(Taw eae Model Code of Safe Practicema ct rt Foreword CONTENTS ‘Summaries of Chapter Contents 1 Introduction LL Scope 12 Limits of Applicability 1.3. Safety Principles Fundamental to Area Classification 14 ‘The Management of Area Classification 1.5 Key Terms 16 Vaporization Characteristis of Petroleum Fluids 1.7 Variations in Type and Level of Ventilation 18 Buoyancy of Release . 19 Special Terminology—the Hazard Radius 4.10 Other Terms ‘The Technique of Hazardous Area Classification 21 Introduction 22. Preliminary Data Needed for the Assessment 23 Identification of Sources and Grading of Release—Basic Principles || 26 Firstly, the Simplified Direct Type Example for the Area Classification of the Commonly Encountered Types of Petroleum Facilities. 217 Secondly, the Procedure for the Area Classification of Less Uniform Types of Petroleum Facilities, including Crude Oil/Gas Separation and Production Facilities, Refineries, Natural Gas Liguics and LPG Processing . 211 The Classification of Petroleum Fluids for Purposes of Area Classification 2.12 ‘The Application of the IP Flashpoint Classification 2.13 Completion of the Area Classification. by Speieaon of ‘Apparatus: Sub-aroupand Temperature Class: 215 The Area Classification Drawing The Classification of Storage Tankage, Bulk Loading and Unloading by Road and Rail, Petroleum Jetties, and Balk Distribution and Marketing Facilities by the Method of Direct Example 3. Scope 32. Storage Tanks (Fixed and Floating Roof) in Open Air Ventilation—Classes I, 1) ana se) General 33 Road Tanker Loading—Classes f, (2) and 111@) 3.4 Road Tanker Discharge—Classes I, 11(2) and 111(2) 35. Rail Car Loading—Classes 1, 11(2) and I11(2) 3.6 Marine Facilities and Jetties—Classes I, 11(2) and I11(2) xiii 10 2 12CONTENTS 3.7 Drum Filling—Open Air Ventilation—Classes 1, 11(2) and 112) 3.8 Filling and Service Stations 39 Bulk Pressurized LPG Installations in Distribution and Marketing and Medium Sized’ User Installations The Classific Wellhead Areas ‘of Drilling Rigs and Other Equipment Systems Used in Well Operations and Production 4.1 Introduction . 42 Classification for Drilling, Workover and Wireline Operations in Open Areas 43° Wirelining 44 Other General Considerations for Rigs and Other Sources of Release on their Wellheads and Associated Drilling Facilities 45 Surface Mud Systems 46 Gas Vent 47 Other Spaces 48 Weil Test Systems 49. Producing Oil and Gas Wells on Land 4.10 Non-elecitical Sources of Ignition 4.11 Offshore Contingency Alternative Procedure for Classification of an Upstream or Downstream Petroleum Sector Facility by Consideration of the Individual Point Source 5.1 Scope 53. Explanation of the ‘Point Source’ Concept as used in this Code 54 Determination of the Grade of Release 5:5 Determination of the Extent of a Hazard Zone 56 Pumps 52 Equipment Drains and Liquid Sample Points 58 Compressors 59. Instrument and Process Vents to Atmosphere 5.10 Piping Systems 5.1 Liquid Pools due to Spillage 5.12 Sumps, interceptors and Separators 5:13 Pig Receivers and Launchers 5:1 Surface Water Drainage Systems ‘Variation in Ventilation Conditions 61 Introduction 62. The Classification of an ‘Open Area’. | 63 Less Ventilated Conditions of Sheltered or Enciosed Areas 64 Shehered Areas 65 Enclosed Areas : 66 The Effect of Loss of Ventilation on the Area Classification of an Enclosure Application to the Selection and Location of Electrical Facilities 7.1 Introduction 72 General 13. Selection df Group 11 Apparatus 14 Type of Protection : 75 Selection According to Hazard Zone 7.6 Apparatus Sub-groups 7.7 Temperature Class and Gas Ignition Temperature 7.8 Enclosure (IP) Protection : 79 Other Requirements 7.10 Completion of the Area Classification Document 7.11 Marking of Apparatus 36 ® 2 44 44 45 48 48 48 30 50 50 50 50 st 68 6 64 n 15 1 1 1 B 9 9 9 80 83 83 3CONTENTS 712 Installation 4 713. Avoidance of Physical Damage to Electrical Apparaius and Cables fa 7.14 Maintenance and Inspection : 84 7.15. Mobile, Portable and Transportable Electrical Apparatus and its Connections. rr) 7.16 Personal Apparatus . : 85 1.17 Frictional Sparking Risks with Light Metals eee eras 718 Ignition due to Radio-frequency Electromagnetic Radiation : : 85 719 Battery Rooms 86 720 Cathodic Protection, Earthing and Bonding. , : : ERG 8 Application to the Control and Location of Ignition Sources other than Electrical 87 81 Introduction eee eee pete peeeenense 87 82. Ignition Sources cece 37 84 Mobile Sources including Equipment for Hot Work) te 87 85 Hot Surfaces. . : ce ee Hi90. 86 Fired Heaters and Furnaces : 92 87 Combustion Engines ees So 88 The Ventilation and Classification of the Turbine Hood : 96 89. Air Intakes oe HEH, 8.10 Road and Rail Traffic ; pees : 97 B11 Flares a 97 812. Electrostatic and Pyrophoric Ignition Hazards - oe : 7 £.13 Recommended Layout and Spacing of Petroleum Facilites ote fo 8 Appendices ‘A. Classification of Petroleum. : eee : 99 B Fluid Category : + 101 © Assessment of Buoyancy . Eee See + 104 D Derivation of Hazard Radius eee 105 E Example of the Use of the Point Source Method of Chapter S- + 107 F Types of Protection and Electrical Apparatus that may have an Internal Source of Release + 108 G Safeguards on Gas-fired Prosess Heaters. ae 112 H_ Flammable Limits of Petroleum Products SE EEEHEeE Seer Heed H eee eee ee ee ea T Glossary oe aise eee Done J Publications : : 118 vii om21 3 32 33 34 35 36 37 39 3.10 34 3.2 3.3 3a 31s 3.16 37 3.18 319 3.20 321 3.22 323 41 42 43 4a 45 46 SA 52 53 61 62 63 64 LIST OF FIGURES Application of this Code Application of the Chapter 5 point-source method of evaluation, in conjunction with Chapter 6 in respect of ventilation type and level ‘Area classification symbols, Cone or dome roof tank—Classes 1, 1(2) and {11(2) Floating roof tank Tank with outer protective wall Vent from underground or mounded tank, pump fed—Classes 1, 1(2} and 11(2) Underground tanks, gravity fed, vent pipe diameter below 70mm-—Classes I, 11(2) and 111(2) Road loading facilities, top loading, no vehicle present—Classes I, II(2) and i11@) Filling of road tankers, top loading through open or vent manlids—Classes J, 1(2) and 111(2) Typical Zone 2 provision for spillage area with drainage Final composite classification—typical road tanker top loading installation—Classes 1, 11(2) and T11(2) Road tanker bottom loading with free venting through manlid vents—Classes I, 1(2) and Ma-—n0 ‘weather roofing Classification of Class I petroleum discharge to service station underground tanks Road tanker parked for unloading—Classes I, 112) and 111(2) Railcar, top loading (loading rate above 2.5m*/min)—Classes I, 11@) and [11@) Railcar, bottom loading (loading rate above 25m®/min}—Classes I, 11@) and 111(2) Railcar discharge via hose connection—Classes I, 112) and II1(2) : Jetties—loading and discharge facilities—Classes I, 11(2) and T11(2) . Jetties—discharge facilities only—Classes 1, 11) and 111(2) Drum filling in the open air : Low hose metering pump/dispenser , ‘Low hose metering pump/dispenser with vapour barrier : Low hose metering pump/dispenser with rotating radius arm. High hose metering pump/dispenser—with sight glass and without vapour berrier High hose metering pump/dispenser—without sight glass and with vapour barrier Offshore (open area)—drilling and workover Offshore (open area)—wirelining Land (open area)—drilling and workover, Land (open area}—wirelining. Hazardous area around mud tank (open area) Hazardous area around shale shaker (open area) Liquid pool due to spillage Open sump—zoning shown for primary grade source Separator of interceptor—primary grade source Ventilation check for facilities not covered by Chapler 3 or 4 (sce 5.55, step 3a) to (e)) - Hazardous area from point source—open area—release heavier than air Hazardous area from point source—open area—release lighter than air Extent of hazardous area around unventilated roof (producing sheltered area above an open-sided area: applicable to lighter or heavier than air gas or vapour) . ix 12 4 15 15 15 16 "7 19 20 a65 66 67 68 69 610 61 BL BL LIST OF FIGURES Extent of hazardous area around ventilated roof (producing sheltered area above an open-sided area applicable to lighter or heavier than air gas oF vapour) : Extent of hazardous area around sheltered area with perforated walls containing source (gas or vapour hheavier than air) and meeting the criterion of adequate ventilation Extent of hazardous area around sheltered area with perforated walls containing source (gas or vapour lighter than air) and meeting the criterion of adequate ventilation . Extent of hazardous area around wall producing sheltered area (gus or vapour lighter or heavier than air) : : eee Extent of hazardous area around the aperture of an enclosed area containing a source of release (gas oF vapour heavier than ait) : : Extent of hazardous area around the aperture of an enclosed area containing a source of release (gas lighter than ait) fae : : Vent from more than one enclosed area ventilated with parallel air flows Typical gas turbine arrangement... : ‘Approximate relationship between fluid category, true vapour pressure, flashpoint and IP flashpoint classification eee : 6 0 70 n nm 15 95 1025a 53 54 55 36 7 58 61 62 7 72 73 74 7S Al LIST OF TABLES Pumps Drains and liquid sample points Compressors Process vents : eee Instrument vents Flanges and valves Hazardous area from liquid spills Sumps, interceptors and separators Enclosed area with an internal source of release—effect of ventilation type on zone of hazardous area Enclosed azea with no internal source of release but in connection with an outside hazard zone—effect of ventilation type on zone of hazardous area ‘Types of protection available for the achievement of safety when using electrical apparatus in flammable atmospheres Recommended apparatus sub-group and temperature class for petroleum fluids Apparatus groups and sub-groups in accordance with both recent and earlier British Standards Relationship between temperature class and maximum surface temperature of the apparatus Degrees of IP’ protection for apparatus in accordance with IEC 144 and BS 5420 Typical commonly encountered petroleum materials. sareesSei ee ee rere eee eee FOREWORD 1. For many years the petroleum industry in the United Kingdom has used the various editions of the Institute of Petroleum Electrical Safety Code for guidance in the Classification of Areas. It was decided some time ago that the great importance of this subject warranted its separation from the Electrical Safety Code, and the present volume is the result 2. This new Code, which is Part 15 of the IP Model Code of Safe Practice in the Petroieum Industry, has drawn on the experience and views of the various sections of the petroleum industry and takes into account the more general guidance on the subject published by BSI, IEC and CEN. During its preparation, many discussions have been held with appropriate UK government departments. 3. As with all Institute of Petroleum Codes, it is assumed that the users will be experienced in the xii industry and will hold appropriate technical quali- fications. 4. Appendix I is a glossary of selected terms. When these appear in the Code, they are printed in italics. 5. Any corrections, requests for clarification or views ‘on the application of the Code would be welcome and should be directed, preferably in writing, to: ‘The Technical Manager The Institute of Petroleum 61 New Cavendish Street London WIM SAR. 6 Although it is believed that adoption of the recommendations of the Code will help to reduce the risk of accidents, the Institute of Petroleum cannot accept any responsibility, of whatever kind, for damage or alleged damage arising or otherwise ‘occurring in or about premises, areas or vehicles to which this Code has been applied.SUMMARIES OF CHAPTER CONTENTS CHAPTER 1 Establishes scope and applicability of code and identifies key terms. Classiies hazardous zones and srades of gas/liquid release, Establishes a relationship between grades of release and zone class. Discusses vaporization characteristics of petroleum fiuids, types of ventilation and buoyancy, and their effect on hazardous area classification Figures 1.1 and 1.2 provide a step-by-step guide on classifying hazardous areas using the chapters of this code. Figure 1.1. For standard facilites. Figure 1.2 Where point-scurce method of assess- ment is required CHAPTER 2 Identifies information required to classify an area. Indicates alternative means of defining petroleum Auids for area classification purposes by their flashpoint ‘and also, where extremes of volatility, temperature and Pressure occur, by fluid category. Discusses the application of apparatus sub-group and temperature class to the selection of electrical equipment. Defines the area classification drawing. CHAPTER 3 Provides typical examples, with diagrams, which can be used to classify areas surrounding the following standard facilities: @ (b) © Fixed and floating roof storage tanks, both single and double wall, Vents from underground storage tanks. Road tanker loading and discharge for top and bottom loading aystems Railcarloading and discharge for top and bottom loading systems @ (©) Marine facilities. (f) Drum filing and storage areas. () Service stations. CHAPTER 4 Provides guidance for area classification of drilling rigs both onland and offshore with the aid of type diagrams. Classifies drilling, workover and wireline ‘operations in-both open and enclosed areas, Gives guidance on the classification of surface mud systems, gas vents and oniand wells CHAPTER 5 Lays down a procedure for classifying non-standard petroleum facilities not covered in Chapters 3 and 4, Defines fivid condition category. Defines point-source concept and establishes @ procedure to assess the dimensions of the associated hazard zone by hazard radias{fuid category, giving detailed advice on hazard- ‘ous zones around pumps, drains, sample points, compressors, instrument and process vents and piping systems, sumps, interceptors and ground spills, etc. CHAPTER 6 Outlines both natural and artificial ventilarion, includ~ ing overpressure protection, and their effect on area classification. Establishes the criteria of adequate ventilation. Defines ‘open area’, ‘sheltered area’ and ‘enclosed area’, and describes the application of area classification to each situation. Discusses methods of artificial ventilation and also the effect of loss of ventilation on the area classification of an enclosed area.SUMMARIES OF CHAPTER CONTENTS CHAPTER 7 Gives guidance on selection of electrical facilities according to hazard zone, type of protection, tempera~ ture class, Group Ti apparatus and enclosure (IP) protection, Discusses mobile and transportable ap- paratus. Refers to potential risks arising from fric- tional sparking and from radio-frequency electro- magnetic radiation, CHAPTER 8 Examines other non-electrical ignition sources, includ- ing gas detection, hot surfaces, catalytically active surfaces, high-pressure hydraulic system leakage and fired heaters, combustion engines and gas turbines. ‘Alternatives for the ventilation of the turbine enclo- ‘sure and hood, road and rail traffic, air intakes, flares, and electrostatie and pyrophoric ignitions are con- sidered. xviINTRODUCTION Li SCOPE General guidance as to the main principles, definitions and explanations of terms relating to area classification hhas been set out internationally by the International Electrotechnical Commission and in Europe by CENELEC, followed nationally by bodies such as, in the United Kingdom, the British Standards Insti- tution. These bodies state that, for recommendations for specific industries or applications, reference should bbe made to the codes relating :0 those industries or applications (reference TEC 79-10; BS 5345 Part 2). This part of the IP Model Code of Safe Practice Provides @ guide for the classification of the areas around equipment handling or storing flammable petroleum fluids, to provide a basis for the correct, selection and location of fixed electrical equipment in ‘hose arees. its zoning restrictions should be also borne in mind in regard to the introduction and use of any temporary or mobile electrical equipment. It also provides for appropriate extension of the technique to the control and location of non-electrical sources of ignitionin the vicinity of equipment handling such fluids, and indicates where additional measures may be desired. Recommendations are given in Chapter 8. 1.2 LIMITS OF APPLICABILITY The Code is intended for use in the petroleum exploration and production sector both onland and offshore, in refinery processing, and in the bulk oil Gistribution and retail sectors. The techniques de- scribed use the fund of experience that has developed within the petroleum industry surrounding the long- established hazardous area and sone definitions as stated in this chapter, based upon IEC, CENELEC and BS 5345. ‘The aim therefore is to update and replace all previous published IP guidance and promote the consistent interpretation of these definitions over the ‘whole range of situations which occur throughout the industry from the driling, wellhead and production stage to the ultimate operation of bulk distribution and retail dispensing. Its application to other flammable Guids is strictly limited to handling of those fluids that are similar in physical characteristics to petroleum fluids. As is the case with IEC 79-10, CENELEC and BS 5345, it does not cover ignitable dusts* nor does it have any relevance to the assessment of any toxic risks in the vicinity of equipment handling petroleum Buids (for Which guidance may be found in other IP Codes of Practice). 1.3 SAFETY PRINCIPLES FUNDAMENTAL TO AREA CLASSIFICATION 13.1 Avoidance of Fire and Explosion The aim of area classification is to avoid ignition of those releases which inevitably occur from time to time in the operation of facilities handling flammable liquids and vapours. The approach is to reduce to an Acceptable minimum level the probability of coin- idence of a flammable atmosphere and an electrical or ‘other source of ignition As laid down in TEC 79-10 by the International Electrotechnical Commission, itis not the aim of area classification to guard against the ignition of major releases of flammable materials under catastrophic failure of plant, eg. the rupture of a pressure vessel or Pipeline, oF the cold failure ofa tank which, in properly run facilities, has a very low probability of occurrence This principle is endorsed in CENELEC and in BS 5345. The incidence of such releases must be kept within acceptable limits by correet design, construc- tion, maintenance and operation of facilities (see 1.32) * For information on his subject see BS 6469; “Elctcal apperatus with protection by enclosure for use in the presence of combustible usAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 1.3.2 Good Standard of Design and Operation The area classification technique described here assumes that the facilities to which it is applied are designed, constructed, mainteined and operated in accordance with good industry practice so as to reduce releases to a minimum. Equipment and piping should be designed to British Standards or other national equivalents. The recommendations of the TP Model Codes or their equivalents, regarding good operational and maintenance practice, should be followed. 1.4. THE MANAGEMENT OF AREA CLASSIFICATION “The person responsible for the coordination ofthe area classification should be identified and be experienced in this field. The work, which requiresan interdisciplinary approach, should be carried out by persons who have full knowiedge of the process systems and equipment, in consultation with safety, loss prevention and electrical engineering personnel as appropriate. Agree- ments reached on the area classification should be formally recorded and kept updated. Such records, as drawings and/or tabulated data sheets, should include details as to the sype of protection selected to meet the zone requirements and the apparatus sub-group and temperature class as covered in Chapter Tn principle the classification of an area entails consideration of all the individual sources and potential sources of release of flammable fivid present. Tn practice, as will be shown in Chapter 2, the procedure can be simplified. In many cases the facilities layout and their classification can be derived from a standardized diagram as used successfully in previous IP Codes. This approach has been retained in the present Chapters 3 and 4 (see 2.6). In other cases the fuller procedure of point-source consideration will be necessary (see 27 and 2.8), and this is provided for in Chapter 5. Ta classifying a new facility or a modification, the area classification should be carried out before the design and layout of equipment are finalized. At this Stage it may be possible to make considerable improvements at little cost. The area classification should always be reviewed and drawings modified if necessary on completion of design and before any change is made to existing plant handling flammable petroleum fluids 15 KEY TERMS ‘These terms are consistent with the usage and principles in IEC 79-10, CENELEC and their national counterpart BS 5345. 15.1 Flammable Atmosphere A flammable atmosphere isa mixture of flammable gas for vapour with air in such proportion that, without any further admixture, it will burn when ignited. tn the context of area classification, the term ‘flammable’ is synonymous with “explosive 15.2 Area Classification “Area clossification is the assessed division of a facility into hazardous areas and non-hazardous areas, and the subdivision of the hazurdous areas into zones. 1.53 Hazardous Area and Zone A hazardous area is defined as a three-dimensional space in which a flammable atmosphere may be expected to be present at such frequencies as to require special precautions for the construction and use of electrical apparatus. All other areas are referred to as non-hazardous in this context though they may, in part for whole, form part of a wider restricted area within the facility in which all work is carried out under controt (Gee 8.4.1 and the IP Refining, Marketing and Drilling and Production Safety Codes). Hazardous areas are subdivided into three zones as follows. 153.1 Zone 0 That part of a hazardous area in which 2 flammable ‘atmosphere is continuously present or present for long periods. 153.2 Zone 1 ‘That part of a hazardous area in which a flammable atmosphere is likely to occur in normal operation. 1533 Zone? ‘That part of @ hazardous area in which 2 flammable atmosphere is not likely to occur in normal operation and, if it occurs, will exist only for a short period. 153.4 Extent of Zone “The distance in any direction, vertical and horizontal, from the source of release to the point where the flanimable atmosphere has been diluted by ait to-a ‘sufficiently low level For 2 given release the extent will vary with the vaporizing potential ofthe fluid release, the ventilation state and the buoyancy factor of the vapour (see 1.6, 1, 18 and Chapter 6 respectively) 1.5.4 Source and Grade of Release For the purpose of area classification a source of release is defined as a point from which a flammable gas, ‘vapour or liquid may be released into the atmosphere. ‘Three grades of release are defined in terms of their likely frequency and duration,INTRODUCTION 154.1 Continuous Grade Release A release that is cominuous or nearly so oF that occurs for short periods which occur frequently. 1542 Primary Grade Release A telease that is likely to occur periodically or ‘occasionally in normal operat on. 1543 Secondary Grade Release A release that is unlikely to occur in normal operation and, in any event. will do so only infrequently and for short periods, 155 Relationship between Grade of Release and Class of Zone TSS As in IEC 79-10, CENELEC and BS 5345, and in ‘comparable guides, the grade of release is dependent solely on the frequency and duration of the release. [vis completely independent ofthe rate and quantity of the release, the degree of ventilation, or the characteristics of the uid—although its these factors that determine the exient of vapour travel and in consequence the dimensional limits of the hazard one 1532 Assessment of the grade of release is not always obvious and will require experenced engineering and ‘operational judgement, particularly in regard to the likely frequency of operations such as venting, draining, sampling, seal failure and the opening up of equipment asin the changing o” spades, filter cleaning, etc TEC 19-10, CENELEC and BS5345 give only Qualitative definitions of the diferent grades of release as in 1.54; however, as @ rough rule-of-thumb guide and for continuously operated plant it has been fecommended that a release should be regarded as continuous ifitis likely to be present for more than 1000 hours per year and primary if ii ikely to be present for 10 hours or more per year but less then 1000 hours. A release likely to be present for les than 10 hours per year and for short periods only should be regarded as secondary This assessment should take account of any likelihood of leaks remaining undetected Examples may be seen in Chapters 3, 4 and 5 as to where continuous, primary and secondary grade sources normally occur on typical equipment. 