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Abstract
This section presents the basis for determining electrical area classification
(commonly called area classification) for locations that may become hazardous
because of flammable liquids, gases, or vapor. It includes definitions of classified
locations and guidelines for determining the extent of area classification required.
Use this section in conjunction with API RP 500 and NFPA 30. You can use the
Electrical Manual, Section 300, as a guide for selecting types of equipment suitable
for use in specific area classifications.
Contents Page
1510 Predesign Considerations 1500-3
1511 Purpose and Need
1512 Responsibility for Classification
1513 Industry Standards and Codes
1514 Selection of Equipment
1515 Legal Requirements
1516 Modifications to Existing Facilities
1517 Plant Roads
1520 Classified Locations 1500-5
1521 Classes and Groups
1522 Class I, Division 1 Locations
1523 Class I, Division 2 Locations
1524 Unclassified Areas
1530 Determination of Classification 1500-8
1531 Methods
1532 Evaluating the Location
1533 General Rules
1534 Ventilation
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Classes
The National Electrical Code (NEC) designates hazardous locations as Class I
(flammable gases or vapor), Class II (combustible dusts), or Class III (easily ignit-
able fibers). Because the majority of Company facilities are either Class I or unclas-
sified, this section focuses primarily on those areas.
Groups in Class I
Class I locations are further divided into Groups A, B, C, and D, based on maximum
explosion pressure, maximum safe clearance between mating parts in an enclosure,
and minimum ignition temperature of the atmospheric mixture. (See Figure 1500-1
for a listing of materials by group.)
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Group D Atmospheres
acetic acid (glacial) isopropyl ether
acetone mesityl oxide
acrylonitrile methane (natural gas)
ammonia(3) methanol (methyl alcohol)
benzene 3-methyl-1-butanol (isoamyl alcohol)
butane methyl ethyl ketone
1-butanol (butyl alcohol) 2-methyl-1-propanol (isobutyl alcohol)
2-butanol (secondary butyl alcohol) 2-methyl-2-propanol (tertiary butyl alcohol)
n-butyl acetate petroleum naphtha(4)
isobutyl acetate pyridine
sec-butyl alcohol octanes
di-isobutylene pentanes
ethane 1-pentanol (amyl alcohol)
ethanol (ethyl alcohol) propane
ethyl acetateethyl 1-propanol (propyl alcohol)
acrylate (inhibited) 2-propanol (isopropyl alcohol)
ethylene diamine (anhydrous) propylene
ethylene dichloride styrene
gasoline toluene
heptanes vinyl acetate
hextanes vinyl chloride
isoprene xylenes
(1) Group C equipment is permitted for this atmosphere if the equipment is isolated in accordance
with Section 501-5(a) of the National Electrical Code by sealing all conduit 1/2-inch size or
larger.
(2) Group D equipment is permitted for this atmosphere if the equipment is isolated in accordance
with Section 501-5(a) of the National Electrical Code by sealing all conduit 1/2-inch size or
larger.
(3) For classification of areas involving ammonia atmosphere, see Safety Code for Mechanical
Refrigeration (ANSI B9.1-1971) and Safety Requirements for the Storage and Handling of
Anhydrous Ammonia (ANSI K61.1-1972).
(4) Saturated hydrocarbon mixture boiling in the range 68F to 275F. Also known by the
synonyms benzine, ligroin, petroleum ether, or naphtha.
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1531 Methods
Area classification can be determined in two ways, as described in this section.
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Fig. 1500-2 Relative Magnitudes of Process Equipment and Piping Handling Flammable
Liquids or Gases
Process Small/ Large/
Equipment Units Low Moderate High
Size gal <5000 5000 to >25000
25000
Pressure psi <100 100 to 500 >500
Flow Rate gpm <100 100 to 500 >500
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1534 Ventilation
Definition of Adequate Ventilation
A critical factor in area classification is determining the degree of ventilation neces-
sary to meet the requirements of NFPA 30, the Flammable and Combustible Liquid
Code. NFPA 30 defines adequate ventilation as follows:
An area is adequately ventilated if it is ventilated at a rate sufficient to main-
tain the concentration of vapors within the area at or below 25% of the lower
flammable limit. This shall be confirmed by one of the following:
a. Calculations based on the anticipated fugitive emissions; or
b. Actual vapor concentration sampling under normal operating conditions,
conducted at a radius of 5 feet from equipment.
