haz area classification

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STANDARDS PUBLlCATlON

KOC STANDA RDOR

HA ZA RD O US AREA CLASSIFICATIONDOC. N O . KOC-G-002

DOC. NO . KOC-G-002


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KOC STANDAR DFORHA ZA RD O US AREA CLASSIFICATION

DOC. N O . KOC G 002

DOC. NO . KOC G 002

ISSUING AUTHORITY:STANDARDS TEAM

A nnikrishnan

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T BLE OF CONTENTS

DOC. NO . KOC-G-002

FOREWORD1.0 SCOPE2.0 APPLICATION3.0 TERMINOLOGY4.0 REFERENCE CODES AN D STA NDA RDS5 -0 E N V I R O N M E N T A L C O N D IT I O N6.0 HEALTH, SAFETY A N D ENV IRON ME NT7 .O AREA CLA SS IFIC AT ION8.0 CLASSIFICATION OF PETROLEUM9.0 FLUID CATEGORY10.0 FLA MM ABL E L IM ITS OF PETROLEUM PRODUCTS11.0 GENERAL DESIGN CONSIDERATIONS REFERENCE DA TA12.0 ELECTRICAL APPARATUS13.0 AREA CLASSIF ICATION DRA WIN GS14.0 EXTENT OF HAZAR DOUS ZONES15.0 HAZARD ASSE SSM ENTS

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16.0 IDENTIFICATION OF HAZA R[ OUS ZON ES17.0 DOCUMENTATION

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P A GE N O .566689

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1 21 21 21 6

18.0 APPENDICES 26APPENDIX ICLASSIFICATION AREA BOUN DARIES, HEAVIERT H A N A IR G A S E S I V A P O U R S1 - OPEN AIR S ITUAT IONS 72 - ENCLOSED PREMISES A N D SURR OUND ING AREAS 73 - OPEN PREMISES AN D SU RROU NDING AREAS 84 - ENCLOSED PREMISES WITH PLE NUM O F SAFE ATMOSPHERE 8


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APPENDIX I1

DOC. NO. KOC-G-002

CLASSIFICATION AREA BOUNDARIES, LIGHTERTHAN AIR GASESIVAPOURS1 OPEN AIR SITUATIONS 292 ENCLOSED PREMISES AND SURROUNDING AREAS 293 OPEN PREMISES WITH VENTILATED ROOF AN D SURROUNDING

AREA 30

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APPENDIX ll

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CLASSIFICATION AREA BOUNDARIES FORPARTICU LAR APPLICATIONS1 STORAGE TANKS FIXED AND FLOATING ROOFS WITHIN

BUND WALL 312 PIPELINES AND FITTINGS3 PUMP 8 TURBINE INSTALLATIONS 354 RECIPROCATING, CENTRIFUGAL OR AXIAL COMPRESSORS 45 SAMPLING POINTS IN OPEN OR WELL VENTILATED LOCATION 416 DRAIN POINTS FOR PROCESS WATER IN OPEN OR WELL

VENTILATED LOCATION 427 OPEN OR FREELY VENTED TANKS OR SUMP 438 RELIEF VALVES AND EMERGENCY BLOW OFF9 VENT PIPES IN OPEN AIR 4510 FLARES AN D BURN PITS 611 FURNACES AND HEATERS 612 - PIPELINE PIG LAUNCHERS AND RECEIVERS 4913 ROAD TANKERS AN D COLLECTIONIDELIVERY OPERATIONS 5014 STATIONARY STORAGE BATTERY INSTALLATIONS 5215 EXAMPLE OF HAZARDOlJS AREA CLASSIFICATION DRAWINGS 55APPENDIX IVCLASSIFICATION AREA BOUNDARIES FORDRILLINGIWORKOVER OPERATIONS1 ONLAND DRlLLlNGlWORKOVER OPERATION 572 OFFSHORE DRILLINGIWORKOVER OPERATION 593 ONLAND AND OFFSHORE DRILLING/WORKOVER OPERATION 61APPENDIX VHAZARD IDENTIFICATION TA,BLE 66APPENDIX VI

HYDROGEN SULPHIDE, EXPOSURE AND PHYSIOLOGICAL EFFECTS 67INDEXACKNOWLEDGEMENT 70


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FOREWORD


T h is d o c u m e n t K O C S t a n d a r d f o r H a z a rd o u s A r e a C la s s i f ic a t i o n is in t e n d e d t op rov i de comprehens i ve i n f o rm at i on f o r gu i dance i n t he C l ass i f i ca t i on o f A reas .I n te rna t i ona l ly se t o u t p r inc i pl es , de f i n i ti ons and exp l ana t i on o f t e rm s a re used f o rarea c lass i f i ca t ions throughout KOC fac i l i t i es .T h i s S tandard has been approved by t he S tandards T eam, in c o n s u l t a ti o n w i t h t h eS tandards T echn i ca l Co mm i t t ee (ST C) , f o r use t h rough ou t t h e co rpora teeng i neeri ng and opera t iona l f unc t i ons o f Ku wa i t O i l Com pany (K .S .C . ).

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T h i s S tandard has been p repared under t he d i r ec t i on o f S tandards T eam a ndS t a n d a rd s T e c h n ic a l C o m m i t t e e i n o rd e r t o a c h i e ve t h e f o l l o w i n g o b j e c t iv e s :-

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T o ma i n ta i n KOC requ i rements o f sa fe t y t o p ro tec t pe rsonne l , p l an t andproper ty .T o m i n i m i ze t he r i sk o f acc i den t s by adop t i on o f sa fe and sound eng i neer i ngprac t i ces in o i l gas indust ry .T o p rov i de a s tep-by-s tep gu ide on c lass i f y ing hazardous areas us ing po in t -source me thod o f assessment .To def ine a l ternat i ve means for area c lass i f i ca t ion purposes where ex t remes ofvo la t i l i t y , tem perature and pressure occur .Prov ides typ ica l examples , w i th d iagrams w hic h can be used to c lass i f y areassur rounding the e qu ipm ent and s tandard fac i li t ies .

Feedback as we l l as any su ggest ions or com me nts der i ved f ro m the app l i ca t ion o fth is Standard at any stage of d les ign, purchase, instal lat ion, operat ion andmaintenance are encouraged, and should be d i rec ted to : -T eam Leader S tandards T ea m(Cha irman , S tandards T echn i ca l Com mi t t ee )Engineer ing Group, K OCP. 0 B o x 9 7 5 8 , A h m a d i 6 1 0 0 8S t a t e o f K u w a i tT h e r e v i s i o n o f t h i s K O C S t a n d a r d w a s e n t r u s t e d b y t h e S t a n d a r d s T e c h n i c a lC o m m i t t e e ( S T C ) t o t h e T a s k F o rc e TF - G I0 1 c o m p r i s i n g o f t h e f o l l o w i n g m e m b e rs :-D r . Moh amm ad l lyas (S tandard D iv i s ion) T eam Leader T e l . No . 6 1 4 0 6M r . Fa isa l Mai rza (Standards Div is ion) M e m b e r T e l. N o . 6 1 5M r . G . M i sh ra (Engg. Design Div is ion) M e m b e r T e l. N o . 6 1 0 9 7M r . Fahad A I -Qat tan (HSE D iv i s ion) M e m b e r T el . N o . 6 7 3 8 9M r . S . M. ldr is (P roduc ti on Engg . N & W ) M e m b e r T e l . N o . 2 2 2 9 1


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1.0 SCOPE

DOC. N O . KOC-G-002

This S tanda rd descr ibes the m in im um requ i rements for c lass i f i ca t ion andde te rm i na t ion o f boundary l i m i t s o f hazardous a reas assoc ia ted w i t h t heonshore f ac il it ies opera ted by t h e K uw a i t O i l Company (KSC) in K u w a i t .

2.0 APPLICATION

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2.1 Determinat ion o f Hazardous Area Boundary l im i ts and preparat ion o f AreaClass i fi ca t ion Dra win gs sha l l c ;onform to t he requ i rements o f th i s S tandardand re ference s tandards m ent ioned here in .

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2.2 An y ex cep t i on o r dev i a t i ons f r om th i s S tandard , a l ong w i t h t he i r mer i ts andjus t if i ca tion, sha l l be brough t t o the a t ten t ion o f KO C's Cont ro ll i ngDep ar tmen t , fo r the i r rev iew, cons iderat ion and amen dme nt b y S tandardsTea m ( i f requ i red).

3 .0 TERMINOLOGY3.1 Definitions

AbnormalI n t he con tex t o f ' abnorma l ' ( operati on , t he un tow ard , i rr egu la r thoug h no tnecessar i l y wh ol l y unexpected, , dev ia t ion f rom 'normal ' operat ion.Com bustible l iauidsL i qu i ds hav i ng c l osed cup f l ash po i n t a t o r above 100 F (37.8 C). S o m eexamples o f suc h l i qu ids are kerosene and d iese l fue l .Flamm able AtmosphereA f l ammab l e a tmosphere i s a m i x tu re o f f lamm ab l e gas o r vapour w i t h a ir i nsuch a p ropor t ion t ha t t wi l l bu rn w he n i gn i ted .Flam ma ble l iquidsL i qu i ds hav i ng c l osed cup f l ash po i n t be l ow 100 F (37.8 C) and a vapourp ressure no t exceed i ng 4CI PSlA (276 Ki lopasca ls ) measured a t 100 F(37.8 C).Heavier - th an Air Gas1Vapot.1~I s a gas l vapour w i t h a dens i t y under r e l eased cond i t i on t ha t i s equa l t o o rgreater than 75 percen t o f tha t o f a ir a t a tmos pher i c pressure and 60F( I S 0 C .Upper f l ammable l im i tI s def ined as th e h ighe st concent ra t ion o f f l am mab le gas or vapour i n a ir a ta tmospher i c p ressure a t wh i c h combu s t i on w i l l t ake p l ace . Abo ve th i sconce n t ra t i on a t a tmospher i c p ressure , com bus t i on w i l l no t occur . T he f igu rei s exp ressed as pe rcen tage b y vo l ume.IBP Initial Boilinq Po int)T h e l o w e s t te m p e r a tu r e a t w h i c h a l iqu i d or l i qu id m i x tu re com men ces t o bo i lunder prescr ibed tes t cond i t i ons .


