Section: Evaluations For Hazardous Risks in Power Stations, Application: Mineral Oil Separators

5838 GEEP Contract
Rehabilitation of HCO Treatment Plant

Power Station: Al Quds
Centrifugal separator type OSD60 / WSD60
Section:
Evaluations for Hazardous Risks in Power
Stations, Application: Mineral Oil
Separators
When is explosion proof design required?
explosion proof design has to be considered :
when the intended area of installation is

classified as a hazardous area (Ex-Zone)
when flammable gases, vapors or dusts may be present in the area,

and the hazard assessment indicates a need for a are classification
into a hazardous area (Ex-Zone)
The EN 60076-10 / IEC 60079-10 and its referenced standards can be

used as basic for the area classification and proper selection of
electrical apertures .
2 Evaluations for Hazardous Risks in Power Stations engineering for a better world
Pre-Condition for an Explosion:
Ignition Source Oxygen (O2)

Fire, usually from air
Spark,
Hot Surface
Flammable Material
Gas, Vapor, Mist, Dust
A explosion is impossible if one (1) of these three pre-condition will be eliminated
Effects of an explosion
Cyprus Power Station, 2011

ignition of explosive material in the neighboring naval base
UK, Buncefield Oil Depot, 2005
Toulouse, fertilizer factory, 2001
Explosion-related characteristics – flash point
Classification of flammable liquids:
according to regulation 67/548/EEC for liquids:
Designation: R-Phrases: Criteria:
extremely flammable R12 flash point < 0°C,

boiling point <35°C
highly flammable R11 flash point < 21°C
(but not extremely flammable)
flammable liquids R10 flash point 21°C – 55°C
Liquids with flash points above 55°C do not belong to the group of
flammable liquid as defined in the regulation 67/548/EEC
(subject to ambient temperatures of up to 40°C)
Diesel Oils / Distillate Oils
Product Properties - Classification

• Diesel Oils / Distillate Oils are petroleum distillates and blends of
petroleum distillates and gas oils from the atmospheric and vacuum
distillation, boiling range 170 – 390°C.
• Also typical used designations: Marine Diesel Oil / MDO (DMX, DMA,
DMZ) Marine Gas Oil / MGO (DMX, DMA, DMZ), Distillate Marine
Fuels (DMX, DMA, DMZ), Bunker A, Heating Oil EL, Road Diesel,
Distillate No.2, No.2 Fuel Oil, DST.2, DMT.2, 2-GT, NATO F-76.
• The typical viscosity ranges of the various Diesel Oils / Distillate Oils
is 1,3 … 6,0 cSt @ 40°C which allows a separation at ambient
temperature.
• Diesel Oils / Distillate Oils have typical flash point of > 55°C (DMX
grade > 43°C) as in indicated in the various applicable standards.
• At ambient and process temperatures below the flash point no critical
evaporation of flammable vapors have to be considered.
General Evaluation
• The flash points and initial boiling points of Diesel Oils / Distillate Oils
are usually above the process and ambient temperature.
• A critical evaporation of gases an vapors at temperatures (with an
sufficient safety margin) below the flash point is not given.
• For the determination and identification of hazardous zones the
evaporation of flammable vapors coming from the released Diesel
Oils / Distillate Oils and the released product mist/spray (if any) has to
be considered.
• During normal operation only minor releases of Diesel Oils / Distillate
Oils (if any), may be as part of maintenance (cold condition), to the
surrounding area have to be considered as secondary releases.
• From Diesel Oils / Distillate Oils puddles, may be coming from leaks,
no evaporation of flammable gases have to be considered at usual
ambient temperatures.
Evaluation – Inside Separator

Shut-Down & Operation Vent
Rest’s of fuel oil have to be considered

inside the separator and sludge box
STOP
&
cold
During shut-down periods and operation

with temperatures below flash points no cold
evaporation of flammable vapors inside
sparator & sludge box can be expected
Evaluation – Outside Separator

• Due to the low operation pressure in the Diesel Oils lines an
atomizing of the Diesel Oil and a resulting formation of an ignitable
mist/ atmosphere will not occur in case of an accidental secondary
release (i.e. flange leakage).
• All installed electrical equipment of the ECU modules are of protection
class IP54/55/65. By this protection class a permeation of oil spillages
into the electrical equipment will be prevented in case of a secondary
• An explosion proof design and execution is not mandatory,
Exception:
the actual ambient/process temperature is above the flashpoint,
or the area is classified as an hazardous area (Ex-Zone) by the
operator/contractor due to other reasons (flammable vapors from
other process nearby, insurance requirements, general specification
requirements, etc.).
Residual Fuels / Heavy Fuel Oil (HFO)

