AREA CLASSIFICATION AND STE EQUIPMENT ZONING

GENERAL DISCUSSION

• When we speak of zone 1 or zone 2 equipment we mean that the equipment is rated for
use in areas classified to either zone 1 or 2. So first thing we need is the definitions of
ZONE Areas:

ZONE 0 AREA : Area where explosive gas-air mixture is continuously present or

present for long times

ZONE 1 AREA : Area where an explosive gas-air mixture is likely to occur in normal
operations

ZONE 2 AREA : Area where and explosive gas-air mixture is not likely to occur, and if
it occurs, it will only exist for a short time

SAFE AREA : All other areas than those mentioned above

Above definitions from DNV Tech Notes for Fixed offshore Installations... but an old copy... I really
need to update my library.

In addition to the above classifications as ZONE, there also exist the definitions as Class 1 Division 1,
Class 1 Division 2 that are broadly similar to Zone 1 & Zone 2 respectively.

• Based on the above ZONE definitions we must then look to see how far the ZONE
Classification extends from the source.

The area extent depends upon whether you have a Primary or Secondary grade source hazard and
also whether the gas is heavier or lighter than air. Air is Molecular weight 28 and gases between
Molecular Weight 21 to 35 should be considered to fall in both categories. We would mostly fall into
the category where gases are lighter than air but if the gas gravity, as determined by Ranarex
measurement is greater than 0.75 we need to consider the heavier than air category as well. (Note
that H2S is heavier than air but is not a factor as Zone classification covers explosive mixtures).

"Primary Grade Source" - machinery or plant that can release a flammable substance into the
atmosphere during normal operation. Typical sources: open tanks, sample and draining outlets, pump
glands where leakage may be expected to occur...etc.

"Secondary grade Source" - machinery or plant that can release a flammable substance into the
atmosphere during abnormal situation or infrequent operations. Typical sources pump glands
designed and maintained to prevent leakage, sample or drain outlets operated infrequently, valves,
fittings, gauge glasses etc.

As you may have determined from the above the extent of the classification area can be somewhat
open to individual interpretation. I consider that our pumps are designed and maintained to prevent
leakage and that operation of drains and outlets is infrequent so our equipment is a "Secondary
Grade Source".

Since we do not typically have the Gas Gravity from the Ranarex until the test is ongoing there is a
consideration to classify the gas as both heavy & light which will affect where on the rig you can place
certain items. Erring on the side of caution is recommended but if we can get expected Gas Gravity
info up front then we can stay in "lighter than Air" category. Separation efficiency will also affect our
measured gas gravities... if there is liquid carryover due to poor mist extractor performance or
excessively wet gas then the gas gravity from the Ranarex will read high.

• FOR OUTDOOR AREAS, GASES LIGHTER THAN AIR, AND SECONDARY GRADE
SOURCE OF HAZARD:

Following 1965 edition of IP Electrical Code and area within a vertical cylinder with a radius 3 meter
measured from the source and a height 4.5 meter above and 4.5 meter below the source has to be
classified.

For a Secondary Grade Source this area will be classified as ZONE 2.

In case of a Primary Grade Source the above area will be classified as ZONE 1 and an area of 3
meters horizontal and vertical from the ZONE 1 area will be classified as ZONE 2.

• THAT'S THE END OF THE DEFINITIONS.

Now that we have the definitions we now talk about what equipment can go where with the prime
consideration being that equipment in the zone classified area should not produce a spark or
temperature surface high enough to cause ignition of the potentially flammable gas-air mixture. There
are different degrees of electrical and temperature protection required based upon whether you are to
be operating in a Zone 1 or Zone 2 area.

• HOW DOES OUR EQUIPMENT STACK UP?

Sometimes we talk about our separator being Zone 2. Perhaps a terminology error as the separator
would really be ZONE 0 rated, as it does not have electrical or temperature sources to produce
ignition. The separator does produce a ZONE 2 area due to infrequent releases from Sight Glasses,
Daniels Orifice box, Shrinkage Tester and Sampling ports.

Everything within 3 meters horizontal and 4.5 meters above & below must therefore be rated ZONE
2. This means pump drivers, lights - if we install them on the separator skid, the lab etc.

It also limits where you can place the equipment on the rig as some areas are classified to prohibit
the equipment. Example ... you couldn't place a separator, choke, or flange connection within 3
meters of a rig vent or air intake to pumps and compressors.

The above applies in general to our equipment.