1553 ‘There is, in most cases, under unrestricted ‘open air? conditions a direct relation between the grade of release and the type of zone to which it gives rises i. Continuous grade normally leads to Zone 0. Primary grade normally leads to Zone I. Secondary grade normally lecds to Zone 2, 155A However, it should be noted that the terms ‘Grade af Release’ and ‘Zone’ ate not synonymous, Although continvous, primary and secondary grade releases will normally result in Zones 0, £ and 2 respectively, this ‘may not always be true. For example, poor ventilation ‘may result ina more stringent zone while, with high ventilation provision, the converse will be true (see Tables 6.1 and 6.2). Also some sources may be Considered to have @ dual grade of release with a small continuous or primary grade and a larger secondary grade. An example of this is a pump seal (see 5.6) Kt should be noted that whilsta Zone / area will often be surrounded by a larger Zone 2 area there is no specific requirement for this. Where a Zone J area is not part ofa larger Zone ? then the possibility of any large ‘but infrequent release, which would require a larger Zone 2 area, should be considered. 1555 ‘The grade allocation should be reviewed in the course of the design stages to determine if practicable and economical design or engineering improvements can be made to reduce the number of continuous and primary grade releases. 1536 In the use of the type diagrams of Chapters 3 and 4 it will be noted that the respective grades of release, and thereby zonal identication, have already been taken into account. 1.6 VAPORIZATION CHARACTERISTICS OF PETROLEUM FLUIDS 16.1 Where the petroleum fluid is & liquid, its volatility in relation to the conditions of temperature and pressure at which potential release might take place is an ‘essential factor, since this will determine the extent of rapid vapour formation from that release, Thus for carying out the area classification of a facility a Knowledge of the vaporization potential of the petroleum material to be handled should be determined. For the majority of petroleum products, stabilized crude oil, etc, the IP classification by closed cup flashpoint into the various Classes of Petroleum as defined in Appendix A is adequate for this purpose, ‘and this is used in the type examples given in Chapter 3 (sce 2.11 and 2.12 and the notes to Appendix A) 16.2 For petroleum streams of less uniform volatility, and where there are extremes in temperature and pressure 5 in processing plant, etc, as provided for in Chapter 5, a further classification of volatility has beenAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS developed, in which four additional Fluid Caregories supplemental to the IP Classes of Petroleum have been defined. Details will be found in 2.126, 5.54 and Appendix B. 1.7 VARIATIONS IN TYPE AND LEVEL OF VENTILATION Ventilation isu general term to indicate air movement and replacement by fresh air. Natural ventilation refers to venrilerion caused by wind or convection effects: Astifcial ventilation refers 10 ventilation caused by air purge or by assisted mechanical means such as fans or extractors that may be general or focal. The level of ventilation is an important factor in determining the extent of any hazardous area and the zone number and must always be assessed in accordance with Chapter 6 and the definitions that follow. LTA Open Area ‘Anarea inan open air situation without stagnant areas where vapours are rapidly dispersed by wind and fatural convection. Typically air velocities should rarely be less than 0.5 metres per second and should. frequently be above 2 metres per second. 1.7.2 Sheltered or Obstructed Open Area ‘An area within of adjoining an open area, which may include a partially open building or structure, where owing to obstruction natural ventilation may be less than ina true open area, and this may enlarge the extent of the hazard zone. 173 Enclosed Area ‘An enclosed area is any building, room or enclosed space within which, in the absence of artificial ventilation, the ventilation will be limited and any flammable atmosphere will not be dispersed naturally. NOTE 10 1.72 and 1.73: & distinction between 1.72 and 1.73 is provided by the criterion of adequate ventilation given in 63.4. Where natural adequate entilation is effective, the obstruction can be classified ‘a8 a sheltered area, with the zonal number the same as for the same source in an apen area. ‘Where the degree of obstruction without artificial ventilation gives rise to lower than adequate ventilation, it should be classified as an enclosed areo, and the effect fon the severity of zone numbers assessed in accordance with the ventilation provision ‘0 be selected. 1.7.4. Type and Level of Artificial Vent Within the categories of ‘General Artificial Ventilation’ and ‘Local Artificial Ventilation’, the IEC and CENELEC recognition that there can be differing levels that will affect the zoning characteristics is covered in this Code under the sub-headings in Chapter 6 of dilution, adequate and overpressure ventilation, together with the important consideration of their failure modes. 1.75 Inadequate Ventilation Ventilation, natural or artificial, insufficient to avoid persistence of a flammable atmosphere within sheltered or enclosed areas—the ‘no ventilation’ case of IEC 79- 10 (see 6.5.7). 176 The more complete description of the various types of ventilation, with the guidance of how in conjunction with Chapter 5 they are to be assessed, is given in Chapter 6, Figure 6.1 is a summary of their inter relationship. 1.8 BUOYANCY OF RELEASE It is necessary to estimate the buoyancy af a release because lighter-than-air gases in an open area tend to disperse upwards whilst the reverse is true for heavier than-air gases and vapours. The shape and extent of the hazardous envelope therefore differs (see the comparison between Figures 6.2 and 6.3) See Ap- pendix C for the definition and use of the buoyancy factor. 19 SPECIAL TERMINOLOGY—THE HAZARD RADIUS In addition to the standard terminology used through- ut this Code, it has been found convenient in the presentation of the many cases for point source release Covered in Chapter 5 and in Figures 62 to 6.10 to devise a base parameter which has been designated the hazard radius. A definition of this term is given below: ‘The hazard radius of a source is defined as the largest horizontal extent of the hazardous area which is generated by the source when situated in an open area. Further explanation of how this parameter was derived is to be found in Appendix D. The method of its use, in conjunction with the fluid category of the release and the ventilation level, is given in 5.5. 1.10 OTHER TERMS “The glossary at the end of this Code may be consulted for other terms printed in italics. 1 “To aid the successive use of the following chapters, Figures 1.1 and 1.2 on the succeeding pages may be utilizedINTRODUCTION Application of this Code 1. Familiarize concepts/defintions of area classification in Chapter 1 (1.1 to 1.9) 2. Define instailation/plant/process sections (2.2/2 3) 3. Is quantity of flammable material that may be released sufficient to require classification? Section 2.10(9) No 4, What flashpoint class is involved? Consider other safety Can flammable release occur? precautions =a. nevertheless et | Class |, lt, It oF ae More extreme volatility Unclassified temperature or pressure (2.124 t0 2125) BELA M2) Classi) or mt) — | Fuld Category (A,B. ¢ or 6) (2121/2124) (2.123) (1.6.2/2.11.2/Appendix 8) (Release ilammabie) 5. Is facility of common type as in 2.67 ‘Apply point-source method of Chapter 5 Check no significant differences in iayout (see Figure 12 for detals) ventilation, ete. from type examples in Chapter 3 or 4 Yes xo i 2.6 confirmed. Apply Chapter 3 Differences noted. Apply for storage/distrbution or point source evaluation Chapter 4 for cril 1a/workover (includes Classes |, 11(2) ene MI(2) situations as in 2.8) 6. Grade of release, zone number, buoyancy effect on shape of hazard zane. etc. For the point source inthe type examples of Chapters 3 and 4 rath of sseesront the level of vontiaton te gad Sepivng Chapter 5 {teaueney and duravon ai ese factors have of ie releosos and hence the zone to be indivdualy Sumber the buoyancy actor Evaluated anc applied (lighter or heavier than air) indicsted in Figure 1.2 : dre al inbuilt into the diagrams resented. No further action is needed Final stages for completion ef the area classification. in all cases, having evaluated the extent ofthe hazard zoneand te soparatu aeb ge smut be used to select the appropriate type of protection for eloctrical equipment and sleo ie OF crewing OUP 2nd temperature class (2.13). These should be incorporated inthe final res clecoofeates nome (oF drawings, | moking this selection, the question of whether there i ‘Appendix F, 7.5(b) and 7.6(c) to determine whether itis govern the ultimate type of protection requirement. 8, For non-electrical sources of ignition see Chapter 8. isan internal release should be assessed in accordance with ‘the internat reiease or the oxternal zone assessment that will Figure 1.1 57 AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS Application of the Chapter 5 point-source method of evaluation, in conjunetion with Chapter 6in 7 respect of ventilation type and level Introduction: Steps 1 to § of Figure 1.1 should first be carried out a6 follows, 1 220). (2). (d) Collection of data, drawings, ete.. on facility to be ciessitied. 2.2(b), 2.11, 212 = 22 oi 2 Zosaiity by flashpoint class (Appendix A), or alternatively Bolling range, ete, temperature and pressure to determine fluid category by Appendix 8. 2.2(0) Tollect knowledge on how equipment is to be operated. 22/0) ‘Ascertain level of ventilation, using Chapter 6. 2209) 2.200). cinyloperation not covered by common type examples sat out in Chapter 3 oF (see 2:6) and thet point 27 or 28. Sires method of Chapter 5 should be followed in accordance with eit See ein 2.12.8 should be noted. Buoyancy of releases should be ascertained wheth using Appendix C. fighter or heavier than ait, 1h. Having collected the above data, Chapter 5 may be employed to determine: fe) The grade of release, and thence the zone number (2.3.1, 23.2. 2127 and 5.4 $44, 542 sg oe 3). = (2) Pe Sten ofthe hazard zone for each relevant source of release (eae 6.11. items (s) £0 (c}) sing Ie eae The extent ot ned in 56.6, in conjunction with Figures 6.2 to 6.10 in respect of vontiltion level Spe Be Brocade ourttion on equipment data in 56 (0 8.14 that will nable an appropnate selection of the bose parameter hazard radius (1.9 and 65.3) - Examples of this procedure in Il above are provided in Appendix E. Complete the sesessment as in Step 7 of Figure 1.1: 7. Final stages for completion of the ses caskicoTet Se ne aera ualusted the extent ofthe hazard zone ané ts zone number, Chapter 7 mast beused so sete OS i apbamiate tyaeot pretecton‘or electrical equipment and also te apparatus sub-grouPand Temperature class (2.13). Fee enpuld be incorporated in the final area classification records or drewings. or non-electrical sources of ignition see Chapter 8. Figure 12. it2 THE TECHNIQUE OF HAZARDOUS AREA CLASSIFICATION 21 INTRODUCTION In area classification the approach is to reduce, to an acceptable level, the probability of coincidence of @ flammable atmosphere and an elecitical source on ignition. It requires delineation ofthe facility into hazardous ‘areas and zones, which are further graded according to the estimated probability of the presence of a fammable atmosphere, with restrictions within these areas and zones on the use of equipment with the Potential to cause ignition, in accordance with the guidance provided in Chapter 7 and in fuller detail by the various Parts 3t0 9 of BS 5345 and their IEC 79 and CENELEC EN counterpart publications as to the correct selection of electrical equipment. In these documents the term ‘explosive is used as a synonym for flammable As further outlined in Chapter 8, this analytical approach is also of value when considering the location and control of noneelectrical sources of ignition, such as diesel engines, gas turbine drives, hot surfaces, fired heaters and stati discharge. 22 PRELIMINARY DATA NEEDED FOR THE ASSESSMENT In any facility producing. processing or storing Petroleum fluids, itis normally easy to identify the areas where petroleum is present and which will need to beclassified. The problem isto define the boundaries between hazardous and nos-hazardous areas, and within the former to identify and define the boundaries of the respective Zones 0, / or 2, according to whether the likelihood of the existence of an explosive/ flammable gas of vapour/air mixture is judged to be high, medium, low or 50 low as to be regarded as negligible (non-hazardous) In carrying this out, points from which release can ‘occur in normal operation, startup and shutdown, in emergency operation and in the event of equipment or control system maifunction have to be identified. For this to be assessed, some basic design information must first be assembled which, according to the complexity of the installation, can include: (2) A flow diagram showing flows, temperatures and pressures. (6) Flashpoinis or, where more complex conditions as in 27 may be involved, the boiling ranges or other relevant physical characteristics of the Auids hhangled that will enable the fluid category as defined in 5.5.4 and Appendix B to be determined. ‘These will be needed also for determining the apparatus sub-group and temperature class (see 2.13 and Chapter 7) (©) Where relevant, eg for processing plant, a piping and instrumentation diagram. (@) A layout drawing with typical plans and eleva- tions showing the position of all equipment including operational vents and drains to atmosphere. (©) A knowledge of the equipment features and the mode of operation. () Consideration of the state of ventilation, whether ‘open area, restricted (sheltered) or enclosed see 1.7 and Chapter 6). For sheltered or enclosed situa- tions the position of openings such as doors, windows and inles/outiets for ventilation air will be needed. () Determination, if common type examples as in Chapters 3 and 4 are not tobe used, of whether the release(s) will be lighter or heavier than ait (ee 1.8 and Appendix C), Tis then necessary using the procedures that follow to determine the resulting Zone and Zone I hazardous areas and the secondary grade releases which define the Zone 2 boundaries, together with the extent of these areas.AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 23 IDENTIFICATION OF SOURCES AND GRADING OF RELEASE—BASIC PRINCIPLES 234 The governing principle in respect of area classification laid down by the International Electrotechnical Commission (1976) in {EC 79-10 states that itis not intended to apply to catastrophic failures, which are beyond the concept of abnormality dealt with in that report It cites by way of definition, as do CENELEC, BS 5345 Part? ‘Scope’ and 1.3.1 in this Code, that “Catastrophic failure in this context is applied, for example to the rupture of a process vessel or pipeline’. Tr follows, in the application of area classification to the petroleum sector, that the escape of flammable fiuid from some operations and equipment is so unlikely that, where the equipment concerned is not subject to heavy erosion or corrosion, and is well maintained, it need not be regarded as a source of release. lems of plant equipment that may be included im this category include pressure vessels designed to BS '5500 (Category 1 or 2) or an equivalent recognized code™ and pipework between valves and flanges, etc, designed to ANSI/ASME B31.1 or equivalent.t 232 It follows from the above that the area classification for a plant or facility will entail the evaluation for the releases, usually small, that are possible from the associated or ancillary features which typically will include valving, flanges, vents and sampling and drainage points, instrument connections, releases from rotating machinery such as pumps and compressors, ‘and any areas where spillage from the foregoing sources could collect, ‘Vents or large-size drainage points that would sive large release volumes, but which are plugged oF blanked off during operation, should not be considered in the area classification (see 5.1(0). In well-designed, operated and maintained facilities, therefore, such sources will usually result in secondary grade releases with a limited number of primary and Continuous grade, Subject to any restrictions caused by reduced ventilation within enclosed areas (see Chapter 6), the hazardous area will therefore mainly be Zone 2 with several smaller Zone J areas. Zone 0 areas would normally be restricted to the interiors of cone roof tanks, open sumps and any substantially continuous vents. 24 In principle, the classification procedure entails the consideration of all actual and potential sources of For this purpose, pressure vessels include il/gas separators TAvhinn tebotors exchangers, condensers, coolers, 16 Sree ck cepabty of smal unsecured piping 1 accidental damage Jhoid nevertheless be considered, as under 8.104. “flammable release. Wisimportant to identify and assess all continuous und primary sources of release to determine the extent of the resulting Zone @and Zone 1 hazardous areas, and wherever possible by design to reduce them both in number and extent. For secondary grades of release, it is often only necessary (0 consider those sources located towards the periphery of a plant that may affect the outer boundary of a Zone 2 area, since many plant arcas constitute a general Zone 2 area based on boundary features as outlined below. This consideration should include any areas where spillage could collect. ‘Should the equipment layout be such that it is not possible to assign a general Zone 2 area, then the hazard area provided by each secondary grade source oF group of sources must be examined. 25 In practice, therefore, the classification procedure can bbe simplified, using one or other of the two alternative methods that have been outlined in 2.6 and 2.7/2.8. 2.6 FIRSTLY, THE SIMPLIFIED DIRECT TYPE EXAMPLE FOR THE AREA CLASSIFICATION OF THE COMMONLY ENCOUNTERED TYPES OF PETROLEUM FACILITIES ‘Some arrangements of equipment within the industry areso common and similar in form and in nature ofthe petroleum material handled that experience with earlier codes has shown that they can be classified directly from typical examples. Such arrangements include drilling, workover and wellhead sites, storage tankage (both upstream and downstream), road and railcar filing and discharge, container filling, service station forecourts, and typical bulk installations employed in the distribution and marketing of pressurized LPG. Area classification type examples for these typical arrangements are presented in Chapters 3 and 4 ‘When applying these, the actual facility under consideration must not differ significantly from the type example in layout, type of equipment, class of petroleum fluid or the condition of temperature, pressure or ventilation state. IPno such differences arise users ofthis Code should proceed dirceily to Chapters 3 or 4. Where there are differences they should be taken account of as in 27, applying the procedure of Chapter 5 to the individual point sources of release and Superimposing the resultant hazardous areas on the ultimate standard drawingTHE TECHNIQUE OF HAZARDOUS AREA CLASSIFICATION As one example of a significant difference, the ‘examples given in Chapter 3 are for the typical open ‘area, oF not sigaificantly restricted ventilation locations that are normal for such facilities, In the event that these conditions do not apply the more specific approach of 2.7 or 2.8 should be followed. 2.7 SECONDLY, THE PROCEDURE, FOR THE AREA CLASSIFICATION OF LESS UNIFORM TYPES OF PETROLEUM FACILITIES, INCLUDING CRUDE OIL/GAS SEPARATION AND PRODUCTION FACILITIES, REFINERIES, NATURAL GAS LIQUIDS AND LPG PROCESSING For such non-standard design layout or processes, in which variabilities of temperatures, pressures and equipment will be encountered, and the degree and category of ventilasion may be different, the extent of the vaporization that would take place on release will vary greatly, making it necessary to apply the more specific point-by-point procedure of 2.3.2 provided for in Chapter 5. Differences in ventilation from the open area conditions typical in the type examples in Chapter 3 have been considered in Chapter 5 in accordance with Chapter 6. 28 ‘There are likewise individual ancillary items, such as Pump sets, valve stations, sampling and drainage points, pig launchers and traps, sumps, interceptors and separators and surface drainage, which are associated with facilities corresponding to those in 2.6 but which are not shown in, or may be separately located outside of, the diagrammatic type examples of Chapters 3 or 4: The extent oF these zone areas may be obtained by application of the point source procedure of Chapter 5, 29 ‘A guide to the sequence of steps required in the approach to the classification of all types of instal- lation, by either of the alternative methods of 2.6 and 2.7/2.8, is shown schematically in the accompanying Figures 1.1 and 1.2 to Chapter 1, together with the reference to the appropriate procedure and section/ chapter of the Code. 2.10 {In carrying out such an assessment, either by 2.6 or by 2.7/2.8, the following basic principles should be borne in mind: {a)_In the classification of a new facility or a ‘modification to one existing, the area classification should be carried out before the design and layout of equipment are finalized, as at this stage it may be possible to make considerable improvements at little cost and even some saving. The area classification again should be reviewed and ‘modified if necessary on completion of design, oF before any significant change is made 10 an existing plant or in the class of flammable petroleum fluids that are to be handled. (b) In the case where facilites, c.g. storage, pumps or loading and discharge facilities, may handle a umber of petroleum materials, the classification should be based on the most volatile of these to be anticipated. (©) Because of the imprecision inherent in area classification it is not good practice, even on an ‘open area, 10 denote small pockets of non- hazardous areas within a generat hazardous area unless these are a special feature of the design, eg. 4 ventilation protected enclosure. Likewise, itis normally not necessary to determine the hazar- dous area that would arise from each individual source of release when this would not influence the overall zone boundary. (@) The basie guidance set out in Chapters 3, 4 and 5, ‘except where otherwise stated, elates to open area conditions in which there is good ventilation to ensure the natural dispersion of releases to the ‘atmosphere. These correspond to the typical onshore petroleum facility consisting of struc- tures in the open, and where such conditions may apply offshore. (©) Where less well ventilated or enclosed situations occur, as arise commonly in the offshore sector and can arise in certain onland situations, guidance should be obtained from Chapters 5 and 6, covering the selection of ventilation state to be considered, In carrying this out, itis a good principle firstly to consider whether it is possible to avoid continuous or primary grade releases in reduced ventilation locations such as sheltered ot enclosed areas. Likewise, if itis possible to avoid a layout that, by obstruction, would create a sheltered area contiguous with the hazardous area of an adjacent ‘open area source of release, this will also simplify the area classijicavion (8) In some cases where 2 sufficient ‘straight line’ separation distance cannot be achieved between the potential sources of release and ignition toeee OE i tA AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS meet the direct usard cone extent, the inter- positioning ofa suitably dimensioned imperforate firewall may be practical (see 6.2.5) (g) Although petroleum fluids in any quantity can be flammable, it may be decided that certain loca tions handling only small quantities can, in the context of area classification, be classified as ‘non~ hazardous." For example, this may apply to laboratories for testing small petroleum fuid samples, Nevertheless, in such cases due pre cautions must be taken to prevent ignition possibilities from any type of ignition source (see also Chapter 8) 2.41 THE CLASSIFICATION OF PETROLEUM FLUIDS FOR PURPOSES OF AREA CLASSIFICATION Where the petroleum fluid is 2 liquid, its volatility im relation to the conditions of temperature and pressure at which a potential release might take place is an tssential factor, since it will determine he extent of rapid vapour formation from that release aad Ta many of the commonly encountered types of petroleum facility, such as are referred to in 2.6, the Classification of the petroleum liquid by flashpoint class, in accordance with the Institute of Petroleum classification, will be adequate for this purpose, with its further subdivision of Classes TI and IIT into sub- classes (1) and (2) according to whether the liquids are handled at temperatures above or below the flashpoint {see Appendix A and 2.12 10 2.12.6), This system is used throughout the type examples in Chapter 3. ‘A similar type example system is used in Chapter 4 to cover drilling and associated workover operations. 212 In other situations, as described in 27, in which extremes of fluid volatility, temperature and pressure cour under typical processing conditions and the procedure of Chapter Sis to be applied, four eategories Gf uid condition supplemental to the general classi fication by flashpoint have been introduced; these fluid categories are defined in Appendix B and their application outlined in 53.4. 