• Residual oils or heavy oils coming direct from the refinery column
have usually boiling points >350°C and flash points >100°C.
• For adjustment of the viscosity and ignition properties, these oils will
be usually blended with light fractions (distillate oil, kerosene, etc.)
coming from the refining process, but this blending decreases the
flashpoint of heavy fuel oils and residual oils drastically.
• Heavy Fuel Oils / Residual Fuels of different categories which are

offered on the market are specified with a
flash point of min. 60°C as per ISO 8217 or CIMAC standard.
• At ambient and process temperatures below the flash point no critical

evaporation of flammable vapors have to be considered.
General Evaluation
• However, at liquid/ process temperatures above the flash point (e.g.
98°C separating temperature) an assessment with regard to the
release of flammable vapors should be carried out.
• The initial boiling points of HFO and HFO blends are usually above
the process temperature, but a considerable evaporation of gases an
vapors begins already at the flash point.
• For the determination and identification of hazardous zones the
evaporation of flammable vapors coming from the released HFO
and the release product mist/spray (if any) has to be considered.
• During normal operation only minor releases of HFO (if any), may be
as part of maintenance (cold condition) to the surrounding area have
to be considered as secondary releases.
• From HFO puddles, may be coming from leaks, no evaporation of
flammable gases have to be considered at regular ambient
temperatures.

Shut-Down Vent

inside the separator and sludge box
STOP
During shut-down periods with

temperatures below flash point cold
no evaporation of flammable vapors
into the separator can be expected
Evaluation – Inside Separator Vent

Operation
inside the separator sludge box
?
?
At separating temperatures above the flash

point evaporations are possible and have t (°C) > Flash Point
to be considered while the separator is in
operation.

Operation
GEA Westfalia Separator made
calculations and lab. Tests
in order to verify if inside the
sludge box a
hazardous area
will built-up during
normal operation
t (°C) > Flash Point

Operation
GEA Westfalia Separator made
calculations and lab. Tests
in order to verify if inside the
sludge box a
hazardous area
will built-up during
normal operation
Due to the “High Ventilation (VH)” Air Inlet

of the rotating separator bowl and via
t (°C) > Flash Point
low evaporation rate of the blends Frame Drain
no critical vapor concentration will built-up.

• Due to the low operation pressure in the HFO lines an atomizing of the
HFO and a resulting formation of an explosive atmosphere will not
occur in case of an accidental secondary release (i.e. flange leakage).
class IP54/55/65. By this protection class a permeation of HFO
spillages into the electrical equipment will be prevented in case of a
secondary release (i.e. flange leakage).
Exception:
the area is classified as an hazardous area (Ex-Zone) by the
operator/contractor due to other reasons
(e.g. flammable vapors from other process nearby, insurance
requirements, general specification requirements, etc.).
Crude Oils (CRO)
Crude Oils (CRO)

• Crude oils coming from the well, coming from the de-salting process
or offered on market, after transport and distribution,
have usually flash points below 21°C or below or 0°C.
• De-gassing and flaring during the production process will not shift the
flash point into uncritical ranges, e.g. similar for HFO’s.
• Crude oils oils with a flash points:
< 0°C belongs to extremely flammable liquids
< 21°C belongs to highly flammable liquids
21 - 55°C belongs to flammable liquids (un-usual)
• At regular ambient & process temperatures always
a evaporation of flammable vapors have to be considered
• A hazard assessment and a area classification into (Ex) Zones is
mandatory by the operator/contractor.
Crude Oils (CRO)
General Evaluation
• The ambient temperatures are usually above or closed to the
flash point of crude oils.
• During normal operation minor releases of Crude Oil (may be as part
of maintenance or from leaks) into the surrounding area have to be
considered as secondary releases.
• From crude oil puddles (may be coming from leaks or maintenance
works) an evaporation of flammable gases have to be considered.
• The separating temperature (55°C - 98°C) for crude oil is always
above the flash point. A certain evaporation of flammable gases
from released crude oils have to be considered in any case.
• The evaporation rate of flammable gases at intended temperature is
in most cases unknown, and is subject of the actual used crude oil.
• Assessments with regard to the area classification into
hazardous areas (Ex Zones) should be carried out.
Crude Oils (CRO)