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Lighter - than - Air Gas 1 VapioxIs a gaslvapour with a densi1.y under released condition that is less than 75percent of that of air at atmospheric pressure and 60" F 15 C ) .

DOC. NO . KOC G 002

Lower flammable limitIs defined as the l owest concentra tion o f a flammable gas or vapour in air atatmospheric pressure capable of being ignited. Below this concentration atatmospheric pressure, combustion will n ot occurs (lean gas).The figure ispresented as percentage b y vlolume.NormalIn the c onte xt of 'normal' operation, the actual, real expected day-to-dayconditions taking into account the achieved standards of design,maintenance and production practices.

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Volatile liquidA flammable liquid whose temperature is above its flash point or acombustible liquid having a vapour pressure not exceeding 40 PSlA (276Kilopascal) at 100 F (37.8O C:) and temperature above its flash point.

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3.2 AbbreviationsACGlH American Conference of Government Industrial HygienistsBOP Blow Out PreventerBS Booster Stat ionEEMUA Engineering Equipment and Materials Users AssociationFM Factory MutualGC Gathering CenterUFL Upper Flammable Limi tHSE Health, Safety and E nvironmentIBP Initial Boiling PointKOC Kuwa it Oil Company K .S.C.)LFL Low er Flammable Limi tLPG Liquified petroleum Gas

LSTK Lump Sum Trunk KeyOSHA Occupational Safety and Health AdministrationPPM Parts Per Million


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ROSPA Roya l Soc i e t y f o r t h e P reven ti on o f Acc i den t s

DOC N O. KOC G 002

SCF Standa rd Cubic FootSOH Source o f HazardT LV T hresho l d L i m i t Va l ue

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T W A T i me We i gh ted Averiage

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UPS Unin ter rupt ib le Pow er SupplyV E Verband Deutscher E. lekt rotechniker

4 0 REFERENCE CODES A ND STAND ARDS4 1 In t h e e v e n t o f c o n f l i c t b e t w e e n t h i s S t a n d a r d a n d t h e s ta n d a rd s / codes

referenced here in the m os t s t r i ngent requ i rement sha l l app ly un lessotherw ise spec i f ied.

4 2 List of StandardsT he l a t es t ed i t ion o f t he f o l l ow i ng s tandards and codes sha l l app ly :

4 .2 .1 National Standards and C odesAPI RP 5 0 0 Reco mm ende d Prac t i ce for C lass i f i ca t ion o f Locat ionsfor E lect r ical Instal la t ion at P et roleum Faci l it iesAPI RP 521 Guide for Pressure Rel iev ing and Depressur ing System sBS 3 8 1 C Spec i f i ca t ion for Colours for Ident i f i ca t ion Coding andSpec i a l P~ l rposesBS 4 5 3 3 Lumi nari esB S 5 3 4 5 P a r t 2 Classi f icat . ion of Hazardous Area sBS 6132 Code of Prac t i ce for Safe Operat ion o f A lka l i neSecondary Cel ls and Bat ter iesBS 6 1 3 3 Code o f P rac ti ce f o r Sa fe Opera t i on o f Lead-Ac idStat ionary Cel ls and Bat ter iesEEMUA Recom menda t i on f o r t he P ro tec t ion o f D i ese lPubl i ca t ion 107 Engines Ope rat ing in Hazardous AreasIP Mod el Code Ref in ing Safe ty Codesof S afe Prac t i cePart 3


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IP Mo de l Code Dr i l li ng and P roduct ion Safe ty Code for Onshoreof Safe Prac t ice Operat ionsPart 4

DOC NO. KOC G 002

IP M o d e l C o d e Area Classi f icat ion Code for Pet roleum Instal lat ionOf Sa fe Prac t icePar t 15IE C 7 9 - 1 0 Classi f icat ion of Hazardous Areas

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NFPA 30 Flammablle and Co mb ust ib le L iquids Code

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NFPA 7 0 Nat iona l E lec tr ica l CodeNFPA 325 Fi re-Hazard Proper t ies of F lammable Liquids, Gases and

Vola t i l e So l idsNFPA 4 9 6 S tanda rd for Purged and Pressur ized Enc losures for

Elect r ical EquipmentNF PA 4 9 7 Recom mende d P rac ti ce f o r t he C l assi fi ca ti on o f

F lammable L iqu ids , Gases, or Vapors and o f Hazardous(Classi f ied) Locat ions for E lect r ical Instal lat ions inChemical Process Areas

O S H A 0ccupat i c )na i Sa fe ty and H eal th Adm in is t ra t ionROSPA IS - 9 1 E l ec tr ica l l ns ta l la t ions i n F l ammab l e A tmos phereVDE 0 5 1 0 Spe c i f i ca t ion for E lec tr ic S torage Bat ter ies Bat teryPart 2 Plant Stat ionary Bat ter ies

4.2.2 KOC Standards and CodesKOC FIRE SAFETY REG ULA TIONSKOC - G - 0 0 7 KO C Standard for Bas ic Des ign DataK O C E - 004 KOC Recommended Prac t i ce for Se lec t ion, Ins ta l l a t i on

and Main- tenance o f E lec tr ica l Equ ipment in HazardousAreas. (Parts 1 t o 6)K O C 381 07 /1 T he Comp l e t ion o f Hazard Assessment andClassi f icat ion of Hazardous Areas.K O C D R A W I N G S Area C1as:s ification D raw ings for a l l GCs a nd B Ss.

5.0 ENVIRONMENTAL CONDITION5.1 T he env i r onment o f Kuw a i t , i s severe on a ll equ i pment and mu s t be

cons idered carefu ll y before prc tcurement o f p lant and eq u ipm ent . I t must beassumed t ha t , un l ess o the rw i se spec i f i ed , equ i pment may be sub j ec ted t osand and f i ne par t i c le dus t s torms, sa l t l aden w inds, a i rborne chemica lcon tam i nan t s and ex t reme t empera tu re f l uc tua ti ons .


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5 2 KOC Standard for Bas ic Des ign Data , (KOC -G-007 ) prov ides the deta i l eddes i gn i n f o rmat i on regard i ng t he env i r onment and u t i l i t y supp l y cond i t i onspreva i l ing throug hou t the KOC fac i li t ies .

DOC. N O . KOC-G-002

6.0 HEALTH SAFETY N D E N V I R O N M E N TAl l re levant safe ty requ i rements o f KOC F i re and Safety regu la t ions and theKOC's HSE po l i cy sha l l be s t r i c t l y adhered to , fo r a l l Hazardous Areaclassi f icat ion.

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7.0 AREA CLASSlFlCATlON

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7 1 KOC Controlled Areas7 1 I Restricted Area

A Rest r i c ted Area i s that area in whi ch KOC exerc i ses con t ro l ove r a l lmo vem ents and operations , i.e . the areas w i th in th e boundar ies o f a l l fencedand /or separated enclosures, e.g. Gather ing Centres, Boo ster Stat ions, Oi lGas Ma ni fo lds, Ef fluent W ate r Dispos al /Evapo rat ion Pi ts , Burn Pi ts , Oi l GasWel ls , Oi l Lakes, Tank Farms, Sea Is land and Stora ge Faci l i ty .

7 1 2 Controlled Area

Cont ro l led a rea a re t hose a reas t o w h i ch access i s ga i ned t h roughr e c o gn i z e d g a t e s s h o w i n g a p a s s t o t h e g a t e c o n t ro l l e d . T h is p a s s m a y b ei s su e d t o c o m p a n y e m p l o y e e s o f a l l r e s t r i c t e d a re as o r m a y e x c l u d e c e r t a ina reas where in t h e o p i n i o n o f m a n a g e m e n t , t h e e m p l o y e e w i l l n o t b erequ ired t o v i s i t in norm a l course o f h i s du t i es .

7 1 3 Hazardous AreaA Hazardous Area i s the zone in w h i c h a f l a m m a b l e a t m o s p h e r e m a y b epresent dur ing norm al opera t ion or under abnormal or fau l t cond i t i ons .

7 1 4 Non-Hazardo us AreaA Non-Hazardous Area i s an area n ot recognised as prese nt ing an y par t icu larf i re r isk nor ident i f ied as a zonle in w h i c h a f l a m m a b l e a t m o s p h e re m a y e x i st .

7 1 5 Work Permit AreaIt i s normal prac t i ce for the p lJ rpose o f access t o a re s t r i c ted area to t rea t aRest r i c ted Area as a Hazardous Area, henc e the use o f an y fo rm o f i gn i t i onsource or the car ry ing out o f any operat ion conduc ive to c reat ing sparks , f i reor exp los ion, or the mak ing of any excava t i on , o r t he en t r y o f unpro tec tedvehic les is st r ic t ly prohibi ted unless the appropr iate Work Permi t orman agem ent au thor izat ion has; been i ssued.


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7 .1 .6 Ap prov ed Sa fe A rea

DOC. NO . KOC-G -002

Cer ta in areas w i th in a res t r i c ted area m ay be des ignated as an approved SafeArea, e.g. sm okin g areas; areas design ated for prefa br ica t ion wo rk; park inglo ts and cer ta in workshops; e tc . Such areas are to be c lear ly i dent if i ed andthe regu la t ions cove r ing the i r use, s t r i c t l y ob served.7 .1 - 7 O p e n A r e a s

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Open Areas m ay b e se t ou t w i t h i n a Res t r i c ted A rea i n w h i c h ma j o rma i n tenance o r cons t ruc t i on work i s pe rm i t t ed w i t hou t t he need f o r WorkPermi ts except i f en t ry i n to vesse ls , excavat ions , e lec t r i ca l w or k or o ther ho two rk a re t o be ca rr ied ou t . T he l i m i t s of such O pen A reas mu s t be c lea rl ydef ined on the grou nd b y fenc ing, barr ie rs, e tc. , w i t h su i tab le cont ro l s overmovem ents o f pe rsonne l and p l an t t o ensure t he sa fe t y o f any ad j acen tRest r ic ted or Haza rdous Areas.