23 For cases as outlined in 2.8, the simple interrelation between Classes I, I1(2) and I11(2) and fluid category cis not ponible to set a cutoff point, as tis oust be judged riot Bane circumstances For nsiance,thehazards of raising seeetine From a vehicle fuel tank in an closed garage SDHC oF gerolne ound inspection pit necessiate siret avoidance of all below eriprtfon and only Zone [ electrics! equipment should be permite. ‘enables the clas (Gee 2.12.6) fication by Chapter 5 to be carried out 22 THE APPLICATION OF THE IP FLASHPOINT CLASSIFICATION ‘The term flashpoint ofa liquid isexplained in Appendix ‘Ac and thus for practicable purposes is taken 2s the jndicator of the lowest temperature at which, in the presence of aif at atmospheric pressure, a flammable Fiquid wall give off suficiently rich vapour for ignition to vecur in the presence of a source of ignition. The diference between flashpoint and ignition temperature is explained in 85.2 ‘The IP classification system as in Appendix A, and its subdivision of Classes IT and II] according to ‘whether the condition of handling is at a temperature below or above the flashpoint, is in accord with the principle expressed in TEC 79-10: Anexplosive gas (vapour) atmosphere cannotexist if the flashpoint is significantly above the relevant ‘maximum temperature. ‘This principle is adhered to by CENELEC and in BS 534s. 'A Further principle applied in conjunction with the IP classification by flashpoint, and held in common with TEC79-10, CENELEC and BS 5345 (Part), is that on release in the form of mist, foam or spray @ ‘flammabie liquid can be ignited at temperatures far below the flashpoint ‘A tabulation showing the flashpoint, and thus the class of petroleum, of a number of commonly encountered petroleum products is included in Ap- pendix A. In applying the IP flashpoint classification in Chapter 3, and in those cases where itis used with the procedure of Chapter 5 for facilities described in 2.8, the two principles outlined above will take effect as in 2.121 to 2126 below. 212.1 Class 1 Petroleum ‘A Class [petroleum such as gasoline, ora gasoline type ‘component or a stabilized crude oil, with an extremely Tow flashpoint as indicated in Appendix. A, will always produce a vapour in the flammable range in air even at temperatures far below the ambient. Facilities han- dling Class T petroleum will always require to be area classified, as in Chapter 3 or, where this is used, by Chapter 5 (see 2.12.6 second paragraph) 2.12.2 Class 11 and I1t Petroleum and the Distinction between Subdivisions (1) and (2) In the case of materials whose flashpoint places them in Class TT or IIT these will often be stored or handled at temperatures below the flashpoint—ie. at tempera- tures which give rise to insufficient vapour for ignition. 10| | | | | | THE TECHNIQUE OF HAZARDOUS AREA CLASSIFICATION ‘The two principles in 2.12 should therefore be applied as in 2.12.3 or 2.124 212.3 Class 11) of 1(1) When & Class II oF IIT product eunnot be raised to the Hlashpoi (i, Class (1) oF I1(1)) not its release be in the form of a flammable mist. spray or foam, then for the purposes of rea classification the principles in 2.12 will apply, that such a liquid may be considered nat to sive rise to a hacardous area, so that hazard zoning is not necessary for the surrounding plant.” In such a case it must be confirmed that the liquid temperature cannot be raised by any means in the event of release, e.g, by contact with a hot surface ar Proximity (o an adjacent non-electrical source of ignition (see Chapter 8) As a typical example within the UK mainland a maximum ambient temperature of 30°C can be assumed. while typically offshore in the North Sea a maximum would be 24°C. Aviation fuels of the kerosine type (fashpoint 38°C minimum) may there- fore, under these conditions, be classed as non- hazardous when stored away from processing areas and hot lines and vessels. Because of the greater variability in temperature Class II liquids should, however, be regarded as hazardous, ie, Class [1(2), in processing areas and should be individually assessed in other climatic regions than the United Kingdom (see 3.1.4), 2.124 Class 1(2) or 111(2) When petroleum materials are to be stored or handled. that ate in the Class 11(2) or IHI(2) condition, or are likely to be exposed to conditions of temperature above the flashpoint, the facilities should be classified as laid down for Class 1. It will be seen that this is the procedure that has been applied in Chapter 3. For the alternative cases when the procedure of the point- source method of Chapter Sisto be applied to facilities in the Class 11(2) or I1I(2) condition, see 2.12.6 second paragraph, 2.12.5 Petroleum Products in the Unclassified Category (Flashpoint > 100°C) Petroleum materials having a flashpoint above 100°C san be given the subdivision accorded to Class IIT Petroleum and should be regarded as Class I11(2) when, handled at or above their flashpoints. A distinction, however, should be made between distillates in this unclassified range and products such {Because ofthe possibilty of mis, spray or foam formation during filing, itis nevertheless good pesesce when Class Til} of HI) Products are stored a fxed roo tank or ure loaded into a road or tank vehicle to consider theiatersal lage space as Zone 0. and an area within Im in diameter surrounding vents and other root ‘openings on thetopofsuch tanksas Zone / (ee note {10 Figure 31) mst also be appreciated that, inuddition wo is ammablity as mist and spray. 9 product below is fashpoin’ con be ignited, when Spread oul a¢a thin fim under ground spill conditions ot spilled onto clothing. ian ignition tource = pretent as bitumens, or residual or bunker fuels containing petroleum residue. When such materials are stored in heated fixed roo! tankage (wherein the ullage space is essentially unventilated), the flashpoint as sampled or recorded will not be indicative of the presence of absence of a flammuble wmosphere that may have accumulated in the ullage space. In common with the ullage space of fixed roof tanks or road of rail tank vehicles containing all classes of petroleum. the ullage space should be classified Zone 0, with a 1.5m Zone 1 surrounding vents and other roof openings (see note 2 to Figure 3.1. It should also be recognized in respect of heated petroleum of high flastpoint that although flashpoint and ignition temperature ae different characteristics, at very high temperatures the effects can converge, i. the high temperatures, for example, of a hot surface can ‘create a flammable condition locally which may be ignited by autoignition by that hot surface, as well as, by an alternative ignition source. 2.12.6 Application of 2.12.1 to 2.12.5 in this Code ‘Clauses 2.12.1 to 2.12.5 thus form the volatility basis on which the type examples of Chapter 3 have been based, ‘The wellhead releases dealt with in Chapter 4 need no further classification than already allowed for in that chapter. Where facilities as in 2.8 are to be classified by the Chapter 5 point-source method, but by reference to the lass of petroleum, the relationship between ‘class of Petroleum’ and fiuid category has been given in notes 4 and 5 10 Appendix A and in the note to 5.5.4. From these it will be seen that Class I, TQ) and I11(2) conditions all fall into fluid category C, ie. liquids handled below their boiling point (see also 3.1.4), ‘The ‘finding tree diagrams’ of Chapter 9 will make the above distinctions of procedure clear. 2127 Grade of Release ‘The grade of release has been inbuilt into the type examples of Chapters 3 and 4. For releases to be classified by the point-source method of Chapter 5, the grade of release should be determined as in 5.4. 2.12.8 Buoyaney of Release ‘The operations covered in Chapter 3 will have releases that are heavier than air (see 1.8) and this buoyancy has been allowed for in the type diagrams. Likewise, the buoyancy of the wellhead fluid releases in Chapter 4 have been allowed for in its sections (see Appendix C) ‘Those dealt with in Chapter 5 may be in cither the lighter or the heavier category, and the procedure outlined in Appendix Cand 5.5.5, to take the buoyancy factor into account, should be applied. Where a release can be both lighter and heavier than air, eg as on a hy¢roprocessing plant, see note (b) Appendix C.AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 2.43 COMPLETION OF THE AREA CLASSIFICATION BY SPECIFICATION OF APPARATUS SUB-GROUP AND TEMPERATURE CLASS. To permit the selection of electrical equipment appropriate to the arew classification, the apparatus sub-group and temperature class should be determined during the area classification based on the flammable Substances that can be released, and this information added :o the drawing and/or records. For this the guidance given in Chapter 7 should be followed Tn applying this the effect of abnormal operations, for example startup and shutdown, should be consi- dered, since such operations may affect the com- position of any substances released and hence their lashpoinis andjor autoignition temperatures. However, it may be reasonable to ignore any such abnormal composition if it is expected co exist within the plant for less than 100 hours per year and provided that there is no continuous ot primary grade release during this period. Secondary grade sources are not likely to release during such a period. See also Appendix F where internal release within apparatus may occur. The apparatus sub-group and temperature class appropriate to crude oil and for various petroleum products are listed in Table 7.2 in Chapter 7. When. mixtures of substances can be released the most restrictive appararus sub-group and temperature class should be specified. If gases belonging to more than fone electrical apparatus sub-group and temperature class are present in non-overlapping areas then it is acceptable to show different groups and classes, Tn considering wide boiling range mixtures or mixtures of gas and liquid the apparatus sub-group should be based on the properties of the gas or vapour that would be released, For example, in the case of @ gas oil hydrotreating process unit in a refinery, it Should be based on the hydrogen-rich recycle gas. A gas containing hydrogen should be regarded as hydrogen when the hydrogen content exceeds 30% vol. 244 For the releases considered in Chapter 4, the apparatus sub-group and temperature class will be TA and T3 respectively, In areas where hydrogen may be present, such as battery rooms, the classification should be TIC and TL (see 719). 2,15 THE AREA CLASSIFICATION DRAWING ‘Area classification records can comprise detailed Grawings with notes and/or can be in the form of 12 tabulations. The area classification drawings should be in sufficient scale to show all the main items of equipment and all the buildings in both plan and levation, including the positions of all openings such ‘as doors, windows and ventilation inlets and outlets, and utility entries if not sealed vapour tight.* They should be marked up to show the boundaries of all hazardous areas and zones present using the shading convention adopted in BS 5345 and shown in Figure 2.1. It is acceptable to indicate any requirement for ‘small local zones/areas,.g, around pumps and control valves, in a note on the drawing, Zone 0 ote: Where i desired to distinguish lighter than air froma “penvir than ai? zones o9 the same drawing, this can be done by ‘ing halt spacing for the hatching ofthe former zones. Figure 21, Ares classifeation ymbols “The drawings and/or notes must indicate where the classification depends on the correct operation of @ special ventilation arrangement. It should consider and indicate the effectof failure of such an arrangement (see 65 and 65). “The preparation of the area classification drawing provides an opportunity to check that the coverage of all sources of release has been comprehensive. Tt also provides an opportunity for smoothing zone bound- aries to remove unrealistic detail. It may be desirable, asin 2.10(¢),to adopt physical plant features, e.g, roads oraccess ways fora readily defined zone boundary line, provided the zone boundary from any source is within these limits, Tt will normally be unrealistic for hazardous areas and zones to be shown encapsulating or largely ‘encapsulating smaller non-hazardous areas, except Where there are vapour-tight physical barriers and special ventilation arrangements to avoid ingress of ‘flammable atmospheres as described in 6.5. “The careful positioning of these openings cun affect the sizing of felated external hazard cones3 THE CLASSIFICATION OF STORAGE TANKAGE, BULK LOADING AND UNLOADING BY ROAD AND RAIL, PETROLEUM JETTIES, AND BULK DISTRIBUTION AND MARKETING FACILITIES BY THE METHOD OF DIRECT EXAMPLE 3.1 SCOPE The procedure in this chapter follows that outlined in 26, for classification of those oil industry operations that are carried out in facilities so similar in layout and the material handled that they can be classified direct, From typical examples. 3d These examples inciude: (2) Tenkage for upstream sector onland storage and distribution of stabilized crude oils; tankage throughout the downstream sector in refineries for crude oil and intermediate and finished Products, in bulk distribution installations and in large-scale consumer receiving premises. ‘The tankage therefore includes the floating roof and fixed cone or dome rocf type (including those which have an internal floating cover), buried or mounded tanks and service station tankage. (b) Road and rail loading and discharge, primarily for refinery and bulk product distribution, but also relevant to the upstream sector in which there is conveyance of stabilized crude oil by these means. (©) Marine facilities for loaditg and discharge. (Drum filing. (6) Retail dispensing on the service station forecourt, () Tankage for high volatility/vapour pressure stocks, eg. Class © (LPG) requiring pressure storage. 312 Class of Petroleum With the exception of (f) above, the products associated with these type examples will be those 3B Classified as Class I, 11 or ITI petroleum, The guidance of 2.12 to 2.124 should be applied. This includes the distinction between Classes 11(2), I11(), 111) and M1}, 313 The following sections 3.2 to 38 therefore give guidance on the area classification applicable to such typical facilites as described. The actual site must not differ appreciably from the example in the layout, equipment size or degree of ventilation. Where there are Gifferences they should be accounted for by con- sidering the individual sources of release and super- imposing on the standard drawing as applicable. 3.1.4 Climate Variations The hazard zone dimensions ia the following diagrams take as their direct basis long-term temperate climate experience in the storage and handling of Class 1 Petroleums (i. gasoline specification produets and Stabilized crude oils of comparable vapour pressure) at a bulk liquid temperature up to 30°C. This is the maximum ambient temperature that may be assumed in the UK mainland (see also notes 3, 4 and 5 to Appendix A). For a Class I product iandied at a temperature of 30°C of above, or for a petroleum mixture ot product containing appreciable quantities of butane or lighter hydrocarbons, the extent of hazardous area should be Breater than the recommendations given in this chapter. In the more pronounced cases, eg. high vapour pressure condensates, or very light hydro- carbon petrochemical feedstock, or blending compo- nents, it may be safer to consider the liquid as a Class O Product as in 3.9 or to apply the appropriate fluid category to the point source procedures outlined in Chapter 5,AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS The division between the Class Hof IT] subdivisions {4) and (2) will also depend upon climatic levels and, in ‘areas outside the United Kingdom, it wll be necessary to determine the maximum ambient temperature levels and the influence that they may have on handling Temperutures [tis to be noted that in Appendix A there is also an upper limit (o the temperature ai which the Class {1(2) of HI) condition should be applied— namely the temperature at which the liquid would dttain the boiling condition (above which the liquid should be regarded as.a fluid caregory'B or A fluid). For none of the handling operations involved in storage. Joading, discharge, etc, that are dealt with in this chapter are these limit temperatures likely to be encountered. 31S Unclassified Petroleums Petroleum products falling into the “Unclassified Class’, ie. flashpoint > 100°C, may, according to the temperature of handling, ether be considered as non- hazardous or, at temperatures in excess of the ‘flashpoint, be considered as Class I11@) liquids However, when unclassified products such as bitumens and heavy residual and bunker fuels are stored under confined heated conditions in fixed roof tanks, flashpoint as sampled is not a sufficient and reliable guide to the presence or absence of a flammable trimosphere that may have built up in the tank vapour Space. For this reason itis prudent, as noted in 212.5, to classify the ullage space of all such tanks as Zone 0, ‘with a small Zone 1 around roof vents and openings. Reference may also be made to the IP Bizumen Safety Code, as now revised (1990) 3.2 STORAGE TANKS (FIXED AND FLOATING ROOF) IN OPEN AIR VENTILATION—CLASSES I, (2) AND T1K(2}—GENERAL “The following type examples apply to both upstream and downstream tankage as defined in 3.1. The examples apply directly to the storage of Class 7 petroleum liquids, for which there should always be Height of bund jt vifgia Gietonce ro buna such « zoning. This guidance may be applied, where Such conditions arise, to the storage off Class 11(2) and THI) liquids (see 3.14) ‘As indicated in 2.123, petroleum liquids that are stored under Class 11(1) of 111(1) conditions will not hormally entail a surrounding external hazard zone requirement in respect of clectrical equipment. Tt is good practice to restrict electrical apparatus within the bund to the minimum necessary. Pumpsand their drives should not be sited within tank compounds (see 3.2.4), 21 Fixed Roof Tankage—Classes 1, 11(2) and IQ) On fixed (cone or dome) roof tanks the ullage space should be classified as Zone 0. This applies also to tanks fitted with internal floating covers ‘The vent system on the tank roof should be ‘considered a primary grade source of release. Vapour will travel along the surface of the roof and fiow downwards close to the tank shell. The area extending ‘3m upwards at right angles to the roof surface, 3m, horizontally from the roof edge and 2m vertically down the shell from the roof edge should be classified as Zone |. ‘The area within the tank bund up to a height equal to the top of the bund or up to Im, whichever is the greater, should be classified as Zone 2 or, with any pits for depressions, Zone 1, because of the greater tendency of heavier-than-air vapours to persist (see 6.5 for further information). ‘Ata distance of 3m from the shell, Zone 2 should be extended upwards to meet the Zone J area. This is shown in Figure 3.1 for the case of a bund which is concentric with the shell of the tank, Where the bunds not concentric but is closer to one side of the tank shell, it may be desirable to adjust the zoned distance accordingly. 3.22 Floating Roof Tankage—Classes 1, 11(2) and me) The hazardous zoning around a floating roof tank should be drawn as in Figure 3.2. The space within the tank shell above the roof should be classified as Zone |. Notet: 1. Because ofthe possibilty of misty spray foam formation the wllage space of Cass MU} and TL) tanks should abo. be regarded as Zone tis recommended that Thearea surrounding any vents or openings ‘onthe root of such tank be regarded 2 Zone | 92 Siameter of 1m se 2.123. 2. Sec also 31.5 for heated residual fel and bitumen tanks Figure 34. Cone or dome roof tark—-Chasses f (2) and 112) 14edie wor sunmeweroinn, CLASSIFICATION BY DIRECT EXAMPLE Nove: This clasiteaion i basal on the practice that the cont wil not be grounded on its egy daring the operational cycle, since the space so” crested below the roof would draw in air and create the possibility of ignition caused by Tieton, Roa should ‘only be landed for inspection, ceeniag and maine fenanee under carefully supervised work permit control. Any vapour space below the root or between the primary and secondary seals shouldbe rested ae Zone EN Height of bund Whole distance tobund Figure 3.2. Floating rot tank The area above and around the tank shell for @ distance of 2m should be classified as Zone 2 and should extend, at the height of the bund, to the bund wall. Any pits or depressions within this Zone 2 should be classified as Zone J. 323 On any fixed or fioating roof tanks with an outer protective wall, the annular space between should be Classified as Zone 1, whatever class of petroleum is stored. The remaining area around the outer wall should be classified in accordance with 3.2.1 or 3.2.2 (see Figure 3.3) 324 ‘The hazard zoning as in 321 or 3.2.2 above will normally be adequate for the fisings on the tank shell, (2) Flooting reat tank BB zone Zone 2 (b) Cone root tonk Figare 33. Tenk with outer protective wa but it should be confirmed that there is no equipment ‘or release within the tank bund which would extend the ‘hazard area. {f this cannot be confirmed, the procedure outlined in 2.8 and Chapter 5 should be applied, Equipment, whether electrical or non-electrical, that could serve as a source of ignition should not be installed within the tank compound unless suitably protected in accordance with the requirements of the area classification. See Chapters 7 and 8, which also give guidance in respect 0 the introduction of temporary equipment eis good practice to restrict electrical apparatus within the bund to the minimum necessary. NOTE: Additional guidance as to the recommended safety spacings between tanks and the public bound- ary, and to other facilities including sources of ignition, will be found in the IP codes ceferenced in 8.13. 3.25 Below Ground or Mounded Tankage (Pump Fed) Where underground or mounded storage has been Provided, the vent from such a tank should be regarded as a primary grade source with the extent of the Zone J hazardous area dependent upon the filling rate in accordance with Figure 3,4, re S = Ground Filing rate 2 Ds (a) (a (a 600 oF les 15 5 More than 600 3 0 Figure 3.4. Vent fom underground or mounded tank, pump fed— ‘Classes 112) and 11}AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS Seo note 2 Ground tovel ‘Notes: 1. Vent pipe opening must have at east 3m of five space around it in all directions to allow dispersal of vapours, and be avay from open windows, doors ec. 2. The height ofthe vent above ground level must be greater than the possible hauid level im any road tenker delivering to the tank, fo prevent overspil and in no case less tnan'5 m above ground level igre 35. Underground tanks, gravity fed, vent pipe diameter below 70mm—Claset I 12} and 112) ‘The tank tunnel providing access to such under ground and mounded tanks will normally be an enclosed area. It should be classified in accordance with Chapter 6, after considering, as in Tables 6.1 and 62, the effect of any artificial vemiilarion system, 32.6 Gravity-fed Underground Tanks Underground tanks fed by gravity are normally restricted to filling stations, or small industrial or domestic premises. Their classification is covered in Figure 3.5 for vents and in 3.4 and Figure 3.11 for the tank manhole and offset fill pipe chamber. 32.7 Mobile Tanks, Road and Rail Tank Vehicles ‘The principles expressed in 3.1.2 to 3.1.5 will apply to the interiors and vents of tank vehicles (see also 3.3.4.3 and 33.3) 33 ROAD TANKER LOADING— CLASSES I, 11(2) AND I1@) 33.1 Introduction This section covers both top and bottom loading for Class I petroleum products in the normal case where such facilities are located in an open area, under temperate conditions of climate as defined in 3.1.4. Twill apply to the loading of stabilized crude oil into road tankers and to cases where Class TI and 111 petroleum products are to be loaded in the Class 1(2) tnd IQ) conditions, ie. at temperatures above their fashpoints. Where Class JI(1) oF 111(1) products are to be loaded in facilities separate from the handling of Class 1,112) or I11(2) products, except for the classification of the internal tank compartments as Zone 0 to safeguard against foam, mist or spray formation, the recom- mendations that follow need not be applied provided that the hazards described in 2.12.3 cannot occur, as would arise where switch loading is to be practised with any of the road tanker vehicles that may be presented for loading at such a facility. Switch loading, Which should be avoided wherever possible, is the situation when a low vapour pressure product such 28 kerosine or gas oil is loaded into a vehicle compart- ‘ment which has previously contained a high vapour pressure product such as gasoline so that a hazardous ‘atmosphere may remain in the vapour space. In such case the loading facility should be classified as in 3.3.3 below for a Class I, 11(2) or I11Q) product. (In all cases, whether switch loading is practised or not, precautions to prevent ignition, in the event of a aground spill, by any source of ignition should of course be taken.) 332 Open Air Facilites {As depicted in the type examples that follow, loading stands of gantries should normally be located in the ‘open air. A roof for weather protection is acceptable but any sides should not unduly restrict natural ventilation and should aliow the space below the roof to be regarded as a sheltered area, as depicted in Figure 36. 