Equipment Zoning for

Hazardous Area Classification

as per IP 15

Prepared By: Ankur Srivastava 1

Chemical Engineer
ankur_2061@hotmail.com
 What is Hazardous Area?

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 design and construction of
equipment, and the control of other potential
ignition sources.

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Why do we need to classify the area?

The aim of hazardous area classification is to avoid ignition of

those releases that may occur from time to time in the operation
of facilities handling flammable liquids and vapour. The approach
is to reduce to an acceptable minimum level the probability of
coincidence of a flammable atmosphere and an electrical or other
source of ignition.

In simple terms, hazardous area classification is a method of

analyzing & classifying the environment, where there is a partial
or total likelihood of a flammable atmosphere to exist, for the
purpose of proper selection of electrical apparatus to be installed
in that environment.

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Factors Affecting Hazardous Area
Classification-1

✓ Source of Release
For the purpose of hazardous 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.

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 Factors Affecting Hazardous Area Classification-2

✓ Continuous grade release

A release that is continuous or nearly so, or that occurs frequently and for
short periods.
✓ Primary grade release
A release that is likely to occur periodically or occasionally in normal
operation i.e. a release which, in operating procedures, is anticipated to
occur.
✓ 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 i.e. a release which, in
operating procedures, is not anticipated to occur. Such releases may be of
known size e.g. fracture of a drain, or unknown size e.g. corrosion hole.

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Factors Affecting Hazardous Area
Classification-3

The grade of release is dependent solely on the

frequency and duration of the release. It is
completely independent of the rate and
quantity of the release, the degree of
ventilation, or the characteristics of the fluid,
although these factors determine the extent of
vapour travel and, in consequence, the
dimensional limits of the hazardous area.

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 Fluid Categories (Table 1.2 –IP15)

Fluid Description
Category
A A flammable liquid, that on release, would vaporise rapidly & substantially.
This category includes:
a) Any LPG or lighter flammable liquid
b) Any flammable liquid at a temperature sufficient to produce, on release,
more than 40% vol. vaporisation with no heat input other than from the
surroundings.
B A flammable liquid, not in Cat. A, but at a temp. sufficient for boiling to
occur on release
C A flammable liquid, not in Cat. A or B, but which can, on release,
be at a temp. above its flash pt., or form a flammable mist or spray
G(i) A typical methane-rich natural gas
G(ii) Refinery hydrogen

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 Zone 0 -Typical areas OOOOOOO
OOOOOOO
OOOOOOO
OOOOOOO
OOOOOOO

(Continuous grade: Release likely to be present for > 1000 hrs per year)
(Sec. 1.6.4 –IP 15)
✓ Vapour space above:
closed process vessels,
storage tanks
closed containers,
areas containing open tanks of volatile, flammable
liquid

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 How to identify Zone 1 areas
Primary Grade: Release likely to be present for between 10 & 1000 hrs
per year (Sec. 1.6.4 – IP 15)

 Flammable gas or vapour concentration is likely to exist in the air

under normal operating conditions
 Flammable atmospheric concentration is likely to occur frequently
because of maintenance, repairs or leakage
 Flammable liquid or vapour piping system (containing valves,
meters, or screwed or flanged fittings) is in an inadequately
ventilated area
 The area below the surrounding elevation or grade is such that
flammable liquids or vapours may accumulate therein

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 Zone 1 -Typical areas

➢ Imperfectly fitting peripheral seals on floating roof tanks

➢ Inadequately ventilated compressor or pump rooms for
flammable gas or for volatile, flammable liquids
➢ Oily waste water sewer / basins
➢ Loading / unloading gantries of hazardous products

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 Typical Zone 2 areas
Secondary Grade: Release likely to be present for 1 to 10 hrs per year
(Sec. 1.6.4 – IP 15)
➢ The system handling flammable liquid or vapour is in an
adequately ventilated area and is so designed and operated that the
explosive or ignitable liquids, vapours or gases will normally be
confined within closed containers or closed systems from which
they can escape only during abnormal conditions such as
accidental release from a damaged gasket or packing
➢ The flammable vapours can be conducted to the location as
through trenches, pipes or ducts
➢ Locations adjacent to Zone 1 areas
➢ Pressurized rooms where flammable gas / vapour can enter in the
case of failure of positive mechanical ventilation

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 Non-hazardous Areas
Typical areas
The following locations are considered non-hazardous
from the point of view of electrical installation:
 Areas where the piping system is without valves, fittings, flanges or
similar appurtenances
 Areas where flammable liquids or vapours are transported only in
suitable containers or vessels
 Adequately ventilated locations surrounding equipment that has
continuous flame sources (e.g. unprotected fired vessels & flare tips)
 DG shed room / shed having adequate ventilation
 GT installation meeting the ventilation (12 ACPH) , pressurization
(0.5 mbar )and flange (not more than one pair of flanges inside the
turbine room) requirements

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 Petroleum Fluid Classes as per IP 15
(Annex A- Table A1)
Class 0 Liquefied Petroleum Gases (LPG)
Class I Liquids that have flash points below 21°C
Class II(1) Liquids that have flash points from 21°C up to &
including 55°C, handled below flash point
Class II(2) Liquids that have flash points from 21°C up to &
including 55°C, handled at or above flash point
Class III(1) Liquids that have flash points above 55°C up to &
including 100°C, handled below flash point
Class III(2) Liquids that have flash points above 55°C up to &
including 100°C, handled at or above flash point
Unclassified Liquids that have flash point above 100°C

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 Storage Tanks -1
Zone 0

Zone 1
Zone 2
Non-Haz.