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7 2 Class i f i ca t ion o f H aza rdou s A=Wi th in the pet ro leum indust ry , Hazardous Areas are c lass i f i ed accord ing tothe probabi l i t y o f a f l ammable a tmosphere be ing present a t any par t i cu lart ime. The term 'Zo ne ' w i l l be used for hazardous area des ignat ions forf lammab l e gases and vapours and t h i s t e rm i no logy has been ado p ted i n t h i sKOC S tandard . T he t e rm 'Z one ' i s equ i va len t t o t he t e rm D i v i s ion as usedin API and o ther Amer i can S tandards . For reference, it sha ll be no ted t ha tZone and 1 cor respond jo in t l y t o D iv i s ion 1 and Zon e 2 or unc lass i f ied areacor respond to D iv i s ion 2 and u nc lass i fi ed area respe ct i ve ly .

7 2 1 Cl ass Loca t i onA l oca t ion i n wh i ch f l ammab l e gases o r vapours a re o r ma y be p resen t i n t heair in quant i ti es suf f i c ient t o produ ce exp los ive or i gn i tab le mix ture .

7 .2 .2 C lass Locat ionA locat ion in wh i ch combusti b le dus t i s or m ay be p resen t i n t he a ir i nquant i t ies suf f i c ient t o prod uce exp los ive or i gn i tab le mix tures .Class I1 l ocat ions are n ot cons idered in th i s S tandard.

7 .2 .3 C lass Locat ionsA l ocat ion in which eas i l y i gn i tab le f i b res or f l y ings are or may be present i nthe air .Class I l l locat ions are no t considered in th is Stand ard.


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7.2.4 ZoneD O C . N O . K O C G 0 0 2

A zone in wh i ch a f lamm ab l e a tmosphere i s con ti nuous l y p resen t o r p resen tf o r l ong pe r iods (T yp i ca l l y more t han 1 0 0 0 hours l year ).7.2.5 Zone 1

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A zone in whi ch a f l ammab l e a tmosphere i s l i ke l y t o occur i n no rma lo p e r a ti o n ( T y p ic a l ly , 1 0 t o 1 0 0 0 h o u rs l ye a r ).

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7 .2 .6 Zone 2A zone in whi ch a f l ammab l e a tmosphere is l i ke l y t o occur on l y underabnorma l opera t i ng cond i t i ons (T yp i ca l l y less t han 1 0 hours /year ) .

7.2.7 UnclassifiedAn unc lass i f i ed area i s an area which i s not c lass i f i ed as Zone 0 Zone rZone 2.Unc lass i f ied Area m ay no t necessari ly be cons idered as 'sa fe ' . A go od

engineer ing judgement shou lc l be exerc i sed to assess the hazard pr ior tous ing s tandard indust r ia l e lec t r i ca l apparatus , conve nt iona l turb ines andunp rotec ted f i red heaters e tc . For example o f unc lass i f ied locat ions , re fer toAPI Recom me nded Prac ti ces RP 5 0 0 , S e c t io n 4.

8 0 CLASSIFICATION OF PETROLEUMT h e c l a s s i f i c a t i o n o f p e t r o l e i ~ msha ll be i n accordance w i t h l ns t i t u t e o fPet ro leum, M od el Code of Sa fe Prac t ice IP - Part 15 , Appe nd i x A .

9 0 FLUID CATEGORYThe f l u id category sha l l be in accordance w i t h l ns t i t u t e o f Pe tro leum, M ode lCode of Prac t i ce IP - Part 15, Appendix B.

10 0 FLAMMABLE L IM ITS OF PETROLEUM PRODUCTSF l ammab l e l i m i t s shal l be i n accordance w i t h I ns t i t u t e o f Pe tro leum, Mo de lCode o f Prac t i ce IP-Part 15, Append i x H; or NF PA-325 .

11 0 GENERAL DES IGN CONS IDERATIONS REFERENCE DAT AI Venti lat ion

1 1 .1 .1 eneralA na tu ra l ly ven t i la t ed l oca t ion sha ll be open and f r ee f r om obs t ruc t i on t o t henatura l passage of a ir th rou gh i t , ver t ica l l y or hor i zonta l l y . Such locat ionsma y be roo fed and/or pa r t ia l l y c losed on the s ides.


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1 1 I2 Prov id ing vent i l a t i on to a l l ow the rec lass i fi ca t ion o f an enc losed area f ro mclassified area t o unclassified area is not allowed H o w e v e r , c h a ng in g t o aless s t r i ngent zon ing ( f ro m Zone 0 t o Z o ne I r f r o m Z o n e 1 t o Z o n e 2 ) m a ybe cons i dered sub j ec t t o t h e approva l o f t h e T ea m Leader, S tandards T eam,KOC.

1 1 1 .3 Adeq uate venti lat ionI s def ined as natura l or ar t i f i c ia l vent i l a t i on that i s suf f i c ient to prevent theaccumulat ion o f quant i t i es o f vapour - ai r mix ture in conce n t ra t i on above 5percen t o f the ir l ow er f l amm able lim i t . Only thos e enc losed areas (rooms,bu il d ings o r spaces) wh i ch a re p rov ided w i t h a t l eas t 28 3 16 c u b ic c m ( 1 Ocub i c f t. ) o f air vo l ume f l o w per m i nu te per 92 9 square c m ( 1 0 0 square ft .)o f the f l oor area, but a t l eas t 6 air chang es per hour , ca n be considered asadequate ly vent i la ted. Indoor l ocat ions sha l l be des ign ated as adequate lyven t i la t ed on l y i f t he cond i t ion no ted i n Append i x A and / o r Append i x B o fA P I R P 5 0 0 a re m e t .

1 1 .1 .4 Inadequate venti lat ionInadequate ly vent i l a ted areas are those rooms, bu i l d ings or spaces that dono t have na tu ra l and mechan i ca l ven t i l a t i on sys tem p rov i d i ng adequa tevent i l a t i on as def ined in c lause 1 1 I3 above.

11 2 Mix ture of Gases at Different Ignit ion Tempe ratures11 .2 .1 Whe re a m i x tu re o f gases is composed o f gases o f d i f f e ren t i gn i ti on

temperatures , des ignat ion o f the ign i t i on temp erature o f the m ix ture sha ll beb y a n y o n e o f t h e f o l l o w in g m e t h o d s :a. T he i gn i ti on t empera tu re o f t ha t gas /vapour i n t he m i x tu re hav i ng t hel owe s t i nd i v idua l i gn i ti on tempera tu re pe r N F PA-32 5 .b . T he ign i t ion t empera tu re o f t he m i x tu re as de te rm i ned by t he t es t

speci f ied in NF PA-325 .11 3 Mix ture of Gases at Different Densit ies11 .3.1 For a gas or mix ture o f gases com pose d ent i re ly o f l i gh ter - than-a i r gases, theexte nt o f th e c lass i fi ed locat ion sha ll sa t i s fy th e requ i rements for l i gh ter - than-

air gases.11.3 .2 Where a mix ture i s composec l o f l i gh ter - than-a i r and heav ier - than-a i r gases

and t he m i x tu re dens i t y i s l ess t han 75 percent o f the dens i t y o f a i r a ts tandard condi t i ons , the ex tent o f the c lass i f i ed area sha l l sa t i s fy therequi rements for l ighter- than-ai r vapours.

11 .3 .3 W here t he m i x tu re has dens it y equa l t o o r g rea te r t han 75 percent of a i r ats tandard condi t i ons , t shal l be considered as a heavier - than-ai r vapour forarea c lassi f icat ion purposes.

Page 13 o f 7 REV. 6


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11.4 Mixture of Gases of Different Groups

DOC. NO. KOC-G-002

Wh ere a mix tu re conta ins gases o f d i f fe rent groups per NFPA-70 the areac l ass i f i ca t i on sha l l sa t i s f y t he requ i rements f o r eve ry g roup f o r wh i ch t heaggrega te vo l ume o f gas cons t it u t es 3 0 pe rcen t o r mo re o f t he m i x tu recompos i t i on .

11.5 Enclosed Area Adiacent to Classified Area

Page 14 of 7 0

A n enc l osed area t ha t i s ad j acen t t o a c lass if ied a rea and w h i c h i s no tseparated f rom the c lass i f i ed area by a vapour - t i ght bar r ie r wal l o r roof sha l lbe c lass i f i ed the same as the h ighest c lass i f i ca t ion inc luded. A n o p en in g inthe wal l o r roof o f the enc losed area sha l l be regarded as source o f hazardw i t h r espect t o t h e a rea ou ts i de t he enc l osu re .

REV.

11.6 Cranes and Oil Field Trucks in Hazardous AreaCranes and o i l f i e ld t rucks or s imi lar veh ic les are a l l owed to move in Zone 1or Zone 2 areas on ly i f su i tab le pro tec t ion requ i red for su ch eq u ipm ent to beused in hazardous areas are prov ided and hot work permi t and veh ic le ent ryperm i ts are obta ined. Som e of such pro tec t ions are spark arres tors andf l ame t r aps on e xhaus t sys tem; p ro tec t i on aga ins t genera t i on o f s t a t ice lec t r i c i t y f rom be l t dr i ves ; d i scharge o f sparks f rom e lec t r i c generatore l ec tr ic s t a r te r and sw i t ches e t c . Re fe r t o EEMUA Pub l ica ti on 1 0 7 f o rdeta i l ed pro tec t ion requ i rement .

11.7 Flammable Gases Vapours Liquids Related T-Class Apparatus Sub-Groups:


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Flammable Gases, Vapours Liquids, Related T-Class Apparatus Sub-Groups Contd.. )

DOC NO KOC G 002

NOTE: For mo re detai led l is- t ing of mater ia ls , grou p c lass i f icat ion a n dau to - i gn i t ion tempera tu res , r efer t o NF PA -497 .