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Design Considerations
If mechanical equipment provides the required ventilation, safeguards are needed to
protect against its undetected failure.
Discharge or exhaust must be to a safe location outside the building.
Ventilation rates can be achieved either by continuous introduction of fresh make-up
air into the enclosure, or by recirculation of air in the room. A recirculation system
should ensure that the air is monitored continuously using a system that automati-
cally alarms, stops recirculation, and provides full exhaust to the outside in the event
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that vapor-air mixtures over 25% of the lower flammable limit are detected. The
MMS limit is 20% in offshore OCS areas. See API RP 500 4.6.2.2.5.
Recirculation should be designed with adequate air movement and direction to mini-
mize dead areas where vapor may collect. If other criteria are lacking, a recircula-
tion rate of 1 cubic foot per minute per square foot of floor area can be used.
Some designs include contingency for introducing large quantities of fresh make-up
air upon detection of vapor-air mixtures over 25% of the lower flammable limit. For
Class I, Division 2 locations, this precaution may not always be warranted because a
concurrent failure of the electrical equipment, which would create a source of igni-
tion for the vapors, is deemed improbable.
Whether or not ventilation is achieved through make-up air or recirculation, good
mixing is required to ensure adequate ventilation of all floor areas, pits, or pockets
where flammable vapors may collect.
If conditions include the risk of a large flammable vapor release occurring in a
confined space, and the calculated rate of diluent ventilation is not sufficient to
dilute and disperse the released vapor to below the LFL within a reasonable time
(i.e., four hours), then supplemental emergency ventilation should be provided.
Emergency ventilation can be natural ventilation through panels or louvers, or
switching recirculation fans to full fresh air make-up or exhaust. The travel direc-
tion of ventilated vapor should avoid its reaching an ignition source outside the
enclosed space being ventilated.
1540 Applications
This section discusses general application of electrical area classification principles.
Applications for specific types of facilities are covered in Sections 3100 to 4100.
Specific applications are also discussed and illustrated in API RP 500 NFPA 30,
NFPA 30A, NFPA 70 (NEC), and NFPA 497A.
Standard Drawing GF-P99987, in the Electrical Manual, Standard Drawings
Section, shows the area classification of a typical processing facility.
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Changes in Service
In determining area classification, consider possible future changes in service of the
equipment. Tanks are particularly susceptible to changes in service. If an area is
likely to require classification because of a change in service, you might want to
install equipment suitable for the anticipated classification at the outset. Electrical
retrofitting is costly.
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Fig. 1500-3 Underground Covered Sump or Oil-water Separator in Adequately Ventilated Area
Sumps or below-grade trenches located within a Division 2 area are normally classi-
fied Division 1, because these are low points where spilled liquid is more likely to
flow and heavier-than-air vapor may collect and remain. Consequently, its best to
avoid installing electrical equipment in these areas. Such equipment would have to
meet Division 1 requirements even though Division 2 equipment would be accept-
able if it were located a few feet away.
1545 Tanks
Areas around tanks, including the roof and vent area, the drainage path and the
impounding basin should be classified in accordance with API RP 500 as appli-
cable, and with the Tank Manual, Section 200.
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Unclassified Areas
Process equipment such as piping, vessels, and exchangers are considered tight,
sealed systems. The area being evaluated does not need to be classified for
hydrogen if it doesnt contain mechanical reciprocating or rotating equipment,
sample draws, vents to the atmosphere, or other potential sources of hydrogen
leakage in significant quantities.
Valve packing leaks in hydrogen service are not a significant source of hydrogen.
Packing leaks will either ignite or disperse so rapidly that there is small probability
that electrical sources can or will increase the risk of ignition.