16CLASSIFICATION BY DIRECT EXAMPLE Tooding arm t Senin 2m 4 Elevation min 10 ported sosition of arm) Zone 2 in Foot areas. Bey (see note) Pion applies toll fred electrical equipment. The bay areas marked se noe’ between the gantry islands canbe considered ‘Note: The above zoning nonchazarcousin the absent c¢ of pillage and with loading arms inthe parked position in readines fr theentry of lesving ofthe road tanker with its manlids cose. Figure 36. Road icading facilities, top loading, no vehicle present—Ciasses I 12) and 112) 333 The Top or Bottom Loading of Classes {, 11(2) The results of these steps are then amalgamated to give or 1H1(2) the final classification, which will apply at all times in The approach to the classification for top or bottom _ respect to the installation of all fixed and temporary loading is carried out in accordance with the steps electrical equipment: ee (@) Tis self-evident that the whole arrangement must ; (a) The loading facility with no vehicle present. Permit the movement of vehicles to and from the (&) The classification of the vehicle, including the loading position and this must take place with the ‘operation of filling. lozding gantry and vehicle in a hazard-free state (© Any consequent spillage This is achieved by the recognition that cervainAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS zones that overlie the area of an entry bay are transient and may, under controlled and safe conditions that are laid down in this Code, be put into temporary abeyance for the entry, and subsequent departure, of the road tanker vehicle. 334 The Classification for the Top Loading of Road Tankers—Classes 1, 11(2) and 111(2) Following the principles established in 3.33 the analysis should be carried out in stages as follows The hazardous zones around all possible sources of release, which could arise from the installed gantry ‘equipment and slop facilities in the absence of a tank vehicle, should be assessed and a practical envelope devised (see 3.3.4.1), Then, when the vehicle has taken its position in the loading bay and manlids are to be opened, the additional zones which arise whilst vehicles are being filled should be determined (3.344). These zones are transient and will not exist when the manlids are closed and the loading arms have been returned to the parked position. Spillages, which could arise during tank vehicle filling and from other operations such as filter cleaning exc, should however be considered and a zone setermined appropriate to the rate and duration when these could occur in practice, bearing in mind the degree of manual participation involved (3.3.45). This zone is designed to ensure that only appropriate electrical equipment is installed within its boundaries. Tis self-evident that, when 2 spillage occurs, vehicles should not be started or allowed to enter or run within the designated area until authorized to do so, afer all hazardous spillage has been removed and/or gas tests have proved the atmosphere safe 3344.1 Classification of the Gantry—No Vehicle Present For this condition the gantry should be classified with the loading arms in the parked position. The lower part of the arms after use will have internal and external wetted areus and evaporation and drainage can take place. Because of the frequency they should be regarded as primary grade, giving rise to a Zone I extending vertically from the island base level to the height of 1.5m above the open end of the loading arms in the parked position of the loading arms, as shown in Figure 3.6 334.2 Weather Roofing Irrespective of whether or not pipe work is installed in the roof space, itis recommended that the whole of the roof space, other than that which may already be within the above-defined Zone J area, should be classified as Zone 2 (refer to Figure 3.6) 18 3343 Classification of the Roud Tank Vehicle Before dealing with the filling of the roud tank vehicle it should be noted that the internal space of the compartments of a road tanker for all classes and subdivisions including M(1}, III(1) or Unclassified, whether top or bottom loading, should be classified as Zone 0 at all times that the vehicle is in service. However, when all mantids and outlets are closed, the exterior of the vehicle can be classified as non. hazardous. ‘With the vehicle in this condition it should be noted that the unoccupied space of an empty bay between the Zones J of adjacent loading islands will allow the safe ‘entry of the road tanker, and its ensuing departure when loaded, subject in both cases to checks that no spillage has occurred and loading arms are in the parked position (sce also 3.3.4.6(5) 3344 The Classification of a Top Filling Road Tank Vehicle during Loading of Classes 1, 11(2) and HN(2) Petroleum Additionally when at the loading stand, with engine off and all electrics that are not explosion protected isolated by the vehicle double-pole master switch, a further Zone 1 will be generated when vents and manlids are opened or filing connections made or disconnected, Tt has been established that the hazardous area of vapour emission from venting manlids during loading ata filling cate of 2.5m? per minute extends in all directions to less than 1 m for Class I petroleum. It is recommended that an area extending in all directions to a distance of 1.5m from the edge of the opening of each manlid, with a vertical drop to ground level, be classified as Zone 1, so allowing for the adjacent manlids and any spiligge from the loading arms whilst being removed, These extents are shown in Figure 3.7. NOTES: 1. Theabove distances allow for the possible release of product from draw-off valves when used for adjustment of load. This same classification will apply when bottom loading road tankers are being filled with open mantids at a top filing installation 3345 Spiliage In addition to the aggregated Zone J areas of Figures 3.6 and 3.7 during the filling operation, a conditional zoning should be provided in respect of fixed electrical equipment in areas where there could be spillage. Such spillage in the loading area should. be considered as a secondary grade source of release. Itcan occur from filters during routine servicing, from the components of pipework systems and, despite the provision of overspill protection devices (see 3.3.7) inCLASSIFICATION BY DIRECT EXAMPLE 15m Side eteverion 15m, Zone 0 Inside tank 1.8 EB en ‘Notes: 1. This classification applies sso for botiom loading with open venting (es 33.5306) 2 Internal Zone 0 for compartments applies (oral lasses of petroleum, Figare 37. Filling of road tankers, top loading through open or vent manlids Classes f, 12) and 112) ‘most up-to-date facilities, from overfilling of vehicle Compartments at rates up to the maximum loading rate, The extent of a spillage should be assessed according to the expecied duration of such an Occurrence with due regard 10 surface grading and drainage systems. Overfilling a vehicle is likely to result in the formation of the largest wetted area or pool Details of surface area drainage (ie. the grading of the paved arca and positions of collecting points, ducts and channels) must be known, Hence the size of poot likely to be formed for a given possiblity of spillage. rate and duration can be estimated. ‘The size of the hazardous area (Zone 2) from these secondary grade sources should be based on the recommendations in 5.11 and the spillage for this Purpose should be assumed to be Category C liquid ‘Where there isa drainage channel, kerb or other means of containment around the gantry area, then no flow of spillage outside the channel or containment area need be considered, but the further extent of vapour travel should be taken into account. Ifa means of containment is not provided around the loading gantry area the likely extent of a spillage ‘must be assessed considering the surface grading. The total hazardous area will normally be greater than that where containment is provided. See Figure 38 for typical zoning‘Notes: 1, This zoning applies tothe installation of fixed electrical equipment Such silage 3346 The Composite Classification Drawing @) Oy AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS of a g & l i } Z ZZ LLL Z Etevotion Drainage channel oroinoge system Z tan present See the note to Figute $9} 2. Dimension beyond drainage channel asseied asin 3.345. Figure 38. Typical Zone 2 provision for spillage fs normally non-hazardous where no silage is ares with drainage control as laid down in the guidance given in the IP From the detailed analysis carried out in steps Marketing Safety Code. These controls include: 3.3.4.1 t0 3.3.4.5 itis then possible to put together a 0 composite of Figures 3.6 to 38, resulting in the final drawing illustrated in Figure 39. ‘Attention should be drawn to the note to Figure 3.9 since the whole arrangement must permit the «ay ‘movement of vehicles to and from the loading positions, with the loading gantry and vehicle in a hazard-free state, This is ensured by operational Ifa loading bay is occupied, an approaching vehicle should not come closer than 6m from the loading position, and the engine should be stopped. A check should be made that, when an adjacent loading position is occupied by a road tanker that is filing, there is no vapour spread ot spillage from this activity (orCLASSIFICATION BY DIRECT EXAMPLE Step 1 Simple aguregntion of Figures 3.5, 37 and 38 18. See note Zone. Zone Zone Spiltoge creas: Step 2 Final composite. with infil of reas as shown on lef of figure. For reatment of unoccupied bay on right in coadition to receive road tanker, se note — seenote & Zane ore tore 3 $ $ pain) he Normally free from hatard when ne spillage present Not: Trancliory non-tezardous condition of the Zane 2 spillage ares ofa bay when empty with no spilage presen that allows entry and ‘Separture of the road tanker with manlis closed and loading arms in lowed posivows Figure 39. Final compost classfeation—typical road tanker (op londing installation ~Clases , 142) and 12) indeed that no breaking of anges or ieakage until the area has been pronounced safe by from maintenance on these adjacent loading the supervisor in charge. positions has occurred hat would render the (iv) Shoulda fire occur during loading (or ‘entry or departure of @ vehicle unsafe). unloading) all operations should be stopped (Gi) In the event of a spillage all loading opera- immediately and unaffected vehicles should tions at the loading points concerned, and at be driven clear. all adjacent loading pesitions, should cease immediately and all foot valves should be 3.3.4.7 Factors of Design and Construction of Road ‘closed, if they are open for off-loading or Tankers, including both Engine and Electrical bottom filing. tn the case ofa spill of Class Equipment, that are Ancillary to the above Area or IH2) petroleum no vehicle starter should Classification be operated until the spill has been cleared, Such factors relevant to the classification procedure, and loading should not be recommenced including eiectrical connection made between overspill 21AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS {high-level cut-off) devices on the vehicle and the touding gantry, and earthing and bonding, will be dealt with in 3.3.6, following the sections on bottom loading. 335 The Classification for Bottom Loading of Road Tank Vehicles—Classes 1. 11(2) and 11(2) 33.5.1 AA detailed analysis should be carried out usin 3.3.4.1 t0 3345 for top loading, from which a composite classification diagram will result Three bottom loading cases may be distinguished: (2). The case of bottom loading where there is free venting of the vapour discharge through vents on the manlis. Bottom loading where there isa vapour collection ‘manifold on the top of the road tanker as outlined in the IP Code of Practice for Road Tank Vehicles Equipped for Bottom Loading and Vapour Recov- ery. In that Code standardized dimensioned layouts between the vehicle and the loading island coupling points have been laid down for the loading and vapour return connections 10 be ‘made through self-sealing hose couplings, thus enabling exchange pick-up arrangements 10 be made at all loading sites so equipped There is no discharge of vapour ‘through compartment vents as in (a] and, since the vapour line and product hoses are closed systems with selF-sealing couplings, there is only a secondary source of release during coupling and uncoupling. Where the loading terminal is equipped for vapour recovery, the mating coupling for the vapour connection on the loading stand is piped toa vapour recovery system sited separately from the loading area, Where vapour recovery is not installed, the IP Code provides for the hose coupling to be mated with a piping system leading to a safe venting point at an appropriate height in the open air above the installation. For the case of a bottom loading vehicle that is to be loaded ata top loading installation, ie. through open manlids, the area classification as outlined in 3.34 to 33.46 and Figure 39 will apply and further consideration need not be given. (b) © 335.2 Weather Protection/Overspill Protection— Bottom Loading In cases (a) and (b) above, overhead protection against ‘weather can be dispensed with, as manlids are not open. for loading purposes. Where, however, extremes of climate make weather roofing desirable, the guidance given in 3.3.4.2 may be followed. Overspill protection by an approved high-level cut- off device is prescribed as standard practice for bottom Joading, and the recommendations in the IP Bortom Loading Code should be noted. The electrical connec- tions for such a system should conform to 3.37. 2 3353 Case te Classification for Borrom Loading of @ Roud Tanker with Free Venting—-Classes 1, H(2) and 11102) Bottom loading operations are carried out from ground level and, because of the absence of the elevated loading arm/walkway arrangements of a top loading installation, the classification requirement is greatly simplified. particularly where weather roofing is not a requirement, The three-step analysis therefore should proceed as follows: (@) Classification of the ground level loading island. Sealed couplings are normally used for the loading connections, from which 2 secondary grade source of release may occur due to leakage. Secondary grade sources of release can also arise due to accidental spillage when the couplings are broken and from filters und their associated equipment. It is therefore recommended that the whole of the loading island be classified as Zone up to a height of 2m above the surface level. This will cover accidental spillages in an area where frequent making and breaking of connec- tions occur and loading is taking place with manual participation. This is shown in Figure 3.10. The horizontal and lengthwise extent will be determined so as to accommodate the loading position of the road tank vehicle and its vent ‘openings (see (b) below). Classification of the vehicle during loading. For vehicles loading with free venting this classi- fication will follow identically that given in 3.3.44 and Figure 37 for top loading. This is shown in Figure 3.10 Provision for spillage. Likewise this should be identical to clause 3.3.4.5 and Figure 38, with a transient Zone 2 area as shown therein, applicable for fixed or temporary electrical equipment. Notes 1 and 2 to Figure 3.8 will be applicable, allowing safe entry ang leaving of the road tanker vehicle in the absence of a spillage, and with operational control of vehicle entry and departure as in 3.3.4.6(b). This transient Zone 2s shown in Figure 3.10. () © 3354 Case 2: Classification for Bottom Loading of @ Road Tanker with Trunked Closed Vapour Collection with or without Connection 10 @ Vapour Recovery Unit The design basis for this case is provided in the IP Bottom Loading Code. Vapour emissions are trunked down from the collection manifold on the vehicle top to @ low-level matching connection on the loading island, coupling being by self-sealing hose. From this the emissions are trunked to a vapour recovery unit or, when this is not provided, to a vent direct to atmosphere in a safe location. There is thus no freeCLASSIFICATION BY DIRECT EXAMPLE. venting in the loading area from compartment maniids. With this exception, the remaining analysis by steps (a), (b) and (¢) of 3.3.5.3 are relevant. Since there is no free venting, the only circumstance in which a discharge to the open can occur is in the event of a failure of the high-level cut-off system activating the emergency venting reliefs on a compartment, The possibility is remote since the IP Botcom Loading Code requires the design of the cut-off system to be both self- checking and fail-safe, Furthermore, it would have to be presupposed that its failure would be preceded first and simultaneously with the failure of the preset delivery control system on the loading stand, Accord: ingly itcan be graded asa secondary grade of release of low probability In an open air situation, without weather roofing, the composite classification of Figure 3.10 should be retained, but the Zone / area up to the 2m vertical height could be considered regraded to Zone 2. Where weather roofing is provided, the area above the Zone J height should be Zone 2 throughout the oof space. 33.55 Safe Disposal of Vented Vapours under 33.54 Where the vapour emission is routed to a vapour recovery system, the latter will be at some distance from the loading areas. With the recovery system in operation the tail end emissions will be lean in hydrocarbon level However, tallow for process upset the vent should be regarded as a secondary grade release, and its hazard cone should be assessed in accordance with $9, ‘Where a vapour recovery system is not provided, the IP Bottom Loading Code recommends provision to enable the vehicle vapour colection manifold hose connection to be coupled to 2 vent outlet removed from the loading area and at least $m above ground level: alternatively the hazard zone from such a vent could be assessed by application of Figure 3.4 (see 3.25) to determine the hazard sone dimensions, since the situations are analogous. Because of the frequency of most loading operations the grading should be Zone |. 33.6 Design and Constructional Requirements for Engines and Electrical Equipment for Road Tank Vehicles Utilizing Loading Facilities Classified in Accordance with this Code Such vehicles should conform to national statutory regulations. In the United Kingdom, for Class T Petroleum these are contained in 11059 (1981), In Outline these requirements may be summarized as follows: (@)_Alletectrical equipment that is operational during 2B ib) © (a) loading must be certified for the particular zone Fequirement (whether energized Irom the tractor Unit Battery or from equipment on the loading rack). ‘The electrical equipment which is fed via the double-pole master switch need not be classified since the master switeh is off during loading and discharge, and is only made when the vehicle Feverts to a non-hazardous classification, ie, no sources of release present. ‘The driver's cab is considered a safe area, subject 10 the conditions detailed below. The atea to the rear of the cab and in front of the trailer is adjacent to the Zone } area generated by top loading, and this distance is @ function of the location of the front compartment mantid. A similar situation will apply in the case of emergency vents on a bottom loading tank vehicle. Hence it is prudent to specify that any electrical equipment located in this area should be isolated by the master switch during loading or discharge. Any clectrcal equipment fed from the live side of che master switch should be suitable for Zone 2. The master switch should also be certified for Zone 2 and protection from moisture and dust ingress should be to IP 65 (see 7.8), Electrical equipment mounted in the cab which is {0 be operational at all times (ie. fed from the live side of the master switch) shall conform to the following. It should have a separate double-pole isolator and MCB or double-pole isolator and fuses 10 Protect both the equipment and the supply cabling from the high fault currents which are available from the vehicle battery. This protection should be located as near as possible to the battery terminals in order 10 minimize the length of unprotected feed cable. Al wiring is to be insulated and sheathed, and fully protected from vibration and mechanical damage. All terminals are to be vibration-proof. Equipment and housing are to be vibration- proof and protected to at least IP $5. Electrical equipment mounted outside the cab and circuits and wiring located outside the cab but connected to equipment inside the cab shall be certified suitable for use in the zone(s) through which it passes or in which it is located. Where different zones are involved the type of protection shail be suitable for the most onerous. Where radios, telephones, printers or other data recording devices are installed in the cab they should be fed via the master switeh and hence isolated during the loading operation, Earthing and bonding. Full details are given in the IP Marketing Safety Code and in the IP Elecirical Safety Code, 1990 revision,AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 1.3m | ' See 3.3.5.3(). step 1.8m. Infit zone 1 4 2 33.5.3(0) 0 O° Interna’ zone © with ver er air times one Connections Pian cloves “This sheet shows individes! components of the classification prior to infill and the addition of the spillage zone (Step 1) _ 7 Noe nation, there willbe a Zone plage aes superimposed forelcral equipment m highas in33.5.16}—when no sil presenti safe for vehicle entry or departure as in the note to Figure 3.9. “ ae . Figure 3.10, Road tanker, bottom loading with tree vent rough mand vents—Classs I, 12) and 1112)}—no weather roofing 4CLASSIFICATION BY DIRECT EXAMPLE, j-Boundary of transient Sone 2 spillage orea, See nates 1 ond 2 Zone t of filing vehicle 09 per 33.53 (b) inttied zene + Zone 1 of loading ‘stand 08 per 3.3.5.3 (0) (Internal zone 0 i Adjoining 1oasing istang tone | Illustration of entry into empty bay in safe condition of no spillage Present ond all connections ané montids closed. See note | Composition with infll and indication of transient Zone 2 spillage area (Step 2) Notes: 1. Transient spillage zone ares normally free from hazard wen no spillage is preseas. 2 For determination of eaten of spillage Zone 2 area (eee 3345). 5: Spilage will extend 25 shown by dotied lines Dependent apon number of loading islands and boys 18m 1.5m \ : \ 20 -L - sath yee of tanker See ‘Note: 4. I'weather roofing provided al space above the Zone J area will be Zune 2 upto the root (ee 33.82) Figure 3.10.—Comd, 25AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 337 Overspill Protection/High-level Cut-off Standardized overspill protection is recommended for high-capacity loading facilities, both for top (3.3.4.5) and bottom loading (3.3.5.2), and the IP Bosom Loading Code provides a recommended basis of design, This design provides for a ten-pin plug and socket between the tank vehicle compartments and. the facilities on the loading stand, The location of these sockets should meet the requirement of the area classification by the following measures. 