Page 1 5 o f 70

Methane F i r edamp)Methane Indust r i a l )M e t h a n o lPe t ro leum Nap h thaPentanePentanolPropanePropanolPropyleneStyreneTolueneX y l e n eAce ta l dehydeDiethy l E therEthyleneHydrogen Su l ph i deButad ieneEthy lene O x ideH y d r o g e nAce t y l ene

REV

T I IT I I AT I AT 3 AT 3 l AT 2 I IAT1 I AT 2 I AT1 I AT Ar I Ar1 Ar4 I A

-r4 B-r2 B-r3 B-r2 AT2 IIBT I IICT 2 NOT YET

SPECIFIED

CLASS IGROUP - D

CLASS IGROUP C

C L A S SGROUP - B

CLASS IGROUP - A


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DOC. NO . KOC G 002 Page 16 of 7 0 REV.11.8 Hvdroqen Subhide Ex ~osure nd Phvsioloqical Effects1 1.8.1 H,S is an ex tre m ely to xi c f lamm able gas. Since it is heav ier tha n air, it canco l lec t in low p laces . I t is co lour less and has rot ten-egg odour. I n l o wconcent ra t ion in air, it i s de tec tab le by i t s odour . How ever , it rapidly

para lyses the sense o f smel l on exposure to h igher concent ra t ion andtherefore, only sme l l can nolt be re lied upo n as a warn ing for dangerousconcent ra t ion .

11 .8. 2 The H,S con cen trat ion in a ir, exposure and i t s e f fe c t on th e hum an body i stabulated i n App endix VI, th e Hy droge n Sulphide, E xposure and Phys io logicalEf fects .

12.0 ELECTRICALAPPARATUSAl l e lect r ica l equipment to be operated wi th in c lass i f ied zones is requi red tobe formal ly approved and pro lof of compl iance wi th the re levant s tandard(s)submi t ted . Cer t i f ica t ion mus. t be carr ied ou t b y one o f the approved tes tauthor i t ies l is ted in 1 2 .1 .3KOC requi rements for e lectr ica l apparatus to be insta l led in c lass i f ied zonesare speci f ied in detai l in the KOC Recommended Prac ti ce KOC-E-004(Parts 1 t o 6).

12.1 Certification12.1 .1 Cer t i f i ca t ion means tha t an appara tus has been examined by a Nat iona lCert i fy ing Au tho r i ty (or equivalent organizat ion) and, wh ere necessary, teste d

and found t o com p ly w i th t he requ i remen ts o f t h e re levan t s tanda rd (s) .12 .1 .2 I t i s KOC po l i cy fo r a l l e lec t r i ca l appara tus to be approved fo r use wi th in

c lass i fied hazardous areas and duly cer t i f ied t o th is e f fe ct .{ R EV. )

12.1 .3 Electr ica l Equ ipmen t in Hazardous Area- Cert i f icat ion Bodies:For deta i ls of Cert i f icat ion Bodies (Electr ica l Equipment in Hazardous Area)acceptab le to KOC, re fe r C lause 9 .1 5 o f KOC R ecomm ended Pract ice fo rSe lec tion , Ins ta l la t ion and M ain tena nce o f E lec tr ica l Equ ipment inHazardous Area s -F lameproof Enc losure Id r (KO C-E -004 Par t 2 , Rev . 2 ) .


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DO C. N O . KO C G 002

12 2 Types O f Protection For Electrical Equipmentypes o f p ro t ec t i on ava i l ab l e f o r t he ach i evement o f sa f e t y when us i ng

apparatus n f lamm ab l e a t mospheres

Page 17 o 70 REV 6


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t Symbol or mark on6 3 ,. , y - r. b app s in accordan- .< * with.UKCode UK 7 S ~S 1 6s 229

.I

DOC. NO. KOC-G-002

X Note the t w o categories of type of protect ion i Category a Ex ia or EEx ia) being suitablefor Zone se.Certain type s of prote ctio n s apparat us may also be specifically certified for use in Zone 0See BS 5345 Part 8

N A No t yet l isted.

Page 18of 7

Note: A brief description of each of the abo ve recognized types of protection m ay be found intable 7 of BS 5345 Part 1: 1991

REV. 6

13.0 AREA CLASSIFICATION DRAWINGS

13 1 Area Classification drawings shalf be provided for all facilities where volatileliquids or combus tib le gas or vapour is present. These drawings shallindicate by means of plan, elevation and section the extent of the classifiedlocations, both vertically and horizontally. The drawings shall, as a minimum,contain the fol lowing information:

13.2 Differentiation between Zone C , Zone 1 Zone 2 and unclassified locations.The symbolic presen tation of t he various zones shall be as foll ows:Zone rea Zone 1area Zone 2 area Unclassified area


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DOC. NO . KOC-G -002

73 3 These drawings sha l l be produced as par t o f any pro jec t proposa l , f i na ldes ign and as bu i l t fo r an y pro jec ts , cap i ta l or main ten ance th at c reate orchange t he ex te n t o f c l ass i fi ed l oca t ions .

13 4 For LSTK Pro jec ts, t h e co nt rac to r sha ll p repare Hazardous Area C lass i fi ca t iondraw i ngs comp l y i ng t o t h i s S tandard and sha l l ob ta i n t he approva l f r omStandards Team.13 5 W here necessary , Zonal boundar ies sha ll be ra t iona li zed t o ob ta in

sym me t r i ca l c lass if i ed areas tha t m ay be eas il y i dent if i ed .14 0 E X T E N T O F H A Z A R D O U S Z O N E S14 1 Appendices I 11 111 and I V summar ise the bas ic pr inc ip les o f area

c lass i fi ca t ion and prov ide gu idance o n the i r app l i ca t ion to par t icu lar s i tuation.The d is tances spec i fi ed in these Appendices sha l l be cons idered m in im umdis tances necessary to de l i neate the c lass i f i ed locat ion c reated by a spec i f i cre lease po in t or source o f hazard SOH) .

14 2 Appendices I, 11 Ill and IV m ay p rove i nadequa te t o cover c e r t a i n s i tua t ionsof source o f hazards. In such cases the zonal boundar ies sha l l be determinedin comp l i ance w i t h t he re fe renced codes and s tandards c l ause 4.0 and shal lbe subm i t t ed t o S tandards T eam, KOC.

14 3 Below grade so i l i n a c lass i fi ed locat ion sha l l be cons idered a Zone 2 area.T he hor i zon ta l boundary o f t h i s l oca t i on sha l l t e rm i na te a t t he edge o f t hec lass i fi ed locat ion located a bove ground .

14 4 T he bur i ed f l o w l ines w i t h i n t he l i m i ts o f t h e G a theri ng Cen t res f ence shal l bec lass i f i ed as Zone 2 i f requ i red. To jus t i f y such area c lass i fi ca t ion, re fer toAppendix Ill, i t e m 2.1 .2 , Case . C.

14 5 The fo l l ow ing in form at ion i s prov ided for easy re ferenc ing. The bas icpr inc ip les cov ered in Appendices I and I1 are non-spec i f i c in f o r m a n d a p ply t osources o f hazard present ing average ri sk . The Appe ndix Ill and IV deal w i t hpar t icular appl icat ions.

1 4 . 5 . 1 A p p e n d i x I Bas ic Pr inc ip les - H e a v i e r t h a n A i r G a s e sThese pr inc ip les are m ain l y based on the I.P. Mo de l Code o f Sa fe P rac ti ce .

1 4 . 5 . 2 A p p e n d i x I I B a s i c P r in c i p le s L i g h t e r t h a n A i r G a s e sThese pr incip les are m ain l y based o n the requ i rements o f API RP 500 w h i c hare a t l a rge m ore con servat i ve tha n th e equ iva lent I .P . ru les .

P a g e 19 of 70 REV.


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DOC. NO. KOC-G-002

14.5.3 Appendix Ill Particular ApplicationsThe pr inc ip les are based on b lend o f API , IP Model Code of Safe Prac t i ce ,ROSPA ru les and preva i l i ng KOC prac ti ces , as app l i cab le to ac h ieve the m os ts t r ingent , conse rvat i ve and prac t i ca l c lass if i ca tion.Append i x Ill, cur ren tl y cons i s ts o f t he f o l l o w i n g sec t i ons . It wi l l be ex tendedi n f u t u r e if th e need ar ise .SECTIONS1. Storage Tanks

Al l cases are based on API recommen dat ions , IP M od el Code of SafePract ice, Part 15 w h i c h h a v e b e e n m o d i f i e d t o b r i n g t h e m i n l i n e w i t hcontemporary prac t i ce .In cer ta in c i rcumstances, it m ay b e necessary f o r t h e i n -bund a rea t o bec lass i fi ed as Zon e 1. T h e f a c to r s t h a t n e e d t o b e ta k e n i n t o a c c o u n t i nmak ing th i s dec is ion are summar ised in N o t e 3 in t h e A p p e n d ix Ill page32.

2. Pipelines and Fittings

This sec t io n b lends together th e recomm enda t ions conta ined in API; IPand ROSPA codes.Bur ied p ipe l i nes w i l l not normal l y be c lass i f i ed. However , i f f o r somereasons, a form al c lass i fi ca t ion i s requ ired, th e reco mm ende d zonehe i gh t above g round w i l l be 8 meters 25 t . ) . S ince bur ied l ines are notread i l y ava i lab le for i nspect ion, the nature o f main tenance i s cor rec t i vera ther than prevent i ve and therefore , the re laxat ion in t he boundaryl i m i t s pe rm i t t ed t o o the r p i p i ng in open a ir Normal l y to 5 meters asZ one 2) i s no t j us t if ied . See Appe ndix I l l, c lause 2.1.2 Case C forc lassi f ied boundary detai l .Wh ere p ipe l ines are located in s lop ing ter ra in or o ther areas k no w n to bevu lnerab le t o sub -sur face d i spers ion, cons ide rat ion shou ld be g i ven t oi nc reas i ng t he zone dep th t o 15m 50 t . ) .

3. Pu mp Installat ionsThese pr inc ip les are based on ROSPA rules, a l though in a s impl i f iedf o r m .

4 Reciproc ating Centrifugal or Axial Compressors.A s i n t h e a b o v e i t e m 3.

Page 20 o f 70 REV. 6


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5 Sampting Points i n Open or Well-Ventilated Locations.

DOC. NO. KOC-G-002

Thes e pr inc ip les are based o n ROSPA an d IP rules.6 Drain Points for Process Water i n Open or Well-Vent ilated Locations.

Page 21 of 70

A s i n t h e a b o v e i te m 5.