• SPECIFIC CONCERNS:

LIGHTING / ELECTRICAL

Zone 1 & Zone 2 compliance specifications usually aren't that much different so not much of a
step to go to Zone 1 spec from Zone 2. Last Lab I built I asked for a Zone 2 spec on the outer
cabin and the Vendor went to Zone 1 because it was the same cost and fit easier into his product
line. Both Zone 1 & Zone 2 are protecting the same thing... one just deals with more frequent or
expected occurrences.

Lighting placed in our area should be rated Electrical Class for Zone 2.
Temperature Class runs from T1 through to T6 and these correspond to temperatures, for
example on the glass surface of a floodlight. T4 is ok for Zone 2 - Don't have the book with me to
tell you the other T* ratings that are suitable.

PUMPS

Electrical Pumps with Zone classified motor, starter box are fine.

Diesel Pumps - Trickier. You need :

• Anti Static Drive belts,
• Anti Static Fan for the radiator,
• a water-cooled exhaust for surface temperature
need to cool to 200F... this means an oversized
radiator
• Spark Arrestor on exhaust
• Shutdown on air intake

If you have a very long shaft... to get the driver 3 meters or more away from the fluid end then
you meet zone requirements. Even if you could find a set-up like that though I still wouldn't
recommend it for our operation and doubt that customers such as the IOC's would accept it.

HEATERS

Steam type not a problem but the Steam generator needs to be remote, as this is an open flame
diesel burner. You do of course need to protect against hydrocarbons, resulting from a coil
failure, from reaching the Steam Generator.

Gas or Diesel Fired - Trickier. These of course have an open flame in the fire tube and an
exhaust stack.

The open flame within the heater we can argue is isolated from the coils by the water bath
surrounding the fire tube but we should have a low water Alarm and shutdown incorporated on
the shell side. The fire tube should be fitted with a flame arrestor to atmosphere but even at that
there will be an area that is "open" to atmosphere for monitoring the flame. If the heater is 3
meters or more in length one can argue that this source is outside the Zone 2 area created by the
front-end heater piping.

The Vertical Exhaust is a source of both surface heat and spark or ash fallout. Spark arrestor on
the Exhaust is recommended.

Gas or diesel fired heaters can be equipped with various safety systems such as Flame Detector
and temperature Sensors that will control fuel supply to the firetube.

LABS

Here we have a choice, to set them close to the equipment. In which case they should meet
Zone Classification requirements, or set them remote of the equipment in a safe area.

Lab Electrics can be installed that meet Zone Classification requirements however the Computer
equipment is not able to meet Zone Classification requirements.

To overcome the difficulty of computer equipment, resident in a Zone Classified area the Lab
should be fitted with:

• Air Purge System

 • Internal Cabin Pressure Sensor/Shutdowns
• Internal Cabin or Air Purge Supply Lower Explosive Limit (LEL) / Higher Explosive
Limit (HEL) and H2S Gas Sensors for Alarms and shutdowns.
• Alarms and time delay shutdowns for Open doors
• Multi cable Transit (MCT)

Usually an offshore lab as described above will have two compartments, separated by an internal
Air Lock Compartment. The full Zone Classified version has sensors for Cabin pressure. A
positive pressure supply to the Cabin prevents ingress of Hydrocarbon and/or H2S gases. If the
pressure drops below set point an alarm sounds, if pressure drops further the electrics may be
shut down.

Common Mistake in Air purge is the set up of supply. The safe method is a Blower set in a
remote area to supply fresh air to the lab. The feed line has positive pressure so that if punctured
it will not allow ingress Hydrocarbon or H2S gases. The method sometimes used in error is to
have suction in the lab and run a hose to a safe area. If the hose is punctured then the suction
will draw from atmosphere at the puncture, which may have hydrocarbon or H2S gases.

Alarms and Time delay shutdowns for the internal air lock doors - sound if both doors are open
and shutdown if both are open for a set period of time.

MCT is used for feeding cables (SCAN2) into the lab. Lycron insert blocks are removed, cables
run into the lab, then the blocks re-installed to form a compression seal around the cables.

Often you may also find labs equipped with an Uninterrupted Power Supply (UPS) so that if we
do lose power the SCAN2 system doesn't shut down. This would make the alarms and
shutdowns of no value, as do computers that would have their own battery power to keep
running. These need to be shutdown manually if the alarms shutdown the lab power.

Labs should be equipped with an Emergency Light, rated for Zone Classified areas. The
emergency light plugs into the sockets in the lab and if power is lost the Zone 2 light comes on
automatically so we are not lost in the dark.

That's it.

Probably more than you wanted to know. There will be more to this that can be picked up from
reading the various regulations but for what we do I hope this covers and explains the basics.

Now that I've got it written I'll look to get it on the web.