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1551 General
One way to provide adequate ventilation for an enclosed area is to make a reason-
able estimate of fugitive emissions from hydrocarbon-handling equipment within
the enclosed area and then provide sufficient diluent ventilation. This method has
been adopted by the 1990 edition of NFPA 30, Flammable and Combustible Liquids
Code, included in the Standards section of this manual. Using this method requires
certain calculations as described in NFPA 30, Appendix F.
Note This method is also used in API RP 500 for determining limited ventila-
tion. For offshore producing facilities under MMS jurisdiction, calculations for
ventilation requirements must be reviewed and approved by the MMS.
To calculate the required ventilation rate, first determine the anticipated hydro-
carbon leakage rate (under normal conditions). Then add sufficient dilution air to
the space in question to ensure that the concentration of flammable vapor/gas is
maintained below 25% of the LFL for all but periods of process upset, abnormal
operation, or equipment rupture or breakdown.
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You can obtain fugitive emission factors for specific hydrocarbon handling equip-
ment from emission testing at specific facilities or from existing publications such
as these:
API Publication 4322, Fugitive Hydrocarbon Emissions from Petroleum
Production Operations, Volumes I and II (1980)
An EPA/Radian Study conducted in 1979
EPA document, Protocols For Generating Unit-Specific Emission Estimates
For Equipment Leaks of VOC and HAP, 1987 (Document No. 87-222-124-10-
02)
These publications are available from the ETC Fire & Process Safety team. Emis-
sion data should be reviewed to assure emission rates are representative of condi-
tions during normal operation.
An example of how this method is usefula large enclosed process building that
requires environmentally controlled (i.e, heating or cooling) ventilation air. Deter-
mining ventilation rates by the fugitive emissions method can give a lower required
ventilation rate because it is based on a reasonable estimate of hydrocarbon leakage.
Thus, use of this method can reduce operating costs.
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in using Zone practices and equipment. However, at this time most manufacturers of
electrical equipment have not completed the testing and calibration required to
provide Zone system ratings for their equipment.
Figure 1500-4 compares the differences between the two systems with regard to
how areas are classified.
Fig. 1500-4 Comparison of IEC and NEC Classification Areas
Classified Areas
Time That Ignitable Hazardous
IEC Group II NEC Class I Gases are Present
Zone 0 Continuously
Division 1 Normally present
Zone 1 Occasionally in normal operations
Zone 2 Division 2 Not normally present
Cost savings are achieved by having three Zones instead of two Divisions, thereby
creating a narrower range of expected conditions. Equipment for each Zone is more
specifically tailored to those conditions, as opposed to Division equipment, which
may be over-designed for a given application
In the near future classifying areas under the Zone system will present less diffi-
culty than obtaining equipment rated for Zones. Assuming that eventually the Zone
system becomes a world-wide single standard, there will be a difficult interim
period during which both systems must coexist.
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1560 References
American Petroleum Institute (API)
API 2G Production Facilities on Offshore Structures
API 2L Planning, Designing and Constructing Heliports
for Fixed Offshore Platforms
API 14C Recommended Practice for Analysis, Design
Installation and Testing of Basic Surface Safety
Systems on Offshore Production Platforms
API 14F Design and Installation of Electrical Systems for
Offshore Production Platforms (included in the
Electrical Manual)
API 14G Fire Prevention and Control on Open Type
Offshore Production Platforms
API 4322 Fugitive Hydrocarbon Emissions from Petroleum
Production Operations, Volumes I and II (1980)
API RP 500 Classification of Locations for Electrical Installa-
tions in Petroleum Facilities (included in this
manual)
API 540 Electrical Installations in Petroleum Refineries
(included in the Electrical Manual)
Chevron References
Electrical Manual
Tank Manual
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NOTES
4. COVERED O I L- W
ATER OR PRO CESS SUM PS & PLO T LI MIT
DRI P PANS ARE CLASSI FI ED CLASS I , DI VI SI ON 1,
GRO UP D.
5. DI STANCE I N W
HI CH THE AREA CLASSI FI CATI ON EXTENDS
FRO MTHE HYDRO G EN COMPRESSO R SHOULD BE M EASURED
FRO MSO URCE OF PO TENTI AL LEAK.
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