REV. 6

7. Open or Freely Vented Tank or Sum pA s i n t h e a b o ve i t e m 5

8 Relief Valves and Emergency Blow-offsA s i n th e a b o v e i t e m 5 .

9 Vent Pipes in Open AirA s i n t h e a b o ve i t e m 5 .

10. Flares and Burn pi tsW h i l s t t i s prac t i cab le to es tab l i sh the ex tent o f hazardous zonessur rounding burn p i t s there i s no es tab l ished hazardous area l im i tsassoc ia ted w i t h f la res . Genera l i n form at ion and gu idance on des ignprocedures w i l l be f ound n API RP 521 - Pressure Rel iev ing andDepressur ing System s: IP Mo del Code of Safe Prac t ice Part Ref in ingSafety Code.

11. Furnaces and HeatersThese recommendat ions have been based on genera l pr inc ip lespubl i shed in API RP-500 Sec t i on B.

12. Pipeline Pig Launchers and ReceiversThe pr inc ip les are based on API RP 5 0 0 and IP Mo del Code of S afePract ice.

13. Road Tankers and Collection/Delivery Opera tionsRecom menda t ions are based on the ru les pub l i shed in NF PA-30F lammab le and Co mb ust ib le L iqu ids Code.


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14. Stationary Storage Battery lnstallationsI

The ru les dea l w i th th e loca l hazards ar i s ing f ro m th e re lease o fhydrogen duri ng ba t t e r y charg i ng cyc l es . T hey d o no t app ly i n p rem i sesin whi ch hydrocarbon re l eases may occur wh i ch have been f o rma l l yc lassi f ied as hazardous areas i .e. Zones 0 1 or 2

DOC. NO. KOC-G-002

1 4 . 5 . 4 Appendix IV Drilling and Workover OperationsThe pr inc ip les are based on b lend o f API RP-500 IP Mo de l Code o f Sa fePract ice - Par t 15.

Page of 70

14.6 Drillinq and Workover Operations

REV. 6

14 .6 .1 Regular Drilling and Workover OperationsThis sec t ion o f the S tandard prov ides ru les and gu ide l i nes for determin ingboundary l im i ts o f c lass i f ied areas assoc ia ted w i t h the operat ion o fdr i l l i ng lworkover r igs w i re l i n ing operat ions and produc ing wel ls bo th on iandand on mar ine f i xed and mo b i l e p l a t fo rms . T he a pp l i ca ti on o f t hese ru l es isl i m i ted t o t h e we l l heads and t h e f ac i li ti es s t a ted above . It i s n ot app l icab leto p roduc t i on opera t i ons downs t ream o f t he we l l head such as o i l l gasseparation storage proces sing and t rans po r tat ion fac i l i t ies.These ru les are based o n gu ide l ines prov id ed pr imar i l y b y API R P-500 and IPMode l Code o f Sa fe P rac ti ce -Par t 1 5 wh i c h have b een deve loped byexper ience in th e ind ust ry . They app ly to no rmal operat iona l releases o f gasand o i l wh i ch occas iona l ly occur . Ma j o r ca tas trophe such as we l l b l ow ou t isouts ide the scope of th i s S tandard. W el l b low ou t or vesse l ruptures aremajor upsets norm al l y no t cons idered a bas is for area c lass i f i ca t ion and aredealt w i th in i nd ust ry s tand ing operat iona l prac t i ces requ i r ing emergencymeasures.Refer to A ppen dix IV for th e area c lass i f i ca t ion and es tab l i shed zonalboundar ies for Dr i l l ingIWorkover fac i l i t ies.The fac i l it i es i nc luded are as fo l l ow s:

R ig f l oor and Subs t ruc turesWi re l i n ing Operat ionM u d T a n kM u d D i tch T rench or P itM u d P u mpShale ShakerDesander or Desi l terDegasserProducing Wel ls


24/71

14.6.2 Typical Sources of Hazard

DOC NO. KOC G 002

a. In norm al dr i ll i ng operat ions , th e c i rcu la ting dr il li ng m u d i s i nhydros ta t i ca l l y ba lanced s ta te . Hydros ta t ica l t y ba lanced s ta te i s th es i t ua ti on w here t he w e l l b o t t o m ho le p ressure and t he h ydros ta ti c heado f t h e d r i ll ing m u d co l umn ba lance each o the r .

Hydrocarbon and o the r t ox i c mate ri a l re lease t yp i ca ll y occur i n t he f o l l ow i ngcases.

Page 23 of 70

1. Dur ing dr i l l i ng a t a new ba lanced or underba lanced hydros ta t i ccondi t i on, the gases ent ra ined in t h e m u d s o l u t i o n c o m e o u t w h e nexposed t o r educed p ressure a t t h e su r face .

REV 6

T he above phenom enon i s t he m a jo r cons ide ra ti on wh i l e c l ass i fy i ng t hearea arou nd dr i l l ing instal lat ion. Th e other pote nt ia l sources of hazardsare be l l n ipp le , f l ow l ine out le t, sha le shaker and ac t i v e m ud p i t s .

2 . When t he down ho l e p ressure i s f ound t o be unexpec ted l y h i gher t hanthe hydros ta t i c hea d o f t he c i rcu l a ti ng m ud co l umn, t he s i tua t i on ist e rmed as 'kick .Note:Kic k is no t cons idered a basis for area c lassi f icat ion as it i s a majorupset and dea l t w i th in the indust ry s tand ing operat ing prac t i ces

requ i r ing em ergenc y m easures.3. D r i l l p i p e w h e n w i t h d r a w n c a n b e c o a t e d w i t h m u d c o n t a i n i n ghydroca rbon gases g i v ing r ise to smal l releases o f f l am mab le gases.4. Stu f f i ng b ox in w i re l i n ing operat ion i s cons idered a source o f hazard.b Weldins and Cutting

Pre fe rab l y we l d i ng and o r cu t t i ng shou l d no t be ca r r i ed on w i t h i nhazardous areas. it i s manda to r y t ha t t h e l oca t i on i s t es ted f o r gas f r eea tmosphere be fo re t he we l d i ng o r cu t t i ng ope ra t ion can be s ta rt ed .non hazardous area shall no t be inferred as safe area.

Wel d i ng i s pe rm i t t ed in Hazardous areas. However , spec i a l ca re mus tbe t aken i nc l ud ing bu t n o t be l i m i ted t o ensur ing l oca l ly sa feenv i ronm ent . For deta i led in forma t ion o f th i s sub jec t , re fer to IP ModelCode of Safe Pract ice Par t 4. Also re fer to K O C Fi re SafetyRegula t ions .


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14 .6 .3 Exploratory Wildcat OperationsDOC. NO . KOC-G-002

In th e w i ldc at operat ion the r i sk o f haza rd are h igh ly unpred ic tab le .T here fo re , a more conserva t i ve hazardous a rea l i m i t o f 1 5 m 5 0 f t .) f r om thewel lhead sha l l be cons idered, i ns tead o f the norm al l y cons idered l im i t o f 8 m2 5 f t . ). The ru le sha l l a f fec t th e i l l us t ra t i ons in the para 1 and 2 o f t heA p p e n d i x I V w h e r e 8 m 2 5 f t. ) l im i t s s h all b e c h a n g e t o 1 5 m 5 0 f t. ) ,keep ing t he o the r de ta i ls t he same.

1 4 . 6 . 4 Site Location

Page 24 of 7

Si te o f f ices /acco mm odat ions , por tacab ins , Laborator ies and s imilar fac i li t ieswh erein ai r condi t ioners, ref rigerators, h ot p lates, naked iiqhts and othere lec t ri ca l app l iances m ay be present , sha l l be loca ted in a non-c las si f ied area.Smok i ng hu t s sha l l be t r ea ted in t h e s am e w a y . A c c o r d i n g t o K O C F ireSafety Regula t ions , any es tab l i shments or ac t i v i t y in whi ch an open f i r e o r

o the r f o rm o f naked l i gh t m ay be p resent , shal l no t be l oca ted w i t h i n 6 1 m2 0 0 f t .) o f a we l lhead .

REV

Proper wa rn ing s igns an d not i ces for nake d li ghts , sm ok in g and o ther hazardsshou l d be p rom i ne n t l y d i sp layed . No t i ces shou l d a lso i nd i ca te where f ir ef i ght ing equ ipment , breath ing apparatus and f i r s t a id k i t a re s tored.

15.0 HAZARD ASSESSMENTS15.1 Whi l s t t he de ta i l s g i ven in Sect ion 1 3 are genera ll y app l icab le to operat ions

wi th in the f i e lds areas o f KOC, t i s essent ia l that the i r re levance to anypar t icular p lant receives careful considerat ion.T h e s a f e ty a s s e s sm e n t r e p o rt e d i n t h e K O C S ta n d a r d 3 8 1 / 0 7 / 1 , t o b er ev is e d w i t h n e w d o c u m e n t n o . K O C - G - 0 0 3 ), m a y p r o v i d e gu id a n ce o n t h evar ious f ac to r s w h i c h requi re t o b e t aken i n t o accoun t in any such appraisal .H o w e v e r , t i s n o t n e c e ss a ry th a t K O C 3 8 1 / 0 7 / 1 , b e r e a d in con j unc t i on

w i t h t h i s S tandard s ince t h i s S tandard is a s t and a l one documen t p rov id i ngrules for Area Classi f icat ion.

15.2 In pr inc ip les , a t l arge, th e hazardous area l im i ts sh o w n ha ve been ver if ied b ycomput i ng t heore t i ca l d i l u t i on l eng ths and compared w i t h ex i s t i ngIn ternat iona l S tandards .

15.3 Method of computation15 .3 .1 Ca l cu la t ions we re ca r r ied ou t em p l oy i ng t h e estab l i shed formulae recorded int h e KOC S ta n d ar d 3 8 1 / 0 7 / 1 . Cer ta in s impl i f i ca t ions we re ma de to fac i l it a te

hand co mp uta t i on w h i c h a re a lso f u l ly de ta il ed i n t he same S tandard .