Fixed Roof Tanks for Classes I, II(2) & III(2) for filling rates
up to 250 m3/h

Blanketing Gas
Bund height

2m

Liquid Level

Tank Wall Dist. To Bund

Collection or Drain Pit
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 Zone 0

Storage Tanks -2 Zone 1

Zone 2
Non-Haz.

Internal Floating Roof Tanks for Classes I, II(2) & III(2)

2m
Bund height

2m
Floating Roof

Collection or Drain Pit Tank Wall Dist. To Bund

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 Zone 0

Zone 1

Storage Tanks -3 Zone 2

Non-Haz.

• Above Ground Pressurized Bulk LPG Installations

Ullage Level Indication

1m

Spill
Catchment Slope
Note 1 Loading & / or unloading connections

Note 1: Provide a 1 m, Zone 2 section from the edges of the spill catchment area
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 Zone 0

Storage Tanks -4 Zone 1

Zone 2
Non-Haz.

Pit mounted KO drum or Oily Water Drain Vessel

R=3m

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 Zone 0

Pumps Zone 1
Zone 2
Non-Haz.

Adequately Ventilated Areas for Oil, Oily Water Pumps

w/Double Mech. Seal & throttle Bush (High Integrity Pumps)

Fluid Level I
Cat.

Hole Size R1 (m)

(mm)

A 2 4

B 2 4

C 2 4.5 R1 =See Table

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 Pumps (continued)

Notes:
1. ‘Level’ defines the release frequency which are based on achieving an
overall value of individual risk of less than 1.0E-5/yr.
‘Level I’ is the highest frequency (≥1.0E-2) & would be the most commonly
encountered. For more information about ‘Level’ refer Annex C-Part 1 & 2
of IP 15.
2. For Levels II & III the hole radius and corresponding Hazard Radius are
different & reference is made to Table 5.1(c) of IP 15.
3. Above slide & table is for ‘High Integrity Pumps’. For standard pumps
without throttle bush refer Table 5.1(a) of IP 15. For standard pumps with
throttle bushes refer Table 5.1(b) of IP 15.

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 Zone 0

Compressors Zone 1
Zone 2
(Adequately Ventilated) Non-Haz.

Release Seal Type Release hole Hazard Radius

Frequency dia. (mm) R1 (m)
G(i) G(ii)
LEVEL I Floating Ring 5 4 6
Purged 12 10 13
Labyrinth

R1 =See Table

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 Zone 0

Pig Launchers & Zone 1

Zone 2

Receivers Non-Haz.

Pig Launcher (Pig Receiver will be similar)

Equivalent Dia. of Hazard

Pool/Collection Pit, Radius R1
(m) (m)
Pool
Less than 5 3
5 to less than 10 7.5
10 or greater 15
L R1

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 Gas-Oil-Water Separator
(Test/Bulk)
Following guidelines should be considered:
1. Consider R = 3 m from the furthest flange/valve in the associated
piping of the ‘Separator’ & draw a Zone 2 envelope encompassing
the ‘Separator’.
2. If there is a liquid sample point on the separator, it should be
considered separately, with the Zone 2 envelope drawn with R = 5.5
m from the sample point.
3. The above mentioned radius & zone class have been referenced from
the ‘ABCD Full Facilities Development’ project ‘Hazardous Area
Classification’ drawings.

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 Flares

Adequately ventilated locations surrounding equipment

that has a continuous flame source e.g. ‘Flare Tips’ need
not be classified (non-hazardous area) solely by the
reason of the fuel gas being considered as a source of
release.

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 Pipe Rack

1. Pipe Rack need to be classified, if required, considering

secondary grade release i.e. Zone 2 only.
2. Area classification for pipe rack need to be considered
only for the portion where there are flanges & valves. A
Zone 2 envelope considering R = 3 m from the
flange/valve packing should be considered for the pipe
rack.

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 Valves

Frequently used valves (including control valves) with

packed glands should be regarded as producing an
additional primary release (Zone 1) with R = 0.3 m.
Electrical equipment within 0.3 m of any valve gland shall
be suitable for operation in a Zone 1 area. Reference is
made to HAC drawings of ‘ABCD Full Facilities
Development’ project.

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 Zone 0

Road Tanker Zone 1

Zone 2

Loading Non-Haz.

• Top Loading through open or vent fill covers

Ground

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 Recommended Apparatus Sub-group &
temperature class for some flammable liquids
(Table 7.2 – IP 15)
Flammable Apparatus sub- Temp. (T) class of
Liquid group suitable equipment
Methane IIA T1
Ethane IIA T1
Propane IIA T1
Crude Oil IIA T3
Diesel IIA T3
LPG IIA† T2

If LPG contains significant qty. of 2-butene then the

appropriate apparatus group is IIB
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 Definition of Temp. Class
(Table 7.3 – IP 15)
• Relationship between temperature class & maximum
surface temperature of the apparatus (in accordance
with IEC 60079-0)
Temperature Class Maximum Surface
temperature (°C)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85

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Thank you for valuable time
and
your presence

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