulator
MV MV

Fuel Gas Manifold in Large
Building as per RP 505
www.EngWorks.ca
Process
Manifold occupies a very small
Area within the building
Does the whole building need to be classified?

Option 1 - Classify the
building as Non-hazardous
O&G Code 2002 Appendix B19 Note to rule 19-000

Piping systems with a pressure of 700 kPa or less
www.EngWorks.ca
(utility gas distribution, equipment fuel supplies, Process
ect.) are consideredwww.EngWorks.ca
“low risk” and do not generally Vent
require the area around them be classified.

Building is unclassified therefore,
common sense does not prevail
Disconnect mounted above

fuel gas manifold
Disconnect adjacent
Fuel gas regulator
www.EngWorks.ca
www.EngWorks.ca

CEC Standata
www.EngWorks.ca
www.EngWorks.ca

RP505 Annex F
Alternative Ventilation Criteria
Application of the Point Source method
described in IEC 60079-10
www.EngWorks.ca
Applicable for use in Indoor Applications
www.EngWorks.ca
Allows the hazardous classification of
portions of an interior based on the
grade of release and degree of
ventilation available

RP505 Annex F
Alternative Ventilation Criteria
Illustrates a calculation method that
allows the user to predict

www.EngWorks.ca
A hypothetical volume
www.EngWorks.ca
The dispersion time of a release
Estimate the level of air movement
required to limit the volume

Example Scenario
Fuel gas manifold for a gas fired steam generator
operating within a large building
Building 12H X 15W X 32LFlammable Methane
Dimensions
Volume
www.EngWorks.ca
5760m
www.EngWorks.ca
Molar Weight 16
3
Material
Air Flow 9 m3/sec %LEL 5%

ACPH 5.63 Release Flange
Source
Ambient 20ºC Release Grade Secondary
Temperature
Operating 350 kPA Safety Factor X2
Pressure
Estimation of
Hypothetical Volume Vz
www.EngWorks.ca
www.EngWorks.ca

Minimum Flow Rate Required
www.EngWorks.ca
www.EngWorks.ca

Maximum Rate of Release
(dG/dt)max = 0.006aP(M/t)0.5
(dG/dt)max = mass release in kg/sec

www.EngWorks.ca
www.EngWorks.ca
a = cross-sectional area of the leak in m2
P = upstream pressure in N/m2
M = molecular weight kg/kmole
t = absolute temperature of release ºK
(Multiply kPa X 1000 to get N/m2)

Rule of Thumb for Cross
Sectional Areas of Release
Use 0.25mm2 for flanges, screwed fittings,

regulator diaphrams and valve glands
www.EngWorks.ca
www.EngWorks.ca
Use 2.5mm2 for purge vents, drains, sample

points, relief valve vents, compressor shaft
seals and booster pumps
Source IGE/SR25

Release rate
(dG/dt)max = 0.006aP(M/t)0.5
www.EngWorks.ca
a = 2.5mm2 = 2.5 X 10-5 m2
www.EngWorks.ca
P = 350kPA = 350000 N/m2
M = 16 kg/kmole
t = 20ºC = 293ºK
(dG/dt)max = 1.23 X 10-4 kg/sec

Volumetric Flow Rate
www.EngWorks.ca
www.EngWorks.ca
1.23 X 10-4 kg/sec 293 = 0.0074 m3/sec
X
0.5 X 0.03328 293
LEL = 0.416 X 10-3 X 16 X 5 = 0.03328

Calgary Oct 10,m2006
Hypothetical Volume
www.EngWorks.ca
V =z
5 Xwww.EngWorks.ca
0.0074 m3/sec
= 23.12m 3
0.0016 sec-1
1/3
3Vz r
r= = 1.78m
4¶ V = 4/3¶r3
C = air changes/sec = ACPH/3600 = 5.63/3600 = 0.0016

Extent of Area Classification
Classified area within the building is limited to the extent

the hazard exists
www.EngWorks.ca
Process
Rest of building remains unclassified
1.78m

Time of Persistance
www.EngWorks.ca
www.EngWorks.ca

For a 100% LEL Release
www.EngWorks.ca
t=
www.EngWorks.ca
-5
0.0016
x Ln 5% x 0.5
100%
t = 11527 seconds = 3.2 hrs
Falls within the criteria of < than 10 hrs for a Zone 2 location
An interesting thought
What are the minimum number air changes it
takes to reduce a flammable release to below its %LEL
within the <10hr Zone 2 design criteria?
www.EngWorks.ca
www.EngWorks.ca-5 Ln LEL% x 0.5
C=
10hrs 100%
-5 x Ln 5.0% x 0.5 = 1.84 ACPH
Methane C =
10hrs 100%
Naphtha C=
-5 x Ln 0.9% x 0.5 = 2.7 ACPH
10hrs 100%
Introduction to the Risk Based
Approach to Area Classification
Method that defines the extent of an
area classification based on an
www.EngWorks.ca
predefined acceptable level
www.EngWorks.ca of risk
Introduced into IP15 in 2002
Similar to the approach used in other
fields for making business and technical
decisions