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15 .3 .2 A key f ac to r w as t h e dec i s ion t o cons ide r on l y t he heav i er t han a i r con ten t o ff l ammable vapours when assess ing zone boundar ies a t ground leve l . t w a sfur ther assumed that on re lease o f pressure, a l l the d i sso lved or ent ra inedgases in a r aw ( i. e. undegassed) c rude s t r eam wo u l d i mme d i a te ly ' f lash ' t ovapour .

DOC. NO. K O C - G - 0 0 2

16.0 IDENTIFICATION OF H A Z A R D O U S Z O N ES16 1 A r e a C l a s s if ic a ti o n D r a w i n g s nd W a r n i n q S i q n s

Page 2 5 of 70

1 6 . 1 . 1 It i s KOC po l i cy to ensure that personnel are adequate ly warned o f hazardspresent i n operat iona l areas. KOC F ire and Safe ty R egula t ions (warn in g s ignsand no t i ces ) p rov ide general gu ide li nes o n t he need and f o rm o f t h e warn i ngs igns to be d i sp layed.

REV

16.1.2 I t i s mandatory that area c lass i f i ca t ion drawings o f a l l the Gather ing Cent res(GC) and Booster Stat ions BS) be prepared. The f i na li zed and the approveddraw i ngs o f t he pa r t i cu l a r GC and BS shal l be d i sp layed in i t s con t ro l r oomf o r d a y t o d a y r e fe re n ce . T h e d r a w i n g s s h al l b e k e p t u p t o d a t e b y r e v is in gwh en needed, i n case o f add i ti on, de le t ion or reva mp ing o f th e fac il i ti es .

16.1 .3 D isp lay o f such drawings in t he con t ro l r oom shou l d be adequa te andtherefore phys ica l demarcat ion o f zone areas is no t requ ired. How ever ,should warn ing s igns or hazard ident i f i ca t ion be cons idered necessary , theyshal l be general ly in accordance w i t h t he requ i rements o f sec t i on 16 .2be l ow . T he need f o r t h e warn i ng s igns will be de te rm i ned i n consu l t a t i onw i t h t he F ir e HSE Depar tmen t o f KOC.

16.2 D e m a r c a t i o n of B o u n d a r i e s16.2 .1 Su i tab le means suc h as boundary markers , s igns , or o ther l oca l

i dent i fi ca t ions m ay be used in cons u l ta t i on w i t h KOC F ire HSE Depar tment ,t o dem arcate the boundar ies .

16.2 .2 Genera l requ i rements for boun dary m arkers are presented p i c toria l ly i nAppendix V.16 .2.3 The hazardous zone boundary m arkers are pa in ted so as t o d i sp lay one co lourwh en approachi ng and ano ther w he n l eav i ng t he c l ass i fi ed a rea .

T he co l ou r sys tem t o be used shal l be as f o l l ows :Z one 1 App roac h i ng RED fac i ng

E x i t i n g Y LLOW fac ingZone 2 A p p r o a c h i n g Y LLOW f ac i ng

E x i t i n g WHITE fac ing


27/71

The preferred colours are:

I DOC. NO KOC G 002

RED S i gna l Red t o BS 3 8 1 No . 537YELLOW G o l de n Y e l lo w t o B S 3 8 1 C N o . 3 5 6 o r e q u i va l e n t)

age 26 o f 70

17.0 DOCUMENTATION

REV

17.1 A l l cor respondence, draw ings, i ns t ruc t ions , data sheets , des ign ca lcu la t ions ,or any o ther wr i t ten in format ion sha l l be in the Engl i sh language and a lso inArabic w here spec i f i ed.

17.2 A l l d imens ions , un i t s o f measurement , phys ica l constants , e tc . sha l l be in SIun i t s , un less o therw is e spec i f i ed.

17.3 Al l docu me nts, tex t , speci f icat ion, data sheets, dra win gs etc. ) shatl beprov i ded with elect ronic f i les in a KOC approved so f twa re MsW ord , Excel,Au toCa d etc .) . Des ign ca lcu la t ions sha l l a l so be sub mi t ted in a KOCapproved w i de l y used so f tware .

18.0 APPENDICESAppendix I Classi f icat ion Area Boundar ies, Heavier than Ai r

GasesIVapours.Appendix II Class i f i ca t ion Area Boundar ies , L ighter than Air

Gases/Vapours .Appendix Ill Classi f icat ion Area Boundar ies, For Par t icular

Appl icat ions.Appendix IV Classi f icat ion Area Boundar ies, For Dr i l l ingIWorkover

Operat ions.Appendix V Hazard Ident i f i cat ion Table.Appendix VI Hydrogen Sufphide, Exposure and PhysiologicalEf fects Table.


28/71

DOC NO KOC- 3-002 Page 7 o f 7.

REV 6r _____1I APPENDIX___ ^_ ~___ J

CLASSIFICATION AREA BOUNDARIESHEAVIER T H A N AIR GASES VAPOURS

OPEN AIR SITUATIONS1 . _ _ _ _ _ _ 1 Open Air SituationsHazardous area extends vert ~cal ly8m above SOH and hor~zontally15m, In all directton sBeyond 8 m f rom SOH n hor~zonta lplane th e vertrcal lrmrt of the areamay be reduced to 8m provrdedthat the normal tendency for the1 gas to spread cfownward andGRUUND 8 m m ou tw ar d 1s no t prevented orrestr~cted.appl ies t o both Zone 1 and Zone2 areas).Wit hi n this area any pits trenches,culverts, etc. belo w ground levelshall be classified as Zone 1

2. ENCLOSED PREMISES & SURROUNDINGAREASCASE A: HAZARDOUS ATMOSPHERE INBUILDING UNDER ABNORMALCONDITIONS

2 Enclosed Premises andSurrounding AreasCASE A:Hazardous Atmosphere InBuilding Under AbnormalConditionsSince lack of ventilat ion limits rateof dispersion th e whol e of theinterior is classified Zone 1 Thearea surrounding is classified Zone

GROUN 2, whereby the openings in the1 EVEL building or wall i f no t vapour- t ight ,L are taken as the S OH.

CASE B: HAZARDOUS ATMOSPHERE INBUILDING UNDER NORMALCONDITIONSCASE B:Hazardous Atmosphere inBuilding Under NormalConditionsIn this case bot h the interior of thebuilding and the surroundin g areaare cia ssified Zone 1. Theboundarie s are as detailed in 1above.Cases A and B relate t ounpiercetf vapour-t igh t roofs.In t h e case of vented roof-structures, the classified 701ie vglllbe extended 8 m vertically abo v ethe highest vent poin t.


29/71

I APPENDIX IDOC. NO. KOC G 002

CLASSIFICATION AREA BOUNDARIESHEAVIER THAN AIR GASES / VAPOURS

IPage 28 of 70

3. OPEN PREMISES AND SURROUNDING AREAS 3. Open Premises and SurroundingAreas

REV

CASE A HAZARDOUS ATMOSPHERE IN OPEN CASE AROOFED STRUCTURE UNDER ABNORMAL Hazardous Atmosphere in OpenCONDITIONS Roofed Structure Under Abnormal

Conditions

GRDUNDLEVEL

I n t h i s c as e , t h e e n t ir e a re a w i t h i nt h e o p e n p r e m i s e s s h a l l b e

7 c l ass i f i ed as Zon e 2._l~ ~h e s u r r o u n d i n g a re a s h a l l b et r e a t e d a s i f t h e SOH w a s l o c a te din t he a i r i. e. i n 1 a b o v e .

CASE B HAZARDOUS ATMOSPHERE IN OPEN ROOFED CASE BSTRUCTURE UNDER NORMAL CONDfTlONS Hazardous Atmosphere in OpenRoofed Structure Under Normal

n t 8r1 f m fr1 / ConditionsIn t h i s c as e, b o t h t h e a re a s w i t h i nt h e o p e n p r e m i s e s a n d t h e

GROUND mLEVEL s u r r o u n d i n g a r e a s h a l l b e c l a s s i fi e dZ o n e 1 T h e b o u n d a r i e s a r e a sde ta i l ed i n 1 above .

4. ENCLOSED PREMISES WITH PLENUM OF SAFE 4. Enclosed Premises with Plenum ofATMOSPHERE Safe AtmosphereW h e n a p u r g in g s t re a m o f s a fea t m o s p h e r e i s s u p p l ie d t oe n c l o s e d p r e m i s e s l o c a t e d i n ah a z a r d o u s a r e a ( W h e t h e r c l a s s if ie dI I I I a s Z o n e 2 o r Z o n e 1, asi ll u s tr a t e d ), t h e n t h e i nt e r io r o f t h eb u i l d i n g m a y b e c l a s s i f i e d a s a nGROUND unc lass i f i ed a rea , a l t ho ugh it is

LEVEL n o t s e p ar a te d f r o m t h e h az a r do u sa re a b y a f ir e w a l l .NOTES

1. W h e n l o c a t e d i n a Z o n e 1 a re a, l o s s o f p u r g e s t r e a m s h o u l d a u t o m a t i c a l l y d i s c o n n e c t t h ee l e c tr i c a l s u p p l y a n d s o u n d a w a r n i n g s h o u l d it n o t b e p r a c ti ca b le t o d i s c o n n e c t t h e s u p p l y o rt a k e m e a s u r e s t o p r e v e n t t h e i n g r e ss o f a d a n g e r o u s a t m o sp h e re , t h e n t h e e le c t r ic a l a p p a r a tu sw i t h i r i t h e p r e m i s e s s h a ll m e e t t h e s a f e t y s t a n d a r d s s e t f o r Z o n e 2 i ns ta l l a t i ons .

2 W h e n l o c a t e d i n a Z o n e 2 a re a, i t i s s u f f i c i e n t t h a t a w a r n i n g i s s o u r l t je d i n t h e e v e n t o f t h el o s s o f t h e p u r g e s t r e a m .3 A doub le doo r , a i r -l ock r? r lt r y sys tem sh oc~ l t i e i ns ta l l ed a t pe rsonne l errtrances of premises i n

Z o n e 1 area, if it i s i n ten t led to i ns ta l l s tan t fa r0 industrial t y p e a p p a r a t us .