3.4 ROAD TANKER DISCHARGE— CLASSES I, 11(2) AND 112) Bad The following analysis takes into account the fact that, unlike the classification of @ petroleum installation where there is no access except by trained persons, there isa free access of members of the public and their ‘motor vehicles which is peculiar to the conditions 3m applicable to the areas of the service station at which discharge of a road tanker may be taking place, 34.1.1 The Fill Connections as the Receiving Tait Road tankers are discharged by gravity into the underground tanks of the service station by one of the systems shown in Figure 3.11, ie. either fil point in the pit or manhole chamber of the tank, or by offser fil ‘point in which the hose connections can be made above ground or in a separate pit ‘The area classification will be as shown in Figure 3.11 follows: (a) Within the tank itself and within any manhole chamber or pit in which there are tanker delivery hose connection points—Zone 0. Within any manhole chamber not containing tanker delivery hose connection points—Zone |. For the tank hose connection points in (a) or (b) there will be a Zone 2 hazard zone vertically for 1.28m above forecourt level, extending horizon- tally for 3m and coming down to forecourt level, at a radius of 4.25m from the connections, ) © 25m 25m, fone O Inside fonkand fillchamben (0) Fin point in pit ‘Zone 0 inside faak () oftser fiit point in pit “aide tone (e) ort Figure 31 Fill point edove ground Classifeation of Cass I petroleum discharge to service station underground tanks %6CLASSIFICATION BY DIRECT EXAMPLE, 3412 Hoses The following releases can occur during these opera tions and the vehicle engine and double-pok: master switch should be shut olf before connections are made, Conneetion, Discharge und Disconnection of (a) Conditions at the fill point. The removal of the sealing cap from the fillp;pe prior to connection may give rise to 2 small release of flammable vapour, ‘The completed hose connection between the delivery vehicle and rece'ving tank comprises a closed system, so that during the period of delivery there is no source of release (other than, from the tank vent as in 326 and Figure 3.3) uuniess leakage occurs from the hose connection points When the hose is disconnected the wetted surface area of the tank fillpipe will be exposed until the sealing cap is replaced and hence there will be a small release of flammable vapour for a very short time, In addition, there isthe drainage that will occur from the disconnected hase (see (b) below} ‘The above should be considered minor second- ‘ary grade sources of relecse although they occur uring normal operation, bearing in mind that they take place under controlled conditions and at relatively infrequent intervals and are covered by the Zone 2 area outlined in item (¢} of 34.1.1 and Figure 3.11 Hose/line draining and ciassfication of the road tanker unloading parking area. Disconnection. of the hose from the delivery vehicle, which should precede disconnection from the receiving tank, will expose internal wetted areas of hose and coupling on the vehicle and dripping may occur. This should be considered as a secondary grade source of release, for which there should be a Zone 2 area which extends 4.25m horizontally from the tanker discharge connections and ! m in all other directions from the connections extending down to ground level Inaddition, because of vapour and drips during compartment gauging, there should be a Zone J area within I m in all directions from the centre of any tank top opening, extending 2m above the tank shell, and aso a Zone J area within 03m of the tank shell. extending vertically down to ground level (sce Figure 3.12), 0) 34.1.3 Entey and Departure of the Road Tanker ‘The above-ground Zone 2 hazard is only present whilst lank filing or draining of hoses is taking. place. Providing no spillage has occurred and while the fill caps are in position and manlids are closed then the area is safe for entry and exit of tankers, This section is consistent with the design and 2 construction guidance given in the UK Health and Safety Executive Guidance Note HS(G}I, Perro Filling Stations: Construction and Operation, prepared in association with the Institue of Petroleum and other relevant bodies, It should be noted that local site conditions may require individual variations, and each site should be considered separately. In particular, the horizontal Zone 2 distances quoted will depend upon the likely wetted area of a liquid spillage, and this will vary with the paving and drainage provision and the degree of containment from walls and other obstructions, in which respect see 3.3.4.5 As an example of a site variation, where there is an imperforate wall at the boundary extending sideways not less than 67m from any fill point and not less than ‘3m in height this may be taken to constitute the boundary of the hazard zone (see 6.2.5) For other aspects of service station area classi- fication see 326 and Figure 3.5 in respect of underground tank vents, and 38 to 3.8.12 for the general aspects of service station layouts including dispensing pumps and operational buildings. 342 Vapour Balancing during Discharge There is a progressive trend for vapour balancing between the discharging road tanker's compartments and the receiving tank at a service station, This is ‘carried out by a hose connection from the service station vent system which is coupled to the vapour ‘manifolded connections of the road tanker of the type outlined in the IP Bortom Loading Code. Care must be taken that the hose connection point from the tank vent(s) i always securely closed off when no vehicte is coupled up for vapour balance as in the ‘ease where a vehicle that is discharging has no vapour return manifolding. Failure to observe this precaution can lead to the discharge of flammable vapours at unsafe levels, bypassing the normal tank vent outlets. A secondary grade release can take place when coupling or uncoupling the vapour balancing hose connection to the vehicle, which will ie within the Zone 2 area referred to in 3.4.1.2(b) above. 343. Discharge of a Road Tanker to an Above- ground or Elevated Tank, using its Own or a Separaté Pump A diferent situation to that in 3.4.3 arises when a road tanker has to be discharged into an above-ground tank, and a pump is necessary to provide the required head (a) Where it is practicable this may be carried out by the provision of a suitable discharge point outside the general plant hazard zone boundaries, ¢.. in @ convenient layby with piped connection to the receiving lankage, If a vehicie-mounted pump is to be used, requiring the engine to be run and thei I I I I I I I AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS ere 0.3m 1 03m 4.25m FR cones Zone 2 4.25 Figure 12. Road tanker: parkes for unloading—Classs 119) end 112) conductive type and is honded both to the electrics live in order to power she pump. (wo further cases arise’ {i) If the product to be discharged is in Class T()or ITI(), area classification will not arise, and it will be necessary only 1oensure that the tanker is earthed (e.g, through conducting tyres} and that the coupling hose is of the (iy receiving piping and to the tanker shell. However, the product to be discharged is in Class T (or less probably Class 11(2) or TTT2)) then the operation itself will give rise to hazard zone areas as specified in Table 5.1 for the vehicle pump and in Figure 3.12 for theCLASSIFICATION BY DIRECT EXAMPLE coupling point, As the criterion of 8.4 and 8.10 will not be met, this operation should he ‘carried out only under work permit control (b) Where it is not practicable to allot an unloading location in a non-hazard zone, the latter situation will aguin arise where a Class 1 112) or TI(2) material is 1o be discharged, In addition, and irrespective of the class of petroleum, the vehicle will have had to enter, leave and, during discharge, remain with its engine running and electrics live, in the hazardous zone ascribable to the fixed equipment of the plant. As stated in the IP Refining Safery Code this should be permitted only ina Zone ? area of the plant, and, since 84 and 8.10 will not be met. will be subject to strict work permit control, which should include confirmation of t2e absence of spillage and that the area is gas five. (6) An often preferred alternative is to carry out the off-loading by a fixed plant pump, fed by gravity from the road tanker. Thishas the advantage that the equipment on the vehicle is de-energized during off-loading and that the vehicle flexible hoses and couplings are not subject to pump discharge pressures. In this case the plant pump should be area classified in accordance with 5.6, and coupling points, host and line clearing as above. Entry and departure of the vehicle should again be controlled by work permit as in 84 and 8.10, 3.5 RAIL CAR LOADING—CLASSES, 1, 12) AND 112) 351 Rail car loading facilities can vary in design and can consist of a loading siding provided with a number of loading points spaced at intervals to suit rail car dimensions. An alternative to his multi-point system ‘can be a single-point installation in which the loading arms are grouped in one position and the train of rail ‘cars moved so that each car is brought into place successively. In either case the installations are fundamentally similar to the road tanker loading facilities considered in 33 and should be similarly analysed. Paragraphs 3.1.2 to 3.1.5 apply to rail car loading. However, the loading rate and thus vapour evolution can be higher dium with road vehicles. The size of the ‘hazardous area should be increased at these higher loading rates with allowance for greater width of rait cars and larger ioading arms as follows, 352. Top Loading of Rail Cars @)_A primary grade source of release oveurs whilst the rail car is being loaded due to vapour emission from the open or venting manlids. Primary and. 29 secondary grade sources uf release occur from the loading :irms when being removed from the rail car to the parked position, (rom spi overfilfing and [rom filters and other associa equipment. For loading rates above 2.5 m? per minute it recommended that an area extending in all directions to a distance of 2 m from the edge of the opening of each mantid, with a vertical drop to ground level, be classified as Zone J and that this be extended to cover the total length of the gantry to allow for different positions of the rait car or cars in the case of a multi-point system. The 2m horizontal extent will cover the greater width of the rail car (see Figure 3.13) (6) The Zone / atea for the gantry should extend from ground level toa height of 3m from the bottom of the loading arms when in the parked position (c)_ The interior of the rail car will, as in the case of a road tanker (3.3.4.3), be Zone Oat all times that the vehicle is in service. However, when all manlids and outlets are closed, as for the running condition and for entry and departure after loading, the exterior ofthe railcar can be classified as non-hazardous. (The comrol conditions for the safe entry and departure are dealt with in 3.5.5.) (4). Spiitage. Weited areas from spillage will normally be restricted by the ballast on the track and it is recommended that a Zone 2 area should extend 5m horizontally in all directions from the extremities of the gantry structure, with # height of im. [fan impermeable catchment area with or without drainage channels covers part of this then the extent of the Zone ? area should be assessed as detailed under 3.3.4.5, (€) The composite of the above factors is shown in Figure 3.13. It should be noted that the whole of the arca below the weather roofing should be classified as Zone 2 down to the Zone 1 area, 3.53. Rail Car Bottom Loading—Classes 1, 11(2) and T11(2) A similar analysis should be carried out as in 3.5.2 for top loading, bearing in mind that bottom filling is carried out from ground level, viz, (a) Seuied couplings are normally used from which a secondary grade souree of release may occur due to iBakage. Secondary grade sources of release can arise due to overilling or acidental spillage when couplings are broken, and from fers and associated equipment. {b)_ For bottom loading at rates up to and including 2.5 m'/min thearca ofthe loading stand should be classified as Zone J up (© a eight of 2m aboveee ee ee ee ra © @ AREA CLASSIFICATION CODE FOR PETROLEUM INS Uf, Yj yy Extend loterolty for multi point facilities spillage Botiostes te trock) . Ny ocding piotiorm PSLLATIONS. Ue, \ sey below root Single point iooding ene oF multi goin sing : + Sm T rion Z rome? Figure 312, Raileae, top loading (loading rate above 2. ¢0?min}—Ciasses 1.11) and 12) ground level. For rates above 2.5m3jmin the height should be increased to 3m. ‘The classification of the rail tanker will be as in 3.5.2(c). The envelope of the Zone 1 area asso- ciated with the manlids and their vents extends. during filling operations, as described in 3.5.2a) for top loading and down to ground level Spillage. The Zone 2 area that is required to allow for the various secondary grade sourees of release should be derived as detailed in 3.5.2(dp The composite area classification is shown in Figure 3.14, both with and without overhead ‘weather roofing. Note the infill in this composite of the Zone J ‘area vertical heights in (b) and (c) above. SA Rail Car Discharge via a Hose Connection— Classes 1, (2) and 111(2) The area classification for the discharge of a train of rail ears will follow the general principles for theCLASSIFICATION BY DIRECT EXAMPLE ¢¢ of road (anker vehidles in 344 though the Seale will be in most cases bigger and the eoncepis in 353 for rail car loading should be borne in mind, Thus the discharge of a railcar using a tight hose connection is closed system, usually employing self sealing couplings. Secondary sources of release may occur due to leakage and, whes coupling or uncoup- ling, hose andl drainage tine spilage may oceur. A non- fr set of valves in the ease of discharge systems that have a common manifolding, should be installed and maintained in effective working con- dition, o ensure that back low from receiving tankage eannot occur a5 a result of hose breakage, or when coupling or uncoupling. ‘When ballasted track underlies the railcar discharge location, the area of spillage willbe curtailed. An area horizontally 3 minal directionsfrom the limits of hose ‘and coupling positions and for aheight of 2m (to allow for raised connections) would normally be classified as Zone 2 together with any intervening space. However, in the case of railcars its recommended that, because of the degree of manual participation and the multiple number of cars, such areas should be classified as Zone 4,as in Figure 3.15. Where there is an area that is paved or concreted over, the extent of the spillage area may be increased since soakaway will be prevented. In such a case the procedure under 3.34.5 shoulc be applied, with due consideration of boundaries such as spillage channels, drains or leaks. In the positioning of rail car trains at discharge points, care must be taken that adequate braking of rail cars is applied with the buffers in the uncompressed condition, Failure to observe this can result in subsequent movement of ears throughout the parked train such that attached hoses can become stretched and ruptured NOTE: Despite the precedingclassification for Class 1, T1(2) and T11(2), sources of ignition should not be allowed within these overall areas because of the ignition capability under ground spill ‘thin film’ conditions. 355. Conditions for Safe Entry and Departure of Rail Tank Car Trains to and from Loading and Discharge Facilities—Classes I, 11(2) and T11(2) ‘The area classification guidance given in 3.5.3 and 3.5.4 for the loading and discharge of rail tank cars is in accord with the more general guidance for such installations as given in the IP Marketing and Refining Safery Codes. Main line locomotives are not protected against ignition possibilities and, as in the case of road tanker entry and departure in 336, operational control of train movements has to be fully co-ordinated with and match the area classiicasion of the installation. 31 $351 ‘The following points provide such guidance, forming, an important part of the general analysis of che installation layout: (a) Tracks serving loading or discharge purposes should wherever possible be reserved specifically for that purpose. They should be sited at least 15m from the nearest running line or unesiricted roadway. (©) Insulating joints should be fitted to rail tracks‘into and out of loading and unloading areas to prevent the passage of stray currents within the area arising from electrified rails and track signalling systems. Rails should be honded at all other joints in the loading and unloading area and bonded to the ‘main eardhing system of the unloading equipment. (c} Steam locomotives, except of the fireiess type, and rail vehicles with an oil lamp should not be allowed within 15m of a point where Class I or Ti) petroleum is being loaded or discharged, (2) Unprotected electric locomotives or diesel loco- ‘motives, unless conforming with the EEMUA 107 (OCMA MEC-1) "Recommendations for the pro- tection of diesel engines operating in hazardous areas’ (see Chapter 8), should not be allowed within 9m of a point where Class I or 1Q) petroleum is being loaded, discharged or stored, Within such distance of these operations only lighting etc. certified as appropriate to the area classification should be permitted (©) However, under the conditions that all product transfer operations are stopped, all pumps shut down, valves and manlids closed and outlets and hose ends capped, then, by exchange of a written certificate of confirmation between the instal- lation and the train controller that these require- ments have been met, unprotected diesel or electric locomotives may, for marshalling pur- poses, be allowed to approach within 9 metres. Thereafier the locomotive must be removed fom the area before product connections and transfer operations can commence. () The above certificate must confirm that hand brakes on the ral ears have been properly applied, in accordance with local instructions, and that all butfers are in the uncompressed condition, (@) Physical barriers should ensure that return of the locomotive cannot take place without the same conditions as in (e) above having been complied with 3552 For large rail hundiing installations, petroleum trains may be brought in or removed from a separate marshalling siding area in a safe location, and movement of rail cars may chen be taken over by beAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS. ZZ Z) Saaing plot torr a ssiteoe Yj. dottastes 1 trock Le 2m_| Sm so Extend for multi- leasing facility Plea Single- point loading with or without root Zone | iatitied to ‘uniform neigh? oe Zone 0 Zone © Composite end elevation Bottom loading without weather rooting Zone 1 Zone 2 SE igre 3.14. Railer, bottom Joading (loading cate above 2 Sa HQ} and 100)CLASSIFICATION BY DIRECT EXAMPLE 25m Spitioge Doliostea trock wy Note: In the composite inl the Zone / would be leveled off tothe height of 2 Zoneo Zone 0 one} jo.8m See note L se 4 End elevation Bottom loading with wearn: rooting mm above the mantis, Elevation 33AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS ‘means of a winch-operated (rain mover or a mule of a certified safety type. Such a trackside wagon haulage unit may be used in conjunction with a single-point foading unit, such that the train of rail cars is successively brought into place Tor each individual car to be positioned at the loading point. Cantro! systems should ensure that inadvertent rain movement cannot take place without con- firmation that connections to the loading car have been unmade, 3.6 MARINE FACILITIES AND JETTIES—CLASSES I, (2) AND TH(2) 3.6.1 ‘This section considers the hazardous area on the jetty and marine facilities arising from the loading or discharging of a tanker. It includes the hazardous area arising from the cargo hoses and from vents on the tanker. The hazardous area from other equipment on the jetty should be estimated using the appropriate sections of Chapter 5. Area classification on jetties should always be based on the most volatile product, handled, The section does not apply to the vessel itself for which guidance shouid be sought in the appropriate maritime code of regulation, ie. International Electro- technical Commission Publication 92-502, Special Features—Tankers. Further guidance on the pre- cautions to be taken during handling on tankers and at terminals for crude oil and petroleum productsis given in the International Safety Guide for Oil Tankers and Terminals (ISGOTT, latest edition). The IP Marketing and Refining Safeiy Codes may also be consulted. 346.2. Jetties—Loading and Discharge Facilities (a) The hazardous areas should be established for each possible primary and secondary grade source of release associated with the jetty equipment. (b) Primary grade sources of release occur during tanker loading due to vapour vented from tanker compartments or during gas freeing of tanker compartments, should the latter take place whilst the tanker is alongside or adjacent to the jetty. For jetties with facilities for loading (including ballasting) to allow for the primary grade source of release from the tanker vents at all loading rates and wind conditions, it is recommended that an area extending 20m in all directions horizontally all round. ‘the hull ofthe tanker from the water level toa height of 10m above the highest vent point on the vessel should be classified as Zone J. Possible hull locations should be based on the maximum breadth of tanker expected to use the jetty and the expected fore and aft positions at the extreme berthing locations (see Figure 3.16) For this purpose the hull of the tanker shoutd be (Seenote 2) (Seenote 2) 20m 20m Jetty epprooch 20m (See note 2] 2om(si note 2) Notes: 1. The above Zone 1 is additional to any hazardous area assessed in consequence of all other equipment on the jen 2 May be reduced (0 10m for vessels with loading or lscharge rates of 10ra!/min or less 13. The height ofthe hazardous area should be 10m above the highest vent point This may be reduced to Sm forloading rates of 10 m/min oF Tess Figore 316.Jetes—iosding and discharge facilities —ClassesT, 112) and THQ) assumed to be in contact with the jetty; Le. all shore side distances should be measured from the fixed seaward side of the jety. (c) Primary and secondary grade sources of release ‘ean occur Irom fixed and portable equipment such as filters. sample points, slop tanks, loading! discharge marine arms and hoses; drainage and drip trays. pump glands and seals, valves, meters and flanges. The hazardous areas arising from the jetty equip- ment can be assessed by considering each possible source of release in accordance with Chapter 5. TheCLASSIFICATION BY DIRECT EXAMPLE 20m (See note 3) 10m (Seenote 4) soo 20m (See nore 3) 20m (See note 3) ‘Notes: 1, Other hazardous areas om jety should be evalusted by reference to all equipment on the ety. 2 If non-segregatedtallasting or gar recing is erred out, eo the juty must be elased at for loading 3. May be reduced to 10m for veses with clacharge rates of 10ns"nin oF ls, 4, This may be reduced to Sm for discharge rates of 10 m/min O les Figure 3:17, Jeties—discharge facilities only—Classes 1, 112) and 112) irdous zone created by the tanker can superimpose on or enlarge the hazardous area determined for the Jetty only. The loading/unloading equipment, when ‘ot in use and in the parked position, creates a source of ‘release whilst draining. During ship loading/unloading this equipment can give rise to sources of release but ‘such equipment is encompassed by the hazardous area created by the primary sources of release from the tanker, (@) For jetties berthing only barges, coasters or other tankers with loading and discharge rates of 1Om*/min or less, then the horizontal distance in (b) may be reduced tc 10m and the vertical to Sm, 36.3 Jetties—Discharge Facilities Only For jetties where only discharging operations are ‘carried out and there are no loading facilities including ballasting other than to vapour-irce segregated ballast 35 tanks, then venting of flammabie vapours will not take piace during discharging operations. Since the marine arms, hoses, etc., constitute a closed system, only secondary sources of release are likely to occut. It is Fecommended that an area extending from the hull horizontally a distance of 20m in the landward direction up to a height of 10m above the jetty deck and down to water level should be classified as Zone 2 (Gee Figure 3.17). For practical purposes the shore side should be measured from the fixed seaward face of the Jetty and the fore and aft distances from the extreme berthing positions in order to cover all possible Positions of the tanker. Hazardous areas should be established for each individual source of release from the jetty equipment Since some may necessitate localized Zone 1 areas within the above overall Zone 2 area. Where berths are restricted to barges, coasters or other tankers with discharge rates that do not exceed 10 m3/min, then theAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS above distances in Figure 3.17 may be reduced 10 5m horizontaliy If ballasting is curried out during unloading into uunsegregated ship's tanks which could contain vapours. or if gas freeing of tanks is carried out whilst alongside the jetty, then the jetty should be classified in accordance with 3.6.2 above. ‘The classification onboard the tanker vessel itself should be in accordance with 3.6.1. second paragraph. 37 DRUM FILLING—OPEN AIR VENTILATION—CLASSES I, (2) AND 12) ‘This section applies to the filling of storage drums of a nominal capacity of 205 litres or less. 3a Drum filling should normally be carried out in an open or sheltered area(see 6.2, 6.3 and 6.4). IT not, this section does not apply and the drum filling area should be regarded as an enclosed area with a primary grade source, and local exhaust ventilation should be provided (see 6.) ‘The drum should be regarded as a primary grade source of release. The hazardous area should be classified as Zone 1. It should extend Im in all directions from the edges of the filling or venting ‘openings. This area should be extended at a height of 0.5m above ground level to a horizontal distance of 2.5m from the vertical centreline of the érum in the filling position (Figure 3.18) The filing line is also a primary grade source of release. The hazardous area should extend 1.5m in all directions from the end of the filling line. For the filling of containers with Class I1(1) or Class 111(1) petroleum, 2.12.3 will apply, but care should be taken to avoid sources of ignition which could give rise to hazard in the event of @ ground spill 34.2 Drummed Storage Areas—Classes 1 and 11(2) ‘Where reasonably practicable, such containers should 28m 2.5m be stored at ground level (singly o in stacks, but n0 more than four high) and in the open air. This will enable leaks to be more readily detected, and any ‘vapours arising to be dissipated. Such stacks for Class 1 cor 11(2) materials should be placed in one or several compounds if the total volume of packed product exceeds 200m’, with small walls or sills, e.g, of 150mm hheight 10 prevent uncontrolled outfiow. ‘The storage and handling of sealed containers witl not normally give rise to hazardous releases, but the ‘area within the walls or sills should be classified Zone 2 to a height of at least 1 m above the highest container. ‘Theres secondary hazard which could be created by heat from a nearby fire, and there should be a space of at least 10m from potential sources of ignition, ‘occupied buildings and boundary fenecs. Drums should not be stored within tankage compounds for flammable liquids or within 1 m of the compound walls, ‘and stacking should allow adequate spacing for fork lift teucks or similar movers, and never be allowed to obstruct avenues of escape. Fork lift trucks or other movers if used within the hazardous areas above denoted should be 10 Zone 2 standards. ‘Where the recommended zone distances cannot be achieved, consideration may be given to the provision of a fixed water spray system or an appropriate fire wall, 2s in 6.2.5, Such a fire wall should be at least as hhigh as the top of the container stack, and be sited 1-3m from the stack. The fire wall may form part of a bund, unpierced building wall, or boundary wall, and to ensure adequate ventilation normally be on one side only of the stack (again see 6.2.5) 313. Dram Storage in 11@) When it is not practicable to store containers in the ‘open, they may be stored in suitable storage buildings, which should not be used for other purposes. Such buildings should, as in the case of storage in the open air, have means of containing spillage—e.g. by sills or ramps 150mm high across doorways. The flooring should be impermeable to liquid spills. Storage buildings should be well ventilated, pro- jildings—Classes | and osm Figure 3.48, Dram filing inthe open aie 36CLASSIFICATION BY DIRECT EXAMPLE vided openings do not confit with the need fora wall to be fire resisting, and be clussified as Zone 2 up to a height of 2m above the highest container. If heating is provided, heating which could be a source of ignition should not be used, hot water radiators or steam pipes generally being suitable For further details of package store building construction the IP Marketing Sufety Code may be consulted. 