Risk Matrix
www.EngWorks.ca
www.EngWorks.ca

IP15 Risk Based Process
Applicable to situations where the
release rate is unknown, unspecified
www.EngWorks.ca
and of variable quantity
www.EngWorks.ca
Abnormal releases

IP15 Risk Based Process
Determine the level of Individual Risk (IR)
associated with facility
Use the results to determine the equivalent

www.EngWorks.ca
hole size for a given release
www.EngWorks.ca
Use the hole size to determine the release
rate based on the pressure and flammable
material composition
Calculate the hazard radii
Using charts provided in IP15
Calculated using a set of equations provided

Individual Risk (IR)
IR Ignited Release = Fflam x Pign x POcc x V x Nrange
F
flam = www.EngWorks.ca
Frequency of flammable Atmosphere
www.EngWorks.ca
P
ign = Probability of Ignition
P
Occ = Probability of Occupancy
V = Vulnerability
N Range = Number of release sources in range
Closing thoughts
Area Classification should be carried out before the
plot plan is finalized
Specify the Auto-ignition temperature on the
drawings rather than a T-Code

www.EngWorks.ca
Reduce the www.EngWorks.ca
confusion
Buy some ºC
Posting of area classifications on building entrances
or plant areas
Training of plant and construction personnel

Closing thoughts
Area classification may change over the
life of the facility based on operating
andwww.EngWorks.ca
www.EngWorks.ca
Reviews should be carried out
throughout the life of the facility

Careful about reclassifying Zone 2 to
Unclassified

Closing thoughts
Facilities such as storage pumps,
loading and discharge facilities –
www.EngWorks.ca
classification should be
www.EngWorks.ca based on
most volatile material anticipated
the
Not a good idea to denote small

pockets of non hazardous areas within
hazardous areas

Closing thoughts
Adopt physical plant features to denote
area classification boundary lines (roads
paved areas ect.)

www.EngWorks.ca
www.EngWorks.ca
Interface with other disciplines on
projects
May not be familiar with area classification
concepts
Insure vendors are made aware of area
classification requirements
Closing thoughts
Beware of Operator Intervention
www.EngWorks.ca
www.EngWorks.ca

Additional References
Practical Considerations of Area Classification: How
Far to Classify – John H. Rannells IEEE Industry
Applications Magazine May/June 1996

www.EngWorks.ca
www.EngWorks.ca
Industrial Facilities Gain New Area Classification
Guidelines – D.Bishop, D. Jagger, J. Propst, IEEE
Industry Applications Magazine Jan/Feb 2000
Volatility and Mists – Electrical Area Classification

Important Variables, J. Propst IEEE Paper PID 99-09

Additional References
Adapting to the Dual Hazardous Area Classification System, P.
Babiarz, D. Liggett, C. Wellman, IEEE Industry Applications
Magazine March/April 1998

www.EngWorks.ca
A Risk Based Approach to Hazardous Area Classification – KJ
www.EngWorks.ca
Glynn IEE Conference Publication No. 469, IEE 1999
Applying the API Alternate Method for Area Classification –

J.Propst, L. Barrios, B Lobitz, IEEE PCIC Conference
Proceedings Denver 2005
More references cited in Appendix D19 – Engineering Guidelines

Code for Electrical Installations at Oil and Gas Facilities

Questions?
www.EngWorks.ca
www.EngWorks.ca


Hazardous Area Classification Training Course CD Version PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Hazardous Area Classification Training Course CD Version PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Hazardous Area Classification

Calgary - October 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

3. Primary focus will be on North American

Calgary Oct 10, 2006

Sir Humphrey Davy

Calgary Oct 10, 2006

 1920 “Extra Hazardous Location” added to the NEC

Calgary Oct 10, 2006

Primarily used for establishing the type of electrical

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

All this may have an impact on the on-line performance

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Tons of Hydrocarbon Release

Heavy Crude 13756 99.54% 0.43% 0.00%

Gas Production 40178 96.23% 2.15% 1.61%

Gas Plant 57126 96.28% 1.73% 1.97%

Totals 205397 97.41% 1.39% 1.18%

Source Percent of Accidents

 Must be carried out before the choice of

Calgary Oct 10, 2006

Calgary Oct 10, 2006

“final determinations of the classifications

“should also include operations and

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

 Appendix J refers to locations where the

Calgary Oct 10, 2006

 Motor Fuel Dispensing Facilities

 Bulk Storage Plants

 Paint Application Facilities

Calgary Oct 10, 2006

Calgary Oct 10, 2006

 Not Mandated in all jurisdictions

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

 Complement IEC 60079-10 by providing

Calgary Oct 10, 2006

Calgary Oct 10, 2006

Calgary Oct 10, 2006

1920 “Extra Hazardous Location” added to the NEC

Must be carried out before the choice of

Appendix J refers to locations where the

Motor Fuel Dispensing Facilities

Bulk Storage Plants

Paint Application Facilities

Not Mandated in all jurisdictions

Complement IEC 60079-10 by providing

Referenced in RP 500, RP 505 and ISA 12.24.01 as

Minor discrepancies in data between

Refer to the Chemical Abstract Service Registry

MESG – Maximum Experimental Safe Gap

MIC – Minimum Ignition Current Ratio

Compressed Liquefied Gases

Cryogenic Flammable Liquids