30/71

APPENDIX ICLASSIFICATION AREA BOUNDARIES

REVOC. NO. KOC G 002

LIGHTER THAN AIR GASES / VAPOURS

1age 29 of 70

1 Gases wit hin this class commonly encountered include methane, methane mixtures, hydrog enrich gases and ammonia.

2. Except in enclosed spaces, these lighte r-than-air gases seldom produce hazardous mixture s inareas close to ground level, where most electricaf installations are to be foun d. Accordin gly,thi s table has been limited to essential, basic principles.

3 The principles given mus t be applied wi th due regard to the particular circums tances. Specialcare is necessary where lighting equipmen t is positioned above the SOH.

1. OPEN AIR SITUATIONS4 5m 4 5 ~

5m I I

GROUND 5 mLE V

2 ENCLOSED PREMISES 8 SURROUNDING AREASCASE A: TOTAL ENCLOSED VOLUME

INADEQUATELY VENTILATED

GROUNDLEVEL.__ EL ___

CASE : OPEN BASED SHELTERS

1. Open Air SituationsHazardous area exten ds vertically8 m above and 4.5m below SOHand horizontally 4.5m n alldirections, whet her classified asZone 1 or Zone 2 as illustrated.

A R E A LIINADEOUA rrV E N T I L A i N

2 Enclosed Premises SurroundingAreasCASE A:Total Enclosed VolumeInadequately VentilatedWhere the SOH gives rise todannerous atmospheres under-either norm al or abnormalcondit ions then the whole of theinside of the building shall beclassified as Zone 1. Unlessshow n to be unnecessary in anyspecific case, a surroundingdistance of 3 m Horizontally and5 m Vertically and will be classifiedas Zone 2.CASE :Open Based SheltersIn this case, the open base area istrea ted as if the SOH was in theopert air and the upper containedarea as if totally enclosed.The Hazardoos Area extendsvertically 5111 frorn the roof and3131 Itorizor~~tallyith classificatiorl

4 of Zone-


31/71

APPENDIXDOC. NO. KOC G 002

CLASSIFICATION AREA BOUNDARIESLIGHTER THAN AIR GASES VAPOURS

1

age 3 o 7

3 OPEN PREMISES WITH VENTILATEDROOF AND SURROUNDING AREA

REV

W L L

4 5m M XIMUM ORU G R O U N LEVEL

3 Open Premises with VentilatedRoof and Surrounding Area

I I

111

Where the SOH gives rise todangerous atmosphere underabnormal conditions, the followin gareas will be classified Zone 2Area upto limit of open wallstreated as if SOH where in open

air).Entire area wit hin enclosed roofspace.Above roof within an area 4 5 mhorizontally f rom the outerextremity of the ventilation ductsin all directions, and, vertically,8m above the upper-mostventilation point.


32/71

FOR PARTICULAR APPLICATIONS

1 STORAGE TANKS - FIXED AND FLOATING ROOFS WITHIN THE BUND WALLS

REVOC NO KOC-G-002

CASE A FIXED ROOF

p i G i E qCLASSIFICATION AREA BOUNDARIES

Page 31 o 7

GROUNDLEVEL_

CASE : FLOATING ROOF

GROUNL.EVEL .wI Srn( N O T E - 5 ) 4 LJMP plT

CASE C DIESEL TANK DAY TANK

GROUNDLEVEL.__IL.

CASE D: TANKS WITH BLANKETINGi For the tanks wi th nitrogen or fuel gas blanket which do not vent to atmosphere the

classification may be relaxed. The area sh ow n as Zone 1 in Case A lnay beclassified as one 2 .ii For th e tanks with Nitroger1 blan ket hu t vr:rlttr~g to atr~losphere hall b e classified sshown in Case A .


33/71

APPENDIX IllDOC. NO. KOC G 002

CL SSIFIC TION RE BOUND RIESFOR P RTICUL R PPLIC TIONS

Page 32 of 7 0

NOTES

REV

In making these recommendations, due regard has been given to the consistently highlevels of solar radiation experienced in Kuwait, which may develop surfacetemperatures of over 80 (176 F in exposed materials, t he accompanying highevaporation rates, and the significant periods under light breeze or calm conditions.

2 Under typical operating conditions, vapour release fr om both fixed and floating rooftanks occur well above grade and wil l be adequately dispersed before they reachprolonged distances. Hence acceptable safety levels are achieved by rest rict ing theZone 1 classification t o the t ank roof and classifying the in-liquefied area as Zone 2.

3. In certain installations t may be necessary for the entire in-liquefied area t o beclassified Zone 1. This situation may arise if hazardous areas are resulting from otherequipment, fittings, etc. located with in the liquefied wail.

4. Grouping of tanks (as in a tank farm) may lead t o build-up of flammable atmosphereunder adverse conditions of w in d and temperature. As a precautionary measure, t isrecommended that, where an access road is located between the liquefied walls, t heminimum distance betw een these liquefied walls should be 24 meters (75 ft.) unlessdata, obtained fr om surveys carried out under the most adverse conditionsanticipated, indicated otherwise.

5 Area boundaries sho wn on the left of t he illustration wil l be normally applicable.6. Where the liquefied wall is less than 1 5m from the tank then the Zone 2 Area shall

extend beyond the liquefied t o 15 m fro m the tank. For tanks of diameter orn or less,this distance may be reduced to 8m.


34/71

DOC. NO. KOC G 002 Page 33 of 7 r EV

7

APPENDIX ll 1____________ICLASSlFlCATION AREA BOUNDARIES

FOR PARTICULAR APPLICATIONSPIPELINES AND FITTINGS2 __ _ _ _GENERALUnder norm al service conditions, pipelines m ay be subject to failure by internal or externalcorrosio n (if buried) or b y leakage occ urri ng at flanges, ancillary fittings, e tc. It is necessary,therefore, for pipelines or pipe work wi th in plan t fence to be assessed for the probability offailure. These recommendat ions apply to sys tems tha t may release bo th heavier or lighter tha nair vapours/gases. They are applicable to pipe work installed wit hin plant boundaries. Crosscountry pipelines are not normally classified unless special circumstances dictate.

2.1 WELDED PIPELINE SYSTEM2.1 1 Systems No t Re quirirg CIassif ication

All-w elde d pipelines wit hou t valves, flanges or other fitt ings may remain unclassifie dregardless of the ventilation rate. Such piping may be above ground, installed in pit or culvertor buried.

2.1 2Syste ms Requiring ClassificationShould all weld ed pipeline wit ho ut flanges, valves or other fitt ings require classification forsome s pecific reasons, th e classified boundaries shall be treated as foHows:

CASE A: INSTALLED ABOVE GROUN D CASE AFor a system, available for fu llinspection, on area of 3m 10 ft. ) in all

L - EVLL directions wil l be classified Zone 2.

CASE B: INSTALLED I N PIT OR CULVERTOPEN TOPPED OR ENCLOSED)

C O V E R SLABSGKDUNDLEVEL

ACASE C: BUR IED PIPELINES

Normally no t to be classified

CASE B:For a system, available for ful linspection the entire volume of thepitlc ulve rt wil l be classified as Zone 1and th e above ground area wit hin 5 m( 1 ft.) in all directions of th e surfaceopening as Zone 2

CASE C:Buried pipelines wil l no t be classifiednormally. However , for some reasonssuch as poor condition of the pipe.proven record of pitholes and holidays,inadequate cathodic prot ecti on etc.,formal classification may be justifiedwhich wi l l be as per Case-C. Theclassification will b e limited to areawithin the plant boundary only. l h ezone 2 area in this case will extend 817)(25 f t .) above-grountf level verticallyand 8111 25 t . ) irl all tfirectior>s frornS O t i . (see also clause 14.5.3, se 2).


35/71

I APPENDIX llDOC. NO. KOC- 3-002

CLASSIFICATION AREA BOUNDARIESFOR PARTICULAR APPLICATIONS

IPage 34 o 7

2 2 MECH ANICALLY OINTED PIPELINE SY STE M

REV.

t is normal practice t o anticipate that fai lure of f langed or screw pipe joints ma y occurt ime t o t ime. The magnitude of th e leakage arising fr om any part icular faiture will dependo n the class of f luid contained, th e sys tem pressure and the fo rm of seal used. For agiv en set of conditions, unreinfo rced sheet gaskets are likely t o give considerab ly higherleakage rates than metal reinforced types or full restrained elastomeric seals.In vie w of the variables involved, these reco mmendations have been conservatively basedo n a dispersion length of 5 m 16 t . f ro m the valve and f i t t ing and are thus sui table forall classes of hydrocarbon materials.

CASE A: INSTALLED ABOVE GROUND CASE A:For a system, available for fullinspection, an area of 5 m 16 f t . in alldirections shall be classif ied Zone 2.

GROIJNDI EVE1 3

CAS E B: INSTALLED IN PIT OR CULVERTOPEN TOPPED OR ENCLOSED)CnVE:R SLABS

CASE B:For a s ystem, available for fullinspection, the entire volu me of thepit lculve rt shall be classif ied as Zone 1and the above ground area with in 5rn

[ IRL~~JNU 16 f t. In all d~re ct io ns f the surfaceL tVLL openbng as Zone 2.

CAS E C: BURIED PIPELINESNormally no t to be classif ied

2 3 PIPING SYSTEMS W ITHIN INADEQUATELYVENTILATED ENCLOSED PREMISES

CASE C:See note for i tem 2.1.2 Case C

CASE A: ALL-WELDED SYSTEMS WIT HO UT VALVES , FLANGES.FITTING S AN D SIMILAR AC CESSORIES)n th is case, i f l ines are well maint ained and available for f ul l inspection th en th e complete

interior will be classified Zone 2

CASE B: MECHANICALLY JOINTED PIPING S Y S T E M SIn t his case, ttre cornplete tnterior will b e classtf ied 7o1,e 1 S i ~ r r o ~ ~ n t f i n greas shall i ) ~classified as per case 2A of Appendix and 1 1


36/71

CLASSIFICATION AREA BOUNDARIES

DOC. NO. KOC G 002i___


age 5 o f 7 REV.

3 PUM P TURBINE INSTALLATIONS

APPENDtX

Applies to both Heavier and LighterAir GasesNapours.