Shut-Down Vent
Rest’s of crude oil have to be considered

inside the separator
and sludge box
STOP
O2
O2
O2
O2
O2
O2
O2
During shut-down periods at Cold / t (°C) > flash point

ambient temperatures (> flash point)
an evaporation of flammable gases
into the separator must be expected
Crude Oils (CRO)

Start-Up / Operation Vent
The centrifugal clutch and the

neck bearing are possible
ignition sources
during Start-Up
& Operation
O2
O2
O2
Clutch O2
O2 Neck
O2
O2Bearing
Cold / t (°C) > flash point
Crude Oils (CRO)

The friction pads

of the clutch
heats up,
especially during
Start-Up phase
O2
O2
O2
Clutch O2
O2 Neck
O2
O2
Bearing
t (°C) > flash point
Crude Oils (CRO)

The friction pads

of the clutch
heats up,
especially during
Start-Up phase
O2
O2
O2
Clutch O2
O2 Neck
O2
O2
Bearing

The ball bearing can heat up when worn out.
Crude Oils (CRO)

O2
O2
O2
Clutch O2
O2 Neck
O2
O2
Bearing

The hot surfaces can lead into a ignition
of flammable gases
Crude Oils (CRO)

The potential of
hot surfaces cannot
be eliminated
totally.
O2
O2
O2
Clutch O2
O2 Neck
O2
O2
Bearing
Therefore the ignitability of the inner

atmosphere (oxygen-gas mixture) has to
be eliminated before Start-Up and during
operation, in order to avoid an ignition
Crude Oils (CRO)

The ignitability of
gas-oxygen mixtures
can be eliminated
O2
O2
O2
O2
O2
O2
O2
by displacement of:
flammable gases Fresh Air Flushing
Crude Oils (CRO)

The ignitability of
gas-oxygen mixtures
can be eliminated
by displacement of:
flammable gases Fresh Air Flushing
or by displacement of:
oxygen Nitrogen Blanketing
Crude Oils (CRO)

Fresh Air Flushing
In-line stable
before and during detonation
Start-Up / Operation flame arrester
Non-Ex Ex
flow
O2
supervision
O2
FAL
< LEL
O2 < LEL
air blower PIT
O2 < LEL
< LEL
O2 < LEL O2
O2
< LEL
frame drain flame arrester
By flushing with fresh air of sufficient air flow t (°C) > flash point
the gas concentration inside the separator will
reduced below the Lower Explosion Limit “< LEL”
Crude Oils (CRO)
Fresh Air Flushing
Crude Oils (CRO)
Evaluation – Inside Separator In-line stable

detonation flame
Start-Up / Operation arrester Vent
Nitrogen (N2) Blanketing
initial flushing
before and during hood
Start-Up / Operation N2 relief valve
60 mbar
FAL N2 flow
supervision
FIS
blanketing 150 Nl/h

N2
FAL
N2 N2
(pure) FIS
N2
< LEL N2
initial flushing 2500 Nl/h N2
press. supervision
PAL
By initial flushing and N2 blanketing during t (°C) > flash point
operation the oxygen content inside the
separator will be displaced and the entry
of oxygen from outside will be prevented.
Crude Oils (CRO)
Nitrogen (N2) Blanketing
Crude Oils (CRO)
• The ambient temperatures are usually above or closed to the

flash point of crude oils.
• During normal operation minor releases of Crude Oil (may be as part
of maintenance or from leaks) into the surrounding area have to be
considered as secondary releases.
• At ambient & process temperatures always a evaporation of
flammable gases from released crude oils have to be considered.
• An explosion proof design is mandatory and the execution is subject
to the hazardous area classification / Ex-Zone to be considered.
Lube Oils
Lube Oils
Product Properties – Classification

• Mineral oil based Engine Lube Oils (SAE30/40/50; ISO VG…) are
blends of mineral oil base oils and additive packages. The typical
boiling range for mineral oil base oils is 280 - 560°C.
• Engine Lube Oils have typical flash point’s of > 200°C at new
conditions and the flash point may drop down to ~ 150°C during the
operational time.
• The Lube Oil flash points are usually above ambient temperature and
separation temperature (e.g. 95°C) and no critical evaporation of
flammable vapors have to be considered.
• Caution!
In case the Lube Oil contains some amounts of flammable gases (e.g.
coming from gas compressors, etc.), lowering the flash point below or
closed to the separation/ ambient temperature, a critical evaporation
of flammable vapors can be expected!
A hazard evaluation similar to CRO and/or HFO has to be carried out!
Lube Oils

