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ICI INDIA LIMITED, PAINTS BUSINESS

THANE WORKS

FOURTH AREA CLASSIFICATION REVIEW


TPW.WOR.19.06R1

ISSUED BY

: Rinkesh Satija

APPROVED BY

: Praveen Asthana

DATE OF ISSUE

: 10 MARCH, 2009

I. FOURTH AREA CLASSIFICATION REVIEW


1. INTRODUCTION
The works employ electrical equipment and fittings in accordance with the Area
classification done in 1996 and reported in the LEPs.
2.

SCOPE OF REVIEW

The scope of the review covers the entire Thane Paints Works, the object being :
To review the Area classification carried out in 1996 and reported in the LEP and the
subsequent reviews carried out in 2001, 2003 and 2006.
3.

METHODOLOGY

The Source of Release method, which seeks to quantify the risks, has been adopted for
the review. The review is based on :
a) BS EN 60079-10:2003 - Electrical Apparatus for Explosive Gas Atmosphere - Part
10: Classification of Hazardous Area
b) EDP.CEE.00.05D - Procedure for Area Classification (Reference document)
c) EDG.CEE.00.19A - Guide for Area Classification and Related Hazard Aspects of
Laboratories (Reference document)
d) ATEX & CAD
e) NFPA 30- Flammable & Combustible Liquids Code, 2003 Edition
4.

REVIEW TEAM

In accordance with the Guidelines, the primary responsibility for the review is with the
Work Manager. Following members constitute the review team:
Rinkesh Satija
Madhab Chatterjee
Manoj Patil
Sanatan Hazra
Mohan Phadnis (Consultant)
5.

AREA CLASSIFICATION MEETING

The main decisions arrived at are recorded in the attached minutes of the Area
classification meeting.

II. AREA CLASSIFICATION: MINUTES OF MEETING


DATE

10 March, 2009

COMPOSITION

Rinkesh Satija
Madhab Chatterjee
Manoj Patil
Sanatan Hazra
M C Phadnis

1.0

GUIDELINES

1.1

It is agreed that documents titled below would form the basis of


the area classification.
a) BS EN 60079-10:2003 - Electrical Apparatus for Explosive Gas Atmosphere Part10: Classification of Hazardous Area
b) EDP.CEE.00.05D - Procedure for Area Classification: EDG.CEE.00.19A Guide for Area Classification and Related Hazard Aspects of Laboratories
c) ATEX & CAD
d) NFPA 30- Flammable & Combustible Liquids Code, 2003 Edition

1.2

It is further agreed that the Source of Release method, which seeks to quantify
the risks, has been adopted for the review.

2.0

Flammable Process Materials and Properties are detailed below:

S
No.
1
2

Raw Material

Code

Description

Flash Point

Benzyl Alcohol 001002


100 deg C
Mono- Ethylene 001081
110 deg C
Glycol
3
Texanol
001107 Ester alcohol, 2,2,4-trimethylpentanediol- 120 deg C
1, 3 Monoisobutyrate
4
Pine oil X
006271 Mixture of terpene hydrocarbons & 51.5 deg C
terpene alcohol
5
Ethyl Alcohol
Ethyl Alcohol
13 deg C
6
Solvent Ink
5157
Methyl Ethyl Ketone
- 9 deg C
7
H. S. Diesel
> 62 deg C
8
Molten glue
Kept in a closed container and Maintained
at 150 deg C
The list of flammable process materials and properties as above are agreed to. A sample
of Pine Oil was drawn from the lot available at the site and was sent for testing to a lab of
RAMK Group for testing of flash point and the test result was found to be 51.5 deg C.

3.0

Effect of Local Licensing Authority Rules

3.1
The requirements of the Indian Factories Act and the Indian Standards codes
would be adequately met if the Area Classification is done as per the International
standards and ICI Guidelines.
4.0
It is agreed that all plant buildings/sheds fall in the category of Well-ventilated
situations as defined in the code.
5.0
Maximum ambient temperature in Mumbai is expected as 42 deg C. Therefore,
chemicals having Flash point of more than 50 deg C are not considered as
flammable/hazardous materials. Assessment of Materials handled by TPW shows that the
lowest flash point chemical on site has a flash point of 50 deg C - De-foamer- Nopco
NDW. Thus all of TPW is classified as safe area.
However, solvent ink used for printing, has a flash point of 9 deg C. It was also
observed that the quantity handled at a time is not more than 2 lit. and vapours will
always be much lower than the LEL. Hence, it was concluded that there was no hazard
due to the material. As a precautionary measure, that the ink is be stored, near PPO,
separately in a cupboard, located away from any spark producing device, duly marked
and only required quantity will be taken to the equipment. Inventory of ink is maintained
as per the local statutes (average storage qty 28 litres).
Similarly, small quantity (max 2 litres) of solvent (Ethyl Alcohol) is used for testing in
the Q.A. laboratory and it is stored in a cupboard.
It was also concluded that there was no hazard during circumstances other than normal
operation.
6.0
1010 KVA DG set has been installed during the last year. The flash point of the
Diesel is > 62 deg C. Hence, it was concluded that taking precautionary measures for
handling and storing of the HS Diesel in compliance with Petroleum Act, 1934 are
adequate.
7.0
Serac filling machine has also been installed during the current year. It uses
molten glue at 150 deg C. But the quantity used is less than a litre stored in closed
enclosure without affecting the outside temperature. No flaqmmable material is present
within the periphery of 3 metres. Hence no hazard is envisaged from this operation.

AREA CLASSIFICATION
Area for keeping lab
solvent (less than 2
ltrs)

Utiliti
es

PMWH

RMWH

Mezzanine Floor
LA
B

FPWH
2
Imaje
Printer
Storage
Area

RMWH-II

PP
O

Filling
Floor
FPWH
1
- Non Hazardous
Area
- Hazardous
Area