1t may be noted that 4 package storage building used for no other purpose need not be fire resistant if located in a safe position in respect of the distance from other buildings, boundary, etc, though the construction should be generally of non-com- bustible materials. Buildings within such a distance should be fire resistant, and in all cases a light-weight oof, to act as an explosion «elie, may be considered. Storage buildings may be sited on a boundary, oF ‘against a wall of an occupied building, provided that the wall on that side is a fire wall to it full height, and for at least 4m on either side, Where artificial vencilation is 10 be provided the guidance given in Chapter 6 should be followed, with fan motors protected to Zone 2 standard 37.4 Package Manufacture and Reconditioning When packages are to be manufactured at~an Plan installation and this entails har work or the use of any source of ignition, this should be located at least 1S from any filing arca, tankae or storage area where Class 1 or 112} petroleum is stored or handled, Where used drums are 10 be reconditioned or repaired, cleaning and gus /reving should be carried out in the open air or in a well-ventilated building, and appropriate precautions taken against smoking and any source of ignition No hor work should be carried out on any package until it is cleaned and made gas free (usually by steaming). Such hor work/repair should be carried out within an area that can be designated as non-hazardous (see 84.1 and 8.4.2). Containers that have carried 2 heavy oil can appear gus free when tested, but when heat is applied traces of product remaining can vaporize to form a flammable atmosphere: thorough Cleaning out is therefore essential in all cases. NOTE. The above section applies to bulk drum filling and storage. {t does not apply to glass bottle or plastic containers; storage and display in retail sales ‘area of service stations, etc.; nor to the “keeping of Petroleum in cans, drums, etc.’ for which there is statutory regulation in the United Kingdom, EEE cones WH 250 mm ota oun L_ Cotum= forecourt surface 1 pump hydraulic housing to be inuous without apertures Vopour berries (type 2) nere moy vary zone clossiticotion of parts of nousing (See Fig 320 ang BS 7117 for aetails) Section oo | x= whichever is tne greater of (0)1250mm (0) 0 top of the pump hydraulic housing, See also aS 7117 Figure 3.19. Low hose metering pumpiispenser 37ee ee ee ee AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS, 38 FILLING AND SERVICE STATIONS 38.1 Introduction Filling stations are concerned with the storage and supply of fuel and lubricants to motor vehicles. Additionally a service station may include facilities for vehicle servicing, retailing of accessories, storage and retailing of kerosine, as well as for vending ancillaries. 382. Area Clas (Gasoline) ‘This section covers the equipment and layout to be found on che forecourt under the normal open area condition. It should be applied also to non-retail petrol dispensing sites and to dispensing to boats, light aircraft and into portable containers. As applied below, the Zone 2 areas indicated cover the possibility of localized hazardous aimospheres being present for short periods, with such areas well ventilated under ‘open area conditions, The classified areas indicated relate to the installation of fixed electrical equipment, and should not be considered as extending beyond an tunpierced wall, roof or other vapour barrier or solid partition (see 6.25). The normal prohibition of ication for Class I Petroleum Plas smoking, non-electrical sources of ignition and the running of engines, during both the lueling of vehicles and the delivery of fuels from road tankers, should also be vigorously enforced (sec 3.8.9 383. Buried Service Station Tankage (Class 1) fa) Vent from wnelerground tank (Class 1). See 32.6 und Figure 3.5. NOTE: Where vapour balancing connections back to road tank are installed see 3.4.2. (b) Gravity discharge 10 underground service station tanks through screwed hase connections. See 34.1 and Figures 3.11 and 3.12 (0) Other openings 10 the tank. As in (b) above. 384 Classification of Dispenser Units (Class Gasoline) The following general types of dispenser unit may be considered! (@) Low hose dispenser unit. See Figure 3.19. Top of housing to be continuous without apertures. No internal vapour barrier within housing. (©) Low hose dispenser unit with internal vapour barrier as indicared. See Figure 3.20 EBB cones CBee? 3m 250mm Dotum- plinth Dotum-forecourt surtoce 425m Too of the oump hydraulic housing to be continuous without apertures vopour borrier (type 2) here mokes ores dbove Zone 2 (See BS 7H7 for detcils) Section a2 whichever is the ‘greeter of (9) 1250 am (ib) te the top of the pump hydraulic housing. See also 88.7117 Figure 320, Low hose metering pumpidispenser with vapour barrier 38CLASSIFICATION BY DIRECT EXAMPLE 3m Top of rorating arm Reusing Figure 321. Low hose metering pump/dispenser wi (©) Low hose dispenser unit with rotating radius arm, ‘The classification for this type of unit is shown in Figure 3.21, the top of the rotating arm housing being continuous without apertures. (@) High hose dispenser fitted with sight glass and without vapour barrier in the housing. The sight glass connections are an infrequent source of secondary grade leakage, leading to a Zone 2 area as indicated in Figure 322. With no internal vapour barrier the entire area of the lower hydraulic housing and its upper extension column Will be Zone 1. (©) High hose dispenser without sight glass and with eapour barrier. See Figure 3.23. The inner delivery Pipe above the barrier should be unjointed or welded or brazed up to the hose connection joint. This joint need not be considered to be a point of release. See BS7 17: Partl: Figure 11 385 Although not shown on Figures 3.19 to 3.23, all pump dispensing types should incomporate the following added classification features: (a) Dispenser nozzle housings. Recesses in the pump housing to hold the nozzle spout, which may be ¢ 39 tb) Top of rotating erm housing 10 be continuous without opertures x * whichever is the greater of (0) 1250. mm (0) to the top of the rotating radius orm Internal rotating joint Section Plintn rotating radius arm vertical or angled, are Zone 0, with an external Zone | extending 100mm outwards, with exten- sion SOmm above and 100mm below as in BS 77 Airlvapour separator vents. An air/vapour sep- arator which allows air or vapour to escape from the liquid stream prior to its teaching the measuring meters ofthe dispensers often located 0 that its vent emerges from the side of the dispenser housing, in which case it should be sited not less than 100mm from any ventilation openings in that housing. The vent should be Furnished with an appropriate fine mesh flame arrestor (See clause 8.7.1 of BS 7117) and should have a device such as a hollow ball float that will Prevent the ejection of liquid fuel through the Vent. The vent itself should be classed Zone 0 and havea Zone J area extending horizontally 250 mm, from the housing and vertically 100mm above and down to meet the 250mm Zone / at the foot ‘of the pump/dispenser unit. Alternative positions for the air/vapour separator between the hydrau- lie pump and its measuring unit may be selected, cone such alternative being tolocateit in the ZoneO ‘area of the nozzle housing.AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS = on ae ZZZZiroee Zone Greater of (2)1250mm (p) 10 the top of the pump hydraulic housing, See alse Figs. 5,6 one 180mm 750mm 7 Of BS 7117 5) TEOmm [ A vopour borrier moy vary zone clossiticetion ‘of parts of housing, See also Figs. 5.8 and Tor as 77 250 mm Dotum-forecourt 1 30, Figure 322 High hose metering pump/dispenser—ith sight glass and without vapour bacrier 386. References for Clauses 38.4(a) to (e) and 3.8.5(a) and (0) Fuller constructional and other details for the above dispenser types are to be found in BS 7117; Part 1, 1989, ‘Metering Pumps and Dispensers to be Installed at Filling Stations and Used to Dispense Liquid Fuel Part 1. Specification for Construction’, and likewise the UK Health and Safety Executive document HS(G)41, ‘Petrol Filling Stations: Construction and Operation’, in the preparation of both of which the Institute of Petroleum has been represented, and with which the above 3.84 and 38.5 are compatible. It should be noted that the above guidance applies both to a dispenser containing its hyraulic pump unit ‘and to dispensers that are served by remote pumping units 38.7 Vapour Barriers as Used in 3.8.4(b) and (¢) (Figures 3.20 and 323) and Canopies above Dispensing Units BS7117 stipulates appropriate vapour barrier types that may be used, and also the requirements for cross ventilation of housings below the vapour barrier and for upper column extensions (BS 7117: Part !, clause 8.11), 387.1 Overhead Canopies ‘A pump canopy with no opening in its underside may be considered a non-hazardous area. Where there are any openings in the canopy, there should be a ‘minimum 15mm free all-round-ventilated air gap berween it and any underlying classified zone areas (see BS 7117: Part and HS(G)4i)- 388. Prevention of Spillage by Mechanical Damage and Protection of Buildings with Access to the Forecourt (a) Pumps and dispensing units should be protected, for example, by installation on a slightly raised island or plinth to prevent damage by collision that could result in releases of a scale that would invalidate the foregoing classification. Nevertheless, access to buildings within a classi- fied area should be provided with a sill or step not Jess than 150mm in height Kiosks, sales, storage, restrooms and other buildings with any openings to a hazard zone should be classified according to that zone at the same height throughout the building, (See also space heating, 389.1) (o) 389. Control over Non-electrical Sources of Ignition ‘The need for the exercise of control over non-electricalCLASSIFICATION BY DIRECT EXAMPLE EERE zone 1 Lizz, 2080 2 = No sight gloss Vopour barrier. See cise ] pL fie Sere? ct as" rii7 260mm ootm-ptinn Lo - Dotum-torecourt surtee sources of ignition within the purliew ofa service station hhas been stated in 38.2. General guidance as to how area classification can be applied to this control is Provided in Chapter 8. The following recommenda. tions should be considered in respect of service station operation. Tank openings, pumps (other than sealed pumps installed remote from the dispensing point) and dispensers should be located so that their centrelines are not less than 425m from any fixed source of ‘ignition or from the boundary of the premises. They should be sited at adequate distances from under- ground tankage, basement or cellar. Practical steps Should be taken to ensure that no smoking and no Sources of ignition are permitted within 3m horizon- tally from the external housing of a dispenser unit. ‘This will entail the following measures for dispens- ing the product: (2) The engine of a vehicle to which product is to be dispensed should be switched off. (With the engine Funning the vehicle may move unexpectedly oF 41 150 =a = 225m £= whichever is the greater of (0)1250 mm ()10 the ton of the pump hydroutie Rousing. See cise Figs, 6 ond 7 of Bs 717 = 323. High hose metering pumpydispenser—withou sight glass end with vapour barree Product vapour could be ignited by an electrical spark or backtire) Some vehicles have an auxiliary engine or other source of ignition such as refrigeration or heating/ cooking appliances (e.g. cement mixers, motorized caravans icecream or cooked food dispensers) which should also be stopped before dispensing of Class I peiroieum commences. Smoking. There should be no smoking or naked lights in the vicinity of dispensers. Customers should not smoke, or, ifsmoking, should be asked to move to a non-hazardous area, Dispensing should cease if there is any risk from this cause tb) © 389.1 Space Heating of Buildings/Rooms Buildings should be well ventilated and the type and location of all heating apparatus should be such that there will be no possibility of a source of ignition in a hazardous area either during normal operations carried out in that building or room (e.g, lubrication, service or sales rooms, kiosks etc.) or in the event of annt AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS outside spillage on the forecourt (see 3.8.8{b}, second paragraph) It is particularly dangerous in the latier event for staff or customers who may have had clothing or Footwear splashed with gasoline to enter any sueb area for rooms where the type of heating could cause ignition. Where such access could occur fixed heating should be only of the black ficat type, and all staff should be warned against the introduction of any other type of portable appliance (eg. in the case of cold weather) 3.8.10 Vehicle Repair, Servicing Areas and Inspection Pi (a) Thedanger of releases of petroleum fuels, whether accidental or by intentional drainage etc. of equipment and fuel ranks in such areas, should be emphasized to all staff, and the necessity of strict ‘avoidance and contro! of both electrical and non electrical sources of ignition should always be ‘observed, with above-ground repair and servicing ‘areas Zone 2 up to a height of 1m above floor level. Inspection-type pits for motor vehicles cannot be considered as freely ventilated spaces irrespective of location, and it could be unwise to assume that a pit reserved exclusively for vehicle washing would not be used for other work if, for example, a vehicle has a leaking fuel system, Forced ventilation to purge vapours from pits cannot be taken into account when classifying such areas, since it cannot be guaranteed to sweep the area under all conditions, bearing in mind ‘obstructions that can occurand ventilation faiture. Tis recommended that inspection pits within a Zone 2 area be classified as Zone | and that pits within non-classified areas be classified as Zone 2 in respect of electrical equipment including tools, and lighting. However, if any flammable solvents fare in use within the pit or the floor area above, then the pit should be Zone |. NOTE: Petrol removal from a vehicle can be best carried out safely by the use ofa fuel retriever, consisting ofa troiley-mounted container of some 30-100 litres capacity fitted with a hand pump or syphon to remove the fuel, and an earth lead. Retrievers should be kept well away from sources of ignition and, if not to be used for a prolonged period, should be removed from the work area to suitable safe store, In all cases it must be emphasized that no unauthorized unprotected equipment or lights, zor unsafe heating epplicances that could provide tL sonirce of ignition, should ever be introduced into the area of or adjacent to a pit. Where a pit ventilating system is provided its associated tleetrical equipment should be suitable for Zone J. 42 (b) Preparation of equipment for hot work. The relevant scctions of Chapter 8 (8.2 etc.) should be noted, and also the requirements (84.2) for appropriate use and care of portuble gas detector equipment The gat freemg of vehicle fuel tanks ete. preparatory 10 carrying out jot work should preferably be carried out in the open air remote from sources of ignition. If carried out within a building, means of discharging vapours safely to the open air should be provided. (©) For the maintenance and repair of road tanker vehicies reference may be made to the IP Road Tanker Vehicle Workshop Code (new edition in preparation; Ist edition 1980). 38.11 The Handling of Other Fuels at Service Stations such as Diesel and Kerosine The above sections apply to the handling of Class fe. gasoline, fuels. However, it should be noted that BS 7117 docs not differentiate in its design constructional features between dispensing units for Class I (gasoline) and other fuels up to 2 flashpoint limit of 100°C— which includes the kerosine and diesel fuel range. ‘Such fuels fall into the flashpoint category Classes 11(1) and f1(1) respectively, and for their classification in tankage ete reference should be made to 2.12.3, 3.14 and 33.1 38.12 The Dispensing of Automotive LPG Fuels at Service Stations ‘The guidance provided in 3.9 should be followed. 3.9 BULK PRESSURIZED LPG INSTALLATIONS IN DISTRIBUTION AND MARKETING AND MEDIUM SIZED USER INSTALLATIONS ‘This section is intended to apply to bulk LPG handling in the distribution and marketing of LPG. Irexchides refinery and processing plants and also refrigerated storage. These more varied situations are ‘more appropriately classified in accordance with the point source procedure of Chapter 5. 394 This division of procedure rationally follows that in the current revision of the IP Liquefied Petrolewm Gas Safety Code, ia two volumes. Votume 1, “Large Bulk Pressure Storage and Refrigerated LPG’, was com pleted and published in 1987, leaving the forthcoming, Volume 2 to cover storage, handling and transport in the distribution, marketing and user sectors. 392 Pending completion of this remaining volume of theCLASSIFICATION BY DIRECT EXAMPLE LPG Code, which will include a review of area Classification, it is recommended that the guidance given in the following publications be consulted: {a) UK Liquefied Petroleum Gas Industry Technical Association Codes: LPGITA COP I—Installation and maintenance of bulk LPG storage at consumers’ premises, Parts f, Ul and I 4a ) LPGITA COP 7—Storage of full and empty LPG cylinders and cartridges, LPGITA COP 12—Recommendations for the safe filling of LPG cylinders at depots, LPGITA COP20—Automotive LPG refuelling facilities. UK Health and Safety Executive Guidance HS(G)34—The storage of LPG at fixed instal lations 1987,4 THE CLASSIFICATION OF DRILLING RIGS AND OTHER EQUIPMENT SYSTEMS USED IN WELL OPERATIONS AND PRODUCTION WELLHEAD AREAS 4.1 INTRODUCTION This chapter gives guidance on the area classification that may be applied to drilling rigs both onland and on fixed and mobile facilities offshore and to production sites and platforms during workover and wirelining, ‘operations. It does not apply to production operations: downstream of the wellhead, e.g. oil/ges separation, dewatering, or pumping or compressor units, which should be classified in accordance with Chapter 5, while for the storage and loading ete. of crude oil after stabilization to the fluid category C condition as defined in 5.5.4 the guidance for Class 1 petroleum given in Chapter 3 is relevant. ‘This Code gives sound practical guidance that is based on experience. In accordance with the principle of TEC and CENELEC, it applies only to the comparatively small releases of gas and oil that can occasionally occur in these operations. Well blowout is remote and outside the scope of area classification, and is a matter for standing operational practices (see IP Drilling and Production Safety Code for Onshore Operations, Chapter 5). The revised: IP Drilling and Production Safery Code for Offshore Operations (in preparation) will similarly give guidance. Lastly, while this Code is principally concerned with the correct selection and installation of electrical apparatus, as outlined in Chapter 7, it may serve as @ useful guide to the safe operation of non-electrical sources of ignition, such as diesel and gas turbine equipment, hot surface protection ete. (see Chapter 8) 4.1.1 Use of the Chapter As will be seen from the appraisal in 4.1.2 below of typical releases, there are sufficient common factors, despite a number of differences, in drilling, workover 44 and wirelining practices, whether on land or offshore, on fixed or mobile platforms involving semi-sub- mersible and jack-up rigs or other dynamically positioned vessels, to enable this chapter to be set out, as in Chapter 3 (storage, loading etc), in the form of type examples as described in 26. In their application itis necessary to check that there are not significant differences in layout etc. from the examples given that would necessitate the more individual consideration of special features, including application of the point source approach in Chapter 5. ‘The guidance given covers both the ease where the facilities are in unrestricted open area conditions as defined in 17.1 and also the alternatives where they are located in sheltered, enclosed or partially enclosed situations. For the latter, the ventilation condition should be checked against the more detailed infor- mation given in Chapter 6, Its recognized that there will also be MODUs/drill ships operating internationally that are classified in accordance with Chapter 6 of the International Maritime Organization Code for the Construction and Equipment of Mobile Offshore Drilling Units (1980 and reprinted 1983), 4.12 Nature of the Fluid Release Relevant to Chapter 4 During drilling operation, hydrocarbon release to the surface can occur typically in one of two situations (@) As gasiin solution (or partially in solution) which comes out of solution when exposed to reduced Dressures at the surface, typically while driling at near-balance or underbalanced hydrostatically, or as trip gas during the round trip pulling ofthe drill string. (b) Asa ‘kick’ in the event that a downhole formationCLASSIFICATION OF DRILLING RIGS AND OTHER SYSTEMS Pressure is unexpectedly encountered that is in excess of the hydrostatic head of the circulating mud column, Any liquid hydrocarbons entering the circulation systems downhole would under normal circumstances be very much diluted by the mud system, Thus for the purposes of classification of the areas around the drilling installation, item fa) above is the ‘major consideration, with potential sources of release at the bell-nippte and around the flowline outlet, shale shakers and active mud-pits, ‘The case of a *kick’ as in (bi does not affect the area classification as it is dealt with in operating practices under controlled and essentially closed conditions (see 4121). Releases can also occur as follows: (©) Drill pipe withdrawn within the derrick can also be coated with mud contsining flammable gas and constitute a small release (4.2.3) (@) During wirelining operations the stuffing box on the wireline lubricator should likewise be con- sidered a source of release. 4.1.2.1 Example of Typical Operational Control of a ‘Kick’ (see (6) above) Equipment for degassing the mud in circulation is standard on modern drilling rigs, Strict attention when running or pulling pipe is given to keeping the borehole full of drilling uid at al times and at the appropriate density, and devices for measuring the rise and fall of ‘mud tank or pit volume are employed in order to detect the loss of mad to the formation or conversely entry of formation fluids. In addition, the levels ofhydrocarbon gases within the mud tank system are subject to Continuous monitoring, usually by two independent sets of gas detection instrumentation, and can detect very small increases. Thus by continuous monitoring of pit level and mud stream gas an influx of hydrocarbons into the well bore is normally detectable immediately and is brought tothe attention of both the mudlogger and the driller for prompt action. Atthe initiation of a high-pressure kick the ram-type blowout preventers are immediately closed around the rill pipe (or, ifthe kick or blowout occurs with the drill pipe out of the hole, by means of the blind rams), and the mud is circulated through to the rig choke line leading to a back-pressure control manifold and then to the mud degasser unit, The manifold consisting of a series of valves and chokes can be throttled down to give the required orifice area needed to back pressure the well and control it, while circulating and raising the specific gravity ofthe drilling mud by addition of heavy materials, using the kill line zonnection between the high-pressure mud pumpsandits inlet betow the closed am preveniers to hold back the kick. Any free gas can be bled off hough the choke line to the mud degassing vent or flare, Other fluids are usually not a problem 45 because they are squeezed back into the formation ‘The correct installation and operational reliability of this equipment is thoroughly checked and itis pressure tested at frequent intervals throughout the drilling of a ‘wcll. A fall-back position is the opening of the diverter line from the rig choke manifold laid prior 10 the commencement of operations to the burn pit or Rare point located at a suitably remote and acceptable Position on an onland site or to a discharge point suitably away from an offshore platform remote from any sources of ignition. Such controlled operations within closed systems do nol require reclassification of the hazardous areas. Typical control is described in the IP Drilling and Production Safety Code for Onshore Operations, and in the forthcoming new edition of the IP Drilling and Production Safety Code for Offshore Operations. 