Shut-Down & Operation Vent
(flash point >>sep.-temp.)
Rest’s of lube oil have
STOP
to be considered
&
inside the separator
and sludge box
cold / warm
During shut-down periods and operation

with temperatures of up to 95 °C no cold / warm
evaporation of flammable vapors inside
separator/sludge box can be expected.
Lube Oils

• Due to the low operation pressure in the LO lines an critical atomizing
of the LO and a resulting formation of an ignitable atmosphere will not
occur in case of an accidental secondary release (i.e. flange leakage).
class IP54/55/65. By this protection class a permeation of LO spillages
into the electrical equipment will be prevented in case of a secondary
Exception:
the Lube Oil contains amounts of flammable gases or components
lowering the flashpoint critically (flash point < ambient/process temp.),
or the area is classified as an hazardous area (Ex-Zone) by the
operator/contractor due to other reasons (e.g. flammable vapors from
other processes nearby, insurance requirements, general specification
requirements, etc.)!
engineering for a better world
Imprint
Author: Martin Mense

Company: GEA Westfalia Separator Group GmbH, Oelde
Department: Configuration Engineering Marine & Energy, Oil &
Gas
Release date: 01-Mar-2016
Revision number: 2
Target group: MoE staff, Iraq, Maintenance and Operation
Supervisor working at Power Plant Al Quds
Method: compiled in .pptx, converted to .pdf
File name: Evaluations for Hazardous Risks in Power Stations,
Application: Mineral Oil Separators
Photo sources:
© 2016 GEA Mechanical Equipment. All rights reserved. External sources are indicated.
42 engineering for a better world

Section: Evaluations For Hazardous Risks in Power Stations, Application: Mineral Oil Separators

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5838 GEEP Contract

Rehabilitation of HCO Treatment Plant

explosion proof design has to be considered :

when the intended area of installation is

when flammable gases, vapors or dusts may be present in the area,

The EN 60076-10 / IEC 60079-10 and its referenced standards can be

Ignition Source Oxygen (O2)

A explosion is impossible if one (1) of these three pre-condition will be eliminated

Cyprus Power Station, 2011

UK, Buncefield Oil Depot, 2005

Toulouse, fertilizer factory, 2001

Classification of flammable liquids:

according to regulation 67/548/EEC for liquids:

Designation: R-Phrases: Criteria:

extremely flammable R12 flash point < 0°C,

Product Properties - Classification

Evaluation – Inside Separator

Rest’s of fuel oil have to be considered

During shut-down periods and operation

Evaluation – Outside Separator

Product Properties - Classification

• Heavy Fuel Oils / Residual Fuels of different categories which are

• At ambient and process temperatures below the flash point no critical

Evaluation – Inside Separator

Rest’s of fuel oil have to be considered

During shut-down periods with

Evaluation – Inside Separator Vent

At separating temperatures above the flash

Evaluation – Inside Separator Vent

t (°C) > Flash Point

Evaluation – Inside Separator Vent

Due to the “High Ventilation (VH)” Air Inlet

no critical vapor concentration will built-up.

Evaluation – Outside Separator

Product Properties - Classification

Evaluation – Inside Separator

Rest’s of crude oil have to be considered

During shut-down periods at Cold / t (°C) > flash point

Evaluation – Inside Separator

The centrifugal clutch and the

Cold / t (°C) > flash point

Evaluation – Inside Separator

The friction pads

t (°C) > flash point

Evaluation – Inside Separator

The friction pads

t (°C) > flash point

Evaluation – Inside Separator

t (°C) > flash point

Evaluation – Inside Separator

Therefore the ignitability of the inner

Evaluation – Inside Separator

Evaluation – Inside Separator

Evaluation – Inside Separator

frame drain flame arrester

Fresh Air Flushing

Evaluation – Inside Separator In-line stable

blanketing 150 Nl/h

Nitrogen (N2) Blanketing

Evaluation – Outside Separator

• The ambient temperatures are usually above or closed to the

Product Properties – Classification

Evaluation – Inside Separator