413 Based upon the foregoing, the following sections describe the area classification procedure recom- mended. For convenience and in accord with the explanatory diagrams provided in Figures 4.1 to 4.6, these will be dealt with in the following groupings: (a) The rig sub-structure—the area between the tig floor and main platform deck (offshore) or ground level on a land rig, and in which the bell-nipple and blowout preventers are located, ‘The wellhead area down to the cellar deck offshore, or wellhead cellar on land-based rigs. ‘The upper works of the rig, above the rig floor. ‘The circulating surface mud system, including shale shaker, mud pits or tanks etc Miscellaneous small releases from flanges, vents or drains and other spaces in the drilling area. Gas vents from (4) above. o © fa) © ) ‘These subsections differentiate as appropriate between open area and enclosed ot sheltered conditions. Other miscellaneous enclosures not covered by these ex- amples should be dealt with by reference to Chapters 5 and 6, In each the appropriate fluid buoyancy factor of the release has been taken into account, 4.2 CLASSIFICATION FOR DRILLING, WORKOVER AND WIRELINE OPERATIONS IN OPEN AREAS Drilling rigs and welthead areas which can be considered effectively open areas with possibly smail localized sheltered areas are common onshore and in many offshore areas. When the combined rig. sub- structure and production wellhead area can beST ———— AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS Concuerors. WL Figure 41. Offshore {open ares)—riling and with rig witnast rig 73m 75m ‘Stuffing i ee SS spp) anernetived | Wicsine Y. neo, \ wericotor WS wireline BoPs HP wi Moin deck: WIS 3 { SSS ett a sruffine box \ LaGficotor “ip wireline 807s eliar deck WGK \ \ MULL Figure 42. Offshore (open eres}—wirlining 46CLASSIFICATION OF DRILL ING RIGS AND OTHER SYSTEMS eee tay | EY Qo | 8 \ Z "LZ l \ Z Beli anoe BF LZ ine sence G ee g roms iver 2 | P| |B at we 4 -Welinecd Senet! | zom | Figure 43. Land ( considered open as defined in 1.7.1 and 6.2, hazardous areas should be assigned as in 4.2.1 t0 4.25, NOTE: This section does not cover ‘two-tier’ wellhead layouts offshore where one set is located at a level above that of others, 42.1 Subsstructure, Drilling Riser and BOP Area During drilling and workover operations the bell nipple at the top of the riser should be regarded as @ * secondary grade release. In an open area the hazardous area should extend 7.5m (Zone 2} vertically and horizontally from the bell-nipple and down to ground or sea level, When a solid deck or platform is more than Smabove the sea then the hazardous areamay stop 9m below the deck or platform (see Figures 4,1 and 4.2). ‘The horizontal extent may be reduced 10 Sm and the vertical extent below the bell-n/pple reduced to 3m for workover involving a known lighter-than-air gas feld ‘The hazardous area from the beli-nipple or well Extent of Pen stes}-delling and workover centre line will normally include the hazardous area from any sources: for example, from vents and drains on the BOP and its stack and riser system, including blowout preventer valves. In these drawings the hazardous area arising from the mud system has been excluded. The effect of any such sources on the ‘hazardous area should be considered if the mud is regarded as hazardous (see 4.2.4), 42.2 Well Cellars Unless artifcially ventilated, the space around the wellhead in an onshore cellar should be regarded as ‘inadequately ventilated and should be classified in accordance with Table 6.1 as Zone !. ‘The ventilation inthe other spaces should be assessed and the zonal classification and arca boundaries amended for non-open areas. For a sheltered area, as defined in 6.4, the hazardous ‘area should extend 3m outside the shelter or 7.5m from the bell-nipple, whichever is the greater. Gin pole hozerdous: _— (typicoily) reo) Z, LLL, 7 tree — GPG me sntting 9ox -— oe —F | Se vo oie G5 Y rresuion ovine rons nee —B HEL Z_ ten w 1 Beet 47AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS 423 Rig Upperworks Drill pipe withdrawn within the dercick can, as noted in 4.1.2, be coated with mud and produce a small hazardous release which in the open will rapidly disperse due to natural ventilation With an open-design derrick (ie. non-enclosed) a hazardous areu Zone 2should extend to 7.5m above the rig floor. Where rig floor windbreaks are fitted the hazardous area Zone 2 should extend to at least the top of the windbreak. 424 ‘The resultant composite of the above hazardous areas in typical offshore and onshore situations is shown in Figures 4.1 and 43. Tn these drawings the hazardous area arising from the surface mud circulation system is excluded since this is dealt with in 4.5 to 4.5.8. However, if the mud itself is regarded as hazardous, as in 4.5.1, the effect of any sources shown in Figures 4.1 and 4.3 should be considered, as in 4.5.8, 42.5 Operations in Situations where the Rig and/or its Wellhead Area are not ‘Open’ All apertures from an enclosed area containing a source of sources of release should be-regarded as secondary grade sources and the hazardous area should be drawn from the apertures. If the derrick is totally enclosed, e.g. for weather or noise reduction, the internal space should be classified. as Zone I with a Zone 2 area extending 3m outside the ‘enclosure. This applies when no vent line is fitted within the derrick (see 4.6) If the sub-structure is totally enclosed, the internal space should be classified as Zone / with 2 Zone 2 area ‘extending 3m outside the enclosure or 7.5m from the bell-nipple, whichever is greater. ‘An enclosed onshore well cellar and other non-open areas are covered in 4.2.2 43 WIRELINING In wirelining operations the stuffing box on the wireline lubricator should be considered as @ source of secondary grade release. Under open area conditions 2 Zone 2 area should extend to a distance of 7.5m around it (see Figures 42 and 4.4). 4.4 OTHER GENERAL CONSIDERATIONS FOR RIGS AND OTHER SOURCES OF RELEASE ON THEIR WELLHEADS AND ASSOCIATED DRILLING FACILITIES The extent of the hazardous area from any other miscellaneous source, e.g. flanges, vents and drains, will 48 normally be within the hazardous areas described in 42.1 t0 4.255 oF from the lubricator or well centreline when conducting wireline or drilling/workover opera~ tions as in 43, If not, the extent of the hazardous area should be determined from Chapter 5. Vents and drains should normally be to a closed system. ‘The classification of spaces other than those covered above and their ventilation should be assessed in ‘accordance with 4. 44d In considering the classification in 42 and 4.3, itis recommended that electrical apparatus which has to operate under conditions of breakdown of the ‘measures of control should be of a type suitable for Zone | operation (see Chapter 7). See also 4.11 for ‘emergency situations on offshore units. 43 SURFACE MUD SYSTEMS ‘The surface mud system includes the mud circulating, pumps, the shale shaker area and the settling tank, together with any mud degassing equipment. 45.1 ‘The possibility of zhe mud itself being hazardous (eg. an oil-based mud) should be considered. A mud should be considered hazardous when its temperature can be raised to the flashpoint or autoignition temperature during storage, or use (as a result of high subsurface temperature and/or dilution by pick-up of formation hydrocarbons) or upon release, €£, by the heat of the sun of other hot objects or when spray atomization to form a mist can occur. Geological advice may be required to estimate the maximum operating tempera- ture of the mud. The effect of a hazardous drilling mud is considered in 4.58. 452 All parts of the surface mud system except the reserve pits should generally be considered to be active and to be in contact with oil or flammable gas both lighter and heavier than air. When mud from the active system is transferred back to the reserve pits these pits should be treated as if they were active for the purpose of area classification Normally the quantity of hydrocarbon circulating. will be small and therefore the extent of the hazardous area from such primary grade releases will be small. Occasionally the circulating mud can contain more ~ hydrocarbon, resulting in secondary grade release with a larger hazardous area. 453 ‘The active mud tanks should therefore be regarded as a secondary grade source of release. In an open area withCLASSIFICATION OF DRILLING Ric Figure 48, Hazardous aren unrestricted ventilation the hazardous area should be Zone 2 extending 3m from che tank walls and at» height of 3m above ground or floor to a horizontal distance of 7.5m from the tank(s), The space within the tank walls should be Zone I. This is shown in Figure 45. Iis the preferred practice for mud tanks to be sited in an open area, but where ths is not practicable the area around mud tank locaied in an enclosure should, unless there is adequate artfcia ventilation, be classified as Zone 7 to the extent of the enclosure, with an additional Zone 2 area extending 3m from any ‘openings in the enclosure. For artificial ventilation sex 452 and Chapter 6, 4$4 Fora shale shaker located in 21 open area there should be a Zone J area extending 1.5m horizontally and vertically from its periphery, wtha further Zone ?area extending 6m from the Zone | area. This is shown in Figure 46, When a shale shaker is located in an enclosure without artificial ventilation, the enclosure should be classified as Zone 1, with an additional Zone 2 area extending 7.5m from any opesings 438 The extent of the hazardous area from sources on the ‘mud degasser system should be based on the guidance in Chapter 5, iS AND OTHER SYSTEMS [amin on the surface mad system may normally be Gicltled as sources of release because any leakage yal! be small with a low hydrocarbon content Ths jee surrounding a mud pumpis unclassified unless vip Licited in an area thatis classified because of some ‘ther Fully (see, however, 45.8). 457 in teirsct of 453 and 4.5.4 it should be noted that intlation io areas of significant hydrocarbon release Gt he et by the requirement of air change to mect thy, itental and health exposure criteria, rather {ht consideration of farmmabilty. In sheltered se Gmiised areas, local air velocities with the aid of local Lotte entlation can possibly be made high enough 2 470 classifying all ofthe sheltered or enclosed aren ib Zine 1 see 6.4 and 6.) Insomeinstances mud room Mt Gnes of 24 per hour have been selected 454 Wen driling mud itselfis considered to be hazardous cduence of factors as in 4.5.1 the extent of the husrtvas areas. based on Chapter $ should to stated For the equipment on the mud system with y, (Pon tanks being considered as sumps (see 5.12) of the estimated distances based upon 9" those defined above in 45,2 to 4.5.4 wed to define the hazard zones. ™ps and associated pipework, valves and 5 should Mus pr Powe $6 Herardous 1 wt san ve pena) 49AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS fitings should be considered as sources of release whey the mud is itself hazardous, and the extents of the ‘hazardous areas should be based upon Chapter 5. 4.6 GAS VENT ‘The main mud system gas vent can be located at the top. ofthe derrick or it can be remote from the drilling area. 461 When geological or other knowledge allows an estimation of the maximum likely vent rate then the extent of the hazardous area should be based on the Buidelines on vents in Chapter 5. When this infor- mation is not available, the hazardous area should extend at least 15m in all directions from the vent and down to ground level. ‘With a vent at the derrick top, any area within the Gerrick less than i5m from the vent should be considered hazardous, ‘The gas vent should normally be considered a secondary grade release. 47 OTHER SPACES The ventilation in any other spaces on a driling facility not specifically covered in this chapter should be assessed as outlined in Chapter 6 and the zonal classification and area boundaries for non-open areas assessed in accordance with Chapters Sand 6. This will, include: (a) Any enclosures which do not themselves contain a source of release, but which fall within, and with openings to, an external hazardous zone. In such a ‘case the internal space should be classified as having the same zone number as the external aiea unless protected by artificial ventilation as pre scribed in Chapter 6. There need be no hazardous area drawn from apertures in the enclosures beyond that covered by the area within which the ‘enclosures lie Where, for example, on an offshore installation, space does not permit utility process areas, electrical equipment rooms for switchgear, trans- formersetc, control room and accommodation or office areas to be located in a non-hazardous area, recommendations for protection by pressuri- zation//overpressure may be found in 6.538 ib) NOTE: In some cases the provision of an appro- priately rated fire wall between the ignition and release sources can reduce the extent of the hazardous area $0 a8 to provide adequate separation (sce 6.2.5) (©) Battery rooms should preferably be sited in a none hazardous area and, because of their release of 50 electrolytic gas containing hydrogen and oxygen they require specific urea classification. See 7.19 and the IEE Recommendation (Offshore Instal- lations), They should meet BS 6132 and 6133. 4.8 WELL TEST SYSTEMS Equipment to test_wells is often installed on a temporary basis. The extents of hazardous areas associated with a temporary installation should be determined from Chapter 5. When permanent facilities are provided to locate temporary well test equipment in specific locations, hazardous areas should be defined as though the temporary equipment was permanently installed 49 PRODUCING OIL AND GAS WELLS ON LAND 494 The below-ground cellar of an onshore producing gas oF oil well should after removal of the rig continue to be classified as Zone J as in 4.2.2, but with a Zone 2 extension above ground level extending 3m on each side of and Im above the edges of the cellar. 492 Where, however, an onshore producing well emerges flush from the ground, with no below-ground cellar or sump, only the above-ground Zone 2 atea is reievant, extending 3m from the centreline of the assembly, 493 Pumping Wells Where a well is equipped with a submersible electrically-driven pump, the motor of which is located in a cellar or below-ground sump, the classification should be as in 43.1 Where there is no cellar or below-ground sump the classification should be as in 4.9.2 Jn the case of a beam pumping well, the stufing box of the pump should be considered as a secondary grade release with a Zone ? hazardous area of 1m radius superimposed on the classification as in 49.1 or 49.2. 4.10 NON-ELECTRICAL SOURCES OF IGNITION While primarily aimed at the classification of areas for the selection and location of electrical apparatus, as in Chapter 7, the classifications indicated should be taken into account in the consideration of non-electrical sources of ignition. See Chapter 8 (8.4, mobile sources, 8.41, hor work; 8.4.2 to 84.4, gas detection equipment, 85, hot surfaces; 8.5.4, high-pressure hydraulic oil systems; 8.6, fired heaters; 87, combustion enginesCLASSIF'CATION OF DRILLING RIGS AND OTHER SYSTEMS including diesel engines (8.7.2) and gas turbines (8.7.4 10 8.8.3) 89, air intakes: 8.12, electrostatic and pyro- phoric ignition hazards), 4.11 OFFSHORE CONTINGENCY The use of alarm and shutdown systems utilizing gas detection etc., with redundancy to avoid false opera- tion, is covered in examples in Chapters 6 and 8, Where such systems are employed, provision must st be made to ensure independent means of providing “apparatus (such as emergency lighting, escape route lighting, voice and radio communications, etc) that is required to remain in operation with a type of protection suitable for the zone in question under the most adverse conditions. Usually this will mean that the protection is required 10 be of a type suitable in a flammable atmosphere. Furthermore, it should be ensured that such apparatus will not be de-energized or shut off as part of a shutdown procedure. It should be provided with an independent protected power supply such as a battery backup,5 ALTERNATIVE PROCEDURE FOR CLASSIFICATION OF AN UPSTREAM OR DOWNSTREAM PETROLEUM SECTOR FACILITY BY CONSIDERATION OF THE INDIVIDUAL POINT SOURCE 5.1 SCOPE ‘The scope of this chapter has been defined in 2.7 and2.8 as coveringall petroleum facilities which, by variability in their type and layout, operating pressures and temperatures or extremes of fluid volatility, are so diverse that they fall outside the cype examples of Chapters 3 and 4. Typical examples for which the procedure of this chapter should be adopted include oi] and gas stabilization plant, offshore and onshore process and 88 injection installations, natural gas liquid and refinery processing units, and those miscellaneous facilities, metering stations, pumping units, valve and filter stations, pig trapping facilities etc, that may be located independently of, or externally to, the type examples depicted in Chapters 3 and 4. It should be noted that process plant as typified under 27 will normally constitutea general Zone 2erea between plant boundaries within which there will be local Zone J and, more rarely, Zone O areas. Point source classification will entail consideration of each identifiable potential release, ie. pumps, compressors, vents and drain points, sampling connec- tions, separators etc, to determine which of these constitute Zone 0 or Zone / envelopes, or which would affect the overall Zone 2 boundary (see 2.10(c)). In utilizing the sequence of steps set out below to carry this out, it will be necessary, for the point sources concerned, to assess the following items: 1. The frequency and duration, ie. the grade of the release and, if this is not into the open air, the ventilation level of an enclosure in which a release ‘may be sited. This will establish the relationship between the grade of the release and the resulting zone number (0, 1 of 2), ‘The extent of the hazard =one, the size/rate of the release, the vapour-forming characteristics of the uid at the condition, or conditions if variable, at different points of the facility (see 2.11.2), the buoyancy of release (1.8 and Appendix C) and the degree of ventilation (1.7 and Chapter 6) IL. In carrying out these assessments for the individual Points of release, the governing principles set out in Chapter 2 (2.3, 24 and 2.10) should be followed. These are: (a) Where, in the case of a secondary grade Zone 2 release into the open air, it can be seen that the hazard radius obtained (see 5.4.3) of the source will fall within the general Zone 2 plant boundaries then, as stated in 2.4, such hazard sources need not be individually delineated on the drawing. (Where the release is not to the open air but to a lesser ventilated, enclosed or partially enclosed ‘area, a variation in procedure as outlined in 5.55 Step 3 will determine the classification.) In such ‘general’ zoning, it is not the practice to delineate any local non-hazardous areas, unless this is due to a special ventilation provision as under Chapter 6, such as overpressure or dilution ventilation, Features such as large-diameter drain points, vents and manhole covers that are blanked off or Plugged and play no part in normal operation (but are provided to enable draining, venting and gas freeing of the equipment in preparation for entry, inspection or maintenance) should not be co) ©.ALTERNATIVE PROCEDURE FOR CLASSIFICATION considered (see 2.3), The large releases that they would give rise to are not relevant (0 the area classification, and the requisite control when these are to be activated would be by work permit (see Chapter 8). The fuid condition of such a release under the shutdown condition may also vary and be of a different vapour producing level than under normal operating conditions. An example would be the fluids in a fractionator column or receiver which at shutdown ‘might be less well separated from lighter fractions. Guidance for this type of activity falls into the cleaning and gas freving section of codes such as the IP ‘Marketing. Tark Cleaning and Refining Safety Codes. 52 , this chapter comprises two parts (2) Guidance, as in 5.3 to 5.5,as to the individual steps that should be taken to carry out the evaluation of items I and IT above. Sections 5.6 to 5.14, giving details of the release characteristics to be usec for the categories of point source to be considered, with a design commentary as to selection and effect of sizing variation, & 5.3 EXPLANATION OF THE ‘POINT SOURCE’ CONCEPT AS USED IN THIS CODE (@) Before proceeding to theevaluation of equipment, a description of the term ‘point source’ as used in the following sections is appropriate ‘The natures ofthe releases that are to be evaluated under this category as point sources have been identified in 232 and 5.1. Some are true point sources, as with vents, drains and sample points; other equipment items dealt with in 5.6 to 5.14, such as the case of a pump unit (5.6), arecomposed of an assembly having a umber of such indiv- idval release points, each with an individual release potential in terms of frequency and volume (rate) of release, but which after cone sideration as in 5.6 can be treated as a ‘composite Point source’. However, the relevant design notes should always be reviewed, and where necessary any variant circumstances departing from these general design criteria considered, as in 5.5.7(b). ‘The importance of choosing the correct construc- tional materials should be stressed. Thus materials for gaskets, joining compounds, gland packings etc. should be chosen based on proven and satisfactory experience, © © 33 5.4 DETERMINATION OF THE GRADE OF RELEASE 54.1 This. simply is the expression of frequency and duration im accordance with the international defi nitions of ‘continuous ‘primary’ oF secondary" as stated in 154.1 to 15.43, ‘The grade of release is independent of the ventilation levels or the nature and volatility (vaporizing potential) of the fluid, the rate/volume of the release, oF any other physical aspects $42 In assessing the frequency (grade) of a release the Following points are pertinent: (a) Some reteases are controlled operationally, &.g, sampling and drain points, most (if not all) vents, filter cleaning and pig receiving operations. Other releases are not so controlled, but result as, leakage from equipment failure, such as pump seals, glands and pipe flanges. Tn the case of operationally controlled releases no one grade of release is applicable, since the operational frequency chosen will determine whether the equipment release should be graded aS primary, secondary or continuous. Such @ decision can usually be made at the planning stage, and as a rough but informal rule-of-thumb guide reference may be made to 1.5.5.2. Further guidance i given in the design notes in 5.6 to 5.14. For releases that are uncontrolled as in (b) above, generalized assessments from experience for the equipment type in question, eg. pump and compressor seals and glands, flanged joints etc., have been compiled and incorporated in the design notes of 56 to 5.14 and can be used aceordingly—or until individual failure rates become apparent by observation, eg, where service conditions are untypical, as where fluids handled are corrosive or abrasive. Again, correct choice of materials for gaskets, glands, seals ete. is important (see 5.) o) © @ 5.43 Relationship between Grade of Release and Hazard Zone ‘The terms grade of release and ‘zone number’ are not synonymous. The grade of release is dependent only on the frequency/duration of the release. It does not vary with ventilation level or any other variable. The relationship between hazard zone number and grade of release in an enclosed of artificially ventilated area is, however, dependent upon both the grade of release and the degree of ventilation provided (see 1.5.3.1 10 1.53.4, 1.5.5.3 and 1.5.54). In the lntier case the zone number relationship should be arrived at by reference to Chapter 6 andAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS. Table 6.1 or, where the release is external to the ‘enclosed area, 1o Table 6.2. 5.5 DETERMINATION OF THE EXTENT OF A HAZARD ZONE For a release from a point source specific item of equipment the factors determining the extent and hhence the sizing of the hazard zone include the vaporizing potential of the fluid release, its buoyancy, the ventilation state and the rate or volume of the release, 551 ‘The procedure following outlines the steps that may be utilized for this evaluation, using the tabulation data in 5.6 to 5.14 and their accompanying design notes for a ange of equipment sizings. Ttshould be emphasized that the figures resulting are independent of the grade of the release, as a given equipment release for comparable fuid conditions and theextent ofthe hazard zone will be the same regardless of the frequency at which it occurs, whether primary ot secondary, though this will determine as in Chapter 7 the type of protection requisite for installation in that zone. 352 To cater for the large number of different conditions and the need to simplify theie representation in the tabulated formats of 56 to 5.14, wo additional parameters as outlined in L9 and 1.6 have been used. These ate hazard radius and fiuid category as follows. 533. The Hazard Radius ‘This term, defined in 1.9, has been used in the tables in 56 to 5.14 to indicate the horizontal extent of hazardous area generated by a point source in the open air for each of the alternative fluid categories outlined in 5.54. Having been selected from the appropriate section 56 to 5.14, the hazard radius is then used in the steps outlined in 5.5.5 to obtain the three-dimensional form and extent of the hazard zone envelope, taking into account the various ventilation situations shown in Figures 6.2 to 6.10, $54 The Concept of Fluid Condition or Category ‘The extent of vapour travel and, hence, the hazard radius for each point of release to be assessed will be a function of the fluid characteristics and vapour- forming condition under the circumstances of release, including mass or mass rate and the rate of vapori- zation. For release under the more extreme conditions of fluid temperature, pressure and volatility as described in 27 and 2.11.2, the simple class by flashpoint as in Appendix A will not suffice, and the four additional categories of fluid condition outlined below have been introduced in the tables of hazard radii in 5.6 to 3.14, The four categories, distinguished in order of vaporizing potential, are: Fluid Category A. A flammable liquid which, on ‘release, would vaporize rapidly and substantially. This category includes: (a) Any liquefied petroleum gases (IP Class 0) or lighter flammable liquid in processing conditions, whether refrigerated of under pressure, other than in normal storage and distribution (for which the type examples of 39 may be used for con- venience. (©) Any flammable liquid at a temperature sufficient to produce, on release, more than about 40% vaporization with no heat input other than from the surroundings. Fluid Category B. A flammable liquid, not in Category A, but at a temperature sufficient for boiling to occur on release Fluid Category C. A flammable liquid not in Categories A or B, but which can, on release, be at a temperature above its flashpoint, or form a flammable mist. Fluid Category G. A flammable gas or vapour. Further detailed notes on these luid categories, their relationship to hazard radius as defined in 5.5.3 and the ‘means by which, from the physical characteristics of a petroleum liquid other than crude oil (see below), the Suid caregory may be determined, are given in ‘Appendix B. For the upstream application, unstabilized crude oil should be placed in Category B because of the wide boiling range and large proportion of material boiling above 250°C, while stabilized crude oil should be treated as a Category C liquid. Crude oil may be regarded as stabilized when separation from gas has been at a pressure below 1.1 bar(abs), or it has been shipped in a conventional tanker. For condensates see Appendix B (B.2(). NOTE: For the simpler types of operation and type of petroleum that are to be classified by point source (as outlined in 2.8) by the procedure of this chapter, the classification of the petroleum liquids by class of Flashpoint as used in Chapter 3 and defined in 2.12 will be all that is necessary. In such cases, in assessing the hazard radius by the use of the tables of 5.6 to 5.14, Class I, 12) and T112) petroleum should, as in note 4 to Appendix A, be treated as fluid category C, while Classes TI(1) and ITI{1) generally will be categorized as ‘non-hazardous’ in accordance with due consideration of mist or spray formation as in 2.12.3,ALTERNATIVE PROCEDURE FOR CLASSIFICATION 555 Procedure to Assess the Dimensions of the Hazard Zone around the Point Source by Haza Radius/Fluid Category Using these concepts, the procedure to be followed in sizing the three-dimensional zone envelope is outlined in the three steps given below. Steps 1 and 2 are common for all cases; Step 3 will differ according to whether the release is to the open air or to a sheltered area or enclosure, in which case the degree of ventilation will be a further factor. It should be reiterated that the extent and dimen- sions of the hazard zone generated from the release are unaffected by the grade of release (5.5.1). The sizing of the hazard zone will be the same irrespective of its zone number. ‘Step 1. From the information gathered as prescribed in2.2 for each of the equipment tems that constitute a source of release, the fluid category of that release should be ascertained utilizing the guidance given in either 5.5.4 or Appendix B. For the simpler situations outlined in 2.8, the fluid category corresponding to the dass of petroleum will bbe Category C for Classes I, 11(2) and [11(2) or non- hazardous for Classes I(t) or I1I(1) as in the note to $34. In this latter case Steps 2 and 3 will not be necessary. Step 2. Having established the fluid category, the tabulation in the relevant equipment section 5.6 to 5.14 should be read off and the appropriate hazard radius in open air selected in accordance with the relevant factors of design listed, eg. diameter in the ease of drain and sample points, vents, or pump, flange or valve type—all of which will directly influence the size or rate of release. If the hazard radius so obtained appears incon- veniently large, consideration of smaller diameter or of a design variation should be made. If this proves not possible the option of 5.5.7(e) could be considered, Step 3 (a) For release into an unrestricted open area, Having read off from 5.6 to 5.14 the selected hazard radius im open air for the chosen size of equipment, the hazard zone dimensions for releases heavier than air (as described in Appendix C) can be obtained by applying this hazard radius directly to Figure 62, For releases lighter than air the same procedure should be utilized, using Figure 6.3. Sheltered areas. For sheltered area ventilation conditions, the hazard radius obtained in Step 2 should be applied as in 6.4.3, making use of Figures 64 to 68, The zonal classification of the Iuacarddous area srould be the same as for the same source in an open area Enclosed areas. For an enclosed area, whether containing an internal source of release or where () ic) 55 an enclosed area abuts an external hazard zone, 6.5 should be followed. From 6.5. it willbe seen that the type and level of the ventilation will determine the zonal grading ‘of the enclosure in accordance with clause 5.4.3 and Table 6.1 or 6.2 (ifthe release is an external one). Because of the confining nature of enclosed space the spread of vapour throughout that space ‘must be assumed to be throughout its entire area, except in the case () where a part of the enclosed space is separately ventilated by local artificial venti- ation, a8 in 6.5.3 and 6.546 (see note 5 to Table 61), oF where a very large building is concerned with ‘only natural ventilation relative to which there are only moderate sized releases (See note 6 to Table 6.1). For circumstances other than (i) or fi) above, the zonal level derived from Table 6.1 or 6.2 should be applied to the total enclosure, An enclosure containing an internal source of release(s) with openings to the exterior. In such a case 6.5.1.1(¢) will apply. Thus the extent of the hazardous zoning around apertures in connection with the open air should be determined from either Figure 6.9 or Figure 6.10 by taking the open area hazard radius obtained from 5.6 to 5.14 for the biggest of all the sources of release within the enclosure (see also 6.5.9) and (b)). ‘The grading of the external hazardous areas will be in accordance with notes 2 and 3 to Table 6.1. Ducted and exhaust vents from an enclosure. See 6.55(0). (i) ¢) © S56 The use of the alternatives (c) to (¢) in Step 3 will enable the classification of or around the enclosure to be completed. Section 6.6 should be consulted in respect of the effect of loss of ventilation on the area classification and the protection against this that should be given, and this should be added to the records 5.5.7 Comments on the Use of 5.6 to 5.14 in the Above Procedures In the use of 5.6 to 5.14 and their recommendations of hazard radius at the appropriate fluid category, it should be noted that: (@) The guidance provided as to the effect of equipment design should be used to enable a check to be made on initial choice of equipment lype and size relative to acceptable hazard radius Sections 5.11, covering pools from liquid spillage, and 5.12 (sumps, interceptors and sep- arators) are not strictly point sources, but theAREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS (b) As stated in Appendis D, the recommended radii are based on existing good practice but judgement ‘must always be applied in using them. If on a specific item of equipment itis considered for any Feason that an abnormally high release could ‘occur, then the extent of the hazardous area should be increased, Where a case arises that does not conform to the typical release circumstances covered in 5.6 to 5.14, 2 calculation of leak rate can be cartied out to suit the particular situation and a recognized model for the dispersion of hydrocarbons in the atmosphere applied to derive a hazard radius figure. Alternatively, in such situations, the careful monitoring of releases from an already opera- tional equivaient plant layout can be indicative, provided all the factors, including fluid nature and conditions, meteorological conditions etc, are confirmed to be comparable. In all cases it should be confirmed using the procedure of Chapter 6 that the ventilation requirements will be met. ‘On a particular facility the vents and drain points, from vessels and instruments can influence the boundary of the overall Zone 2 hazardous area, ‘and the exact locations of these may not be known when the initial hazardous area drawing is Prepared. The hazardous areas as derived in such a case should then be drawn from the extremities of the equipment or pipework containing the vent or drain point. Inthe use ofthe hazard radtus tabulations in 3.610 5.14 to assess the effect of variation in equipment size, it may be found that even the smallest practicable choice would give rise toa greater size ‘hazard zone than could be met within the limits of the space available. In such a situation, considera- tion may be given to the practicality of adding a fire or deftection wall that could reduce the space requirement, as in 6.25. The final area classification should include a record of all additional supporting details as outlined in 2.13 to 215, NOTE: Examples of the use of the Chapter 5 procedure are given in Appendix E, © (a) 6) « 5.6 PUMPS Pumps should not be sited below grade level. Where weather conditions permit, pumps handling flammable liquids should preferably be installed in the open air in an open-sided structure with only overhead weather protection. This is typical of an onland situation, as in the example given in 6.4.2(a. In.a more severe weather situation, such as offshore 56 orin an arctic climate, a greater degree of enclosure will be necessary and a choice of ventilation options should be made. If a pump has to be enclosed in an inadequately ventilated area, the interior of the enclosure should be classified as Zone 1, since the continuous dilution of any flammable release will not occur, with any openings to the exterior classified in accordance with 6.5.1 and Figure 6.9. In a majority of cases itis preferable to consider a form of ventilation that will mect the criterion of adequate ventilation of a minimum of not less than 12 air changes an hour in accordance with 6.34. This can be achieved either by: (@) 2 louvred construction with sufficient apertured area to give adequate natural ventilation of 12 air changes an hour, allowing classification as a sheltered area in accordance with 6.4.2(b) and 64.3(b); Figure 6.6 will apply to the classification external to the apertured walls; or adequate centilation may be achieved by artificial ventilationas in 6.5.4, and Table 6.1 and Figure 6.9 will again apply. ) Inall the above alternatives, the procedures outlined should be applied in conjunction with factors relevant to the type of pump and nature of the Fluid handled as, in 5.6.1 to 565. 56.1 Sources of release on pumps include their seals, vents, drains, valves, piping flanges and flter/steainers. They are normally all secondary grade sources because flanges are broken, filters opened and vents and drains operated infrequently. Seal filure resulting in appreci- able release of liquid is also unlikely. Should any of these operations be cartied out frequently then the item should be regarded as an individual primary grade source and the hazard radius estimated using the succeeding sections in this chapter. 562 Otherwise a pump should be regarded asa single point source for the purposes of area classification. The composite hazard radius should be determined from Table 5.1 ‘Table 5.1. Pumps Hazard radius (9). - Standard High integrity Fluid category pump pomp A 30 15 B is 3 c 13" 3 “For clean liquids, og fished products which are pumped from stmospherie stoage at rater not exceeding IGOr?/h, the hasard rads a3 be redeed to 3ALTERNATIVE PROCEDURE FOR CLASSIFICATION In this table the term high integrity’ refers toa pump in which the system design reduces the probability of release. For example, high integrity pumps may be of the glandless type or fitted with a double mechanical seal system with means of detecting leakage of the inner seal and no operational vents or drains or other likely release sources for Category A or B material direct to atmosphere A vent or drain blanked in normal operation and used only on a depressured, shutdown plant should not be regarded as an operational vent or drain, 5.63 ‘The hazardous area for the pump should be drawn from the periphery of the pump. For this purpose the term ‘pump’ should include the associated equipment which can be sources of release. 564 Pumps fitted with a single mechanical seal should have fan external throttle bush. If not, the hazard radives should be increased to at least the distance required at one category more severe, e.g. from 7.5 to 15 m because more fluid would be released in the event of seal failure, 5.65 On pumps with single mechanical seals pumping Category A or B liquids there is likely to be some small continuous vapour leak around the seal, Pumps with packed glands are not recommended for these liquids but can be used on Category C liquids when there is likely to be a continuous weep of liquid. ‘The packed glands for Category C liquids and single ‘mechanical seals for Category A and B liquids should both be regarded as a primary grade source with a hazard radius of 0.3 m. This is not intended to govern the type of protection of the motor (which should conform to the general Zone 2area) but can limit the proximity of instrumentation. The larger release which would occur if the seal failed is covered by the secondary grade hazard radius determined from Table 5. ‘Table 52. Drains and liquid sample points “Hazard radius (es) Fluid Diameter* Diameter* Diameter* Diameter" category = 3mm 6mm 2mm 25mm. A 15 15 30 t B 3 5 30 c 03 1s is 3 = Thisisthe diameter of the smallest item on drain or sample line, ling, valve or rettretion orf {For thisdiameter, the radius exceeds 300m. The sizeof the potetial Telesis grater than that normally cansidered for area clacrfcaion land should be avoided. For the cae of releases as tabulate, hick ‘would sult in hazard radi of 30 or 1S, it may be chosen fo use Timiter or restriction orifice reduce hese gues ifa closed system ‘sot te be provided 31 566 ‘Where adequate ventilation is utilized to gain the Zone 2 classification it is recommended that pumps should hhave high integrity seals. S67 See also 8.7.1 for the use of a vapour-tight wall with sealed sleeving between the engine drive and driven pump. 5.7 EQUIPMENT DRAINS AND LIQUID SAMPLE POINTS Sa This section applies to equipment and instrument drains and liquid sample points direct to atmosphere. The hazard from these depends upon construction, and can include, for example: @) &) ‘open valve draining to the ground, ‘open valve draining to tundish and drain system, and (©) vaive draining to closed cabinet and drain system. ‘These have an effect on the zone of release. Gaseous sample points or drain points from gas systems should bbe considered as vents. Good practice is to allow for abnormal release if a sample valve were to be jammed ‘open, for example by double valving. 572 Drains and sample points should be graded based on the expected frequency of use. They should be regarded asat least primary grade sources if used more than once a day. 513 Drains and sample points should be regarded as point sources, The hazard radius should be determined from Table 52, 504 ‘The system should preferably be designed to avoid draining or sampling liquids in Category A or B direct to atmosphere. Where possible such liquids should be cooled so that they are in Category C before draining, or sampling. When this is not feasible, eg. with LPG, then equipment drains should be connected to a closed system. Samples should be taken in a closed container such as a sample bomb. There should be @ hazardous area of 3m radius around the sample points. When the lines and homb are not purged toa closed system there should be an additional hazardous area extending from the point of purging, The size of this arca should be determined from Table 5.2AREA CLASSIFICATION CODE FOR PETROLEUM INSTALLATIONS, 518 (On some process drains, the fluid normally drained is non-flammable, but flammable material could ulti mately be drained. A typical example is water draining from a process vessel. The hazardous area should be based on the flammable liquid unless precautions are taken to ensure that draining of flammable liquid is improbable, Suitable precautions which would reduce the process drain to a secondary grade source of release inchude: (a) ( draining into an intermediate drain pot or the use of multiple valves on the drain including at least one valve which springs closed unless held ‘open by the operator. 516 In the case of process drains, which in normal operation are closed by a space or blank and are used only during shutdown following depressurization, note should be taken of S.1(@) and 2.3.2, second paragraph. However, when itis desired to classify such a drain point, the fluid category should be based on the ‘material at shutdown and the drain should be regarded asa secondary grade source of release. However, where these are of large diameter, 5.1(c) should be followed with opening carried out only under work permis control 5.8 COMPRESSORS The prefatory comments in regard to pumps in 5.6 are applicable to the installation of compressors. S81 ‘Sources of release on compressors include seals, glands ané joints. For the purposes of area classification the compressor should be regarded as a point source. The hazard radius should be based on Table 53. The hazardous area should be drawn from the periphery of the equipment, 582 Any vents or relief valves on flammable material duty, including vents from the seal and lub oil system, should discharge to a closed system or to atmosphere ata safe location. The hazardous area around the vent should be ‘Table £3, Compressors Gas buoyancy Hazard radius (a) Heavier than air 15° Lighter than air 3 "The radius may be reduced to 75m for pressures below 20 arabs) and shalt diameters of SOmm or les For diaphragm compresors the hazard radus may be reduced to 3m provided there are no vents or drains to aimosphere at the compressor 58 based on 5.9. Similarly liquid from knock-out drums or pulsation dampers should preferably drain through vented degassing pot to a closed drain system, The hazardous distance for vents and drains should ‘be determined independently of the compressor based on 57 and 5.9. 583 Piping on the compressor systems may be subject to vibration. The distances recommended in this section assume that failure of joints and nozzles due to vibration will not take place. 584 See also 5.66 and 5.67, which are applicable to compressors. 5.9 INSTRUMENT AND PROCESS VENTS TO ATMOSPHERE ‘Venting of process vessels to the open atmosphere is subject to environmental constraints, except where the release quantity is acceptable. However, the guidance following is offered. 59.1 Vents should be classified as continuous, primary or secondary grades of release depending on the frequency of operation Vents used frequently (e-2 daily) should be classified as primary grade as a minimum, 592 ‘The hazardous area is normally classified as Zone 0, 1 or 2 depending on whether the release is continuous, primary or secondary grade. For some vents there may bea small flow froma continuous or primary grade with 2 larger occasional flow, for example during abnormal or emergency operation. When the expected frequency Of the larger release is such that the source would be graded as secondary for this release, then the hazardous area should be Zone 0 or J, depending on the grade of the smaller release, and surrounded by a larger Zone 2 area defined by the larger flow (see also 5.1(c). $93 Emergency relief systems to atmosphere should be designed in accordance with the IP Refining Safety Code. The catculation methods to determine the distance to the lower flammability limit are in API RP52i and should be used for discharge velocities above 150 mys, 594 The hazardous area from other process vents to atmosphere with discharge velocity of 150:m/s and below should be based on Table 5.4, These recom-ALTERNATIVE PROCEDURE FOR CLASSIFICATION Table 5.4, Process vents Vent vate at ambient conditions Hazard radius (m7) () Lass than 10 3 10-100 1s 100-200 1s ‘Nove: This table apoties onto velocities upto 130 mys. t applies heavierthanair gases and vapours with untestricied discharge ‘psnurde sin 59, For lighter-thanair gases discharged upwards. Sim hazard radius may be used or alteratively the radius may be biained by calewation, mended distances are based on unrestricted upward discharge and dispersion of vapour without condensa- tion. Direct venting to atmosphere of material which could condense should be particularly avoided. 595 ‘Gaseous sample points should be designed so that the flowrate is less than 10m'/a at ambient conditions. It may be necessary to ft some kind of flow restrictor on high-pressure systems, 596 ‘The hazard radius from vents on instrument systems should be based on Table 5.5. This includes vents from Tevel glasses on vessels. ‘Table $5. fnstrument vents Hazard radius (mn) Fluid Diameier™ Diameter Diameter” category ‘6mm 2mm 25mm A 73 18 30 B 3 75, 15 c 03 13 3 G 3 5 5 (2 This isthe diameter ofthe smallest om oa the vent line line, ‘ale oF retcetion ons. 397 Vents from underground storage tanks are considered in Chapter 3. 5.10 PIPING SYSTEMS S101 Piping systems designed and constructed to ANSI/ ASME B3i3 or equivalent and without valves, instruments or flanges should not be considered as sources of release $02 Flanges should normally be considered as sources of secondary grade release. They should be regarded as primary grade when they are broken during normal 99 operation, e.g. for spade changing, so that a release is likely to occur. As a guide a flange should be considered a primary grade of release when itis broken with a frequency greater than once a week. There should be valves adjacent to the flange to minimize any release. 5103 Many flanged joints are rarely broken, e.g. only during major maintenance work, typically at intervals of about 2 years or more. Any leakage from these joints is likely to be small, A nominal hazard radius of 1.5m from the periphery may beassumed for such jointsona well-maintained system provided there are no factors that could increase leakage, ¢.g. pressure of thermal shock, including the effect of rain, or an excessive piping load on the flanged joint. For other flanges the hazard radius is shown in Table 5.6. “Table 56, Flanges and valves Fluid category Hazard radius (en) A 3 B 3 ¢ 1s G 3 ‘Note: Tis able assumes pipework construction to recognized codes apd standards. Foc this reason the possibilty ofthe Blowout of part ‘of a gasket has not been consisered 5.104 ‘Small-bore pipes are more pron¢ to accidental damage and possible release to atmosphere. Bracing of stnall- bore connections used for purging, draining, venting, sampling, pressure gauge connections, injection points, etc, should be considered in accordance with the IP Refining Safety Code. Pipes smaller than 15mm diameter should be avoided. When this is not possible, eg. on instrument systems, then tubing with an upstream isolating valve close to the vessel or main line should be provided. ‘The possibility of release due to fracture should be considered for these small lines, They should be treated as potential drains or vents. S105 ‘Ona valve, the source should be considered to be the packed gland or other sealing device. Well-maintained infrequently used valves should normally be regarded as secondary grade releases because leakage is unlikely, The hazard radius should be assessed as for flanges. Leakage is more likely on frequently used valves with packed glands, including control valves, because of wear on the packing, They should be regarded as producing an additional primary grade release with a nominal hazard radius of 0.3m,