3 1 IN OPEN AIR OR WELL VENTILATED.POSITIONCASE A A SINGLE PACKED GLAND OR Leakage released locally at pum p.MECHANICAL SEAL WIT H OR WITH OUT

BACK UP THROTTLE BUSH)For flammable liquids wi th flash points

Seal vapour leakage to atmosphere liquid loss to open bel ow 32C (90C); handled belowdrainage system. IBP, at all pressures.

Zone 2 area as defined in Appendix ICase I.

When used for flammable liquids wi thflash points below 32C (90F):handled above IBP at ail pressures andtemperatures upto 2 C 392F).However, special consideration shouldbe given t o circuits operating at 1 0 barI- -+ -I (150 psi) or greater, since, n certaincases, an extension of the Zone 2boundaries may be justified. Extensionshall be as per Case A-Ill below.Zone 1 limit 0.3 m ( 1 ft.) Radius spherecentered on seal. Zone 2 area asdefined in Case A-l above.

When used for flammable fluids underconditions other than those covered byI and II above. Special considerationshould be given, to circuit s operatingat 4 0 bar (600 psi) or greater, since, incertain cases an extension of the Zone2 boundaries may be justified.Zone 1 Iirnit 0.3m (1 ft. ) Radius sphere

L R U U ~ J D centered o n seal.I FVFL Zone 2 as defined in il above, exceplV that groontf cover is extended b y

furtl~er rn 25 t . ) in all directiorls t :


37/71


DOC. NO. KOC G 002

CASE B : DOUBLE MECHANICAL SEAL No loca l leakage except under a doubleOR EQUIVALENT) fault situation.When used for flammable liquidslgases

Interspace containing sealing fluid of low under all conditions. Zone area as inflammability, vented andlor drained to Case A- I above.closed system.CLASSIFICATION AS IN CASE A - I ABOVE Special consideration shou ld be given

to circuits operating at 1 bar 150 psior greater, since, in certain cases, anextension of the Zone 2 boundariesmay be justified. Extension shall be asper Case A-Ill above.

- APPENDIX It1Page 6 of 73 2 IN INADEQUATELY VENTILATEDOR CLOSED PREMISES

REV.

CASE A: SINGLE PACKED GLAND OR MECHANICAL Applicable to both Heavier and LighterSEAL WI TH OR WITHOUT BACK-UP than Air GasesIVapours.THROTTLE BUSH)Seal vapour leakage t o atmosphere liquid loss toOpen drainage system.

Leakage released locally at pump.

ALL APPLICATIONS.

CASE B: DOUBLE MECHANICAL SEALOR EQUIVALENT)lnterspace containing sealing fluid of low No local leakage except under a doubleflammability, vented andlor drained to fault situation.closed system.

ALL APPLICATIONTreatment as for Case 2A Appendix Ir ~ n T 8 n l r - 8 n t - 8 n - - j


38/71

APPENDIX I l lI DOC. NO. KOC- 3-002

CLASSIFICATION AREA BOUNDARIESFOR PAR TICULAR APPLICATIONS

CASE C: PUMP S INSTALLATION HANDLINGDEGASSED CRUDE OIL

I IPage 37 of 70

1 SINGLE PACKED GLAND OR M ECHA NICAL Vapour evolution resulting fromSEAL WITH OR W I T HO UT BACK- UP leakage of degassed crude oil isTHROTTLE B USH) substantially less than that arising fro m

'raw ' stock. Some relaxation ofSeal vapour leakage to atmosphere liquid boundary limi ts is therefo reLoss to open drainage system. permissible. Leakage released locally

at pump.

REV.

Treatment as for Case B Appendix Iexcept that b oth horizontal and verticalboundary limits may be reduced to 8m(as shown ). tnterior of pumphouse andarea within 3m of openings areclassified Zone 1 Remaining areas

GROUN with in the boundaries shall beLEVEL classified Zone 2

Boundary limits extend fr om openingsin the pumphouse structure, i.e. doors;vents; permeable walls, etc.

II. DOUBLE MEC HAN ICAL SEALSOR EQUIVALENT)

No local leakage except under a doublefault situation.

Interspace containing sealing flui d of l ow Treatment as for Case 2 A Appendix Iflammability, vented and/or drained to except that bo th horizontal andclosed system. vertica l boundary timits may be

reduced to 8m (as shown). Interior ofpumphouse shall be classified Zonet- -7 -I and surrounding areas Zone 2 .Boundary l~ mi ts extend from openingsin the pumphouse structu re, i.e doors;

m vents, permeable walls, etc.

rPm --Iini L R n U N Drv t

LL


39/71

APPENDIX l lDOC. NO. KOC G 002


Page 8 of 7 REV

3.3 PUMP INSTALLATION ISOLATED FROM PRIME MOVERSBY A VAPOUR TIGHT FIRE WALL

I

C SE A: GENERAL REQUIREMENTS

VEHI LE OOR ROO VENrL O C A T I O N

V A P O U R - T I G H T W A L L S

GROUNDLEVEL

D E F L E C T O R W A L L

NOTES:1 T h e u s e o f v a p o u r - t ig h t w a l l t o c o n t a i n a h a z a r d o u s z o n e w i l l p e r m i t t h e a re a b e h i n d t h e w a l l t o

be unc lass i f ied a rea.2 W h e n f l a m m a b l e m a t e r i a l s ar e h a n d l e d in a c l o s e d b u i l d i n g o r p u m p h o u s e, a l l o p e n i n g s r

v e n t s in t h e s t r u c t u r e m u s t b e c o n s i d e r ed a s s o u r c e s o f H a z a rd ( S O H ) . T h e re f or e , t s h a l l b ec l a s s i f i e d a s Z o n e - 1 o n a re a of 3m i n a l l d i r e c t i o n .

3 In o r d e r t o m a i n t a i n s a f e c o n d i t i o n s , it i s e s s e n ti a l t h a t a c ce s s p o i n t s o r v e n t s t o t h eu n c l a s s i f i e d o r s a f e p r e m i s e s l a y o u t s i d e a n y h a z a r d o u s z o n e a r i s in g f r o m t h e c l a s s i f i e d a re a s.

4 A c c e s s p o i n t s t o b o t h t h e c l a ss i fi e d b u i l d in g a n d t h e u n c la s s if ie d p r e m i s e s s h o u l d n o t b el o c a t e d i n t h e s a m e p la n e o f w a l l ( o r r o o f ) , s i n c e u n d e r a d v e rs e w i n d c o n d i t io n s , v a p o u r s rnayb e c h a n n e l le d a l o n g t h e s u r fa c e s . W l l e r e t h i s i s n o t p r a c t ic a b l e s u i t a b le d e f l e c t o r w a l l s shoultfb e e r e c t e d t o p r e v e n t the d irect f low o f v a p o u r s .


40/71

DOC. NO. KOC G 002 Page 39 of 70 REV. 6rApp~Kxli ICL SSIFIC TION RE BOUND RIES

FOR P RTICUL R PPLlC TtONS

CASE B: GAS TURBINE DRIVES NOTE-5 )

\ V E H I C L E DOUR +--m 4EXHAUST S T A C K

G R U U NL F V E Lx

NOTES1. The use of gas turbine drives brings particular problems arising fro m the high temperature of

the exhaust systems, typically 4 3 0 C to 5 4 0 C 8 0 0 F to 1 0 0 0 F ) .2 When flammable materials are handled in a closed building or pump house, all openings or

vents in structure must be considered as source of Hazard (SOH). Therefore, it shall beclassified as Zone-I on area of 3m in all directions.

3 Building layouts tha t ensure the ho t exhaust stack, well clear of any hazardous zones are to bepreferred, should the exhaust stack be located in a hazardous zone then it must be similarstandard t o those set for a Protected Fired Heater (See Appendix Ill Section 11).

4. It is desirable that the flo w of heat from the turbine room to the classified pump house isminimized in order to reduce the rate at wh ich flammable vapours are formed under faultconditi ons. Particularly critical areas are those i n the proximity of the exhaust s tacks andconsideration may usefully be given t o insulating these areas.

5 The relative positions of the exhaust stack roof penetrations to the po p house vents are rrlostcritical. As the illustrations indicate, t h e use of the side facing vents rn y o v~ri tehe need forexhaust stack insulat~on.


41/71

CLASSIFICATION AREA BOUNDARlESFOR PARTICULAR APPLICATIONS

NOTES C o n t d I

6 O p e n s i d e d t u r b i n e i n s t a ll a t io n s w i l l b e t r e a t e d a s p e r t h e g u i d e l in e s g i v e n i n t h e A p p e n d i x I and11

7 G a s t u r b i n e s a re n o t r e c o m m e n d e d t o b e i n s t a l le d i n Z on e a re a .

4. RECIPROCATING. CENTRIFUGAL R AXIAL COMPRESSORS

A s ph e re o f I m 3 t . ) r a d i u s a r o u n d g la n d , c y l i n d e r a n d fr e q u e n t l y o p e r a t e d d r a in p o i n t s a n dv e n t s .

Centrifugal and.Axial compressorsA sphe re o f I m 3 t . ) rad rus a round sea l , sea l 11 a n k c o v e r , v e n t a n d s e a l or t r a p s

REVOC. NO. KOC-G-002

TYPICAL INSTALLATION WITHIN THE PREMISES WITH OPEN SIDES AND WELL-VENTILATEDROOF SPACE.

age 4 0 of 70

CASE A: HEAVIER THAN AIR GASESIVAPOURSZ o n e 2 a r e a b o u n d a r ie s a s d e t a i l e d in C a s e 3A A p p e n d i x I sha l l be app l i cab le .

CASE B: LIGHTER THAN AIR GASESIVAPOURSZ o n e 2 a re a b o u n d a r i e s a s d e t a i l e d i n C a s e 3 A p p e n d i x II sha l l be app l i cab le .

FOR BOTH CASES A AND B THE FOLLOWING AREAS WILL BE CLASSIFIED ZONE :

Reciprocating Compressor


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DOC. NO. KOC G 002 Page 4 of 7

5 SAMPLING POINTS IN OPEN ORWELL-VENTILATED LOCATION Applicable to Heavier than Air GaseslVapours)

REV.

GENERAL1. Sampling of liquids into an open container should be carried out at a temperature that

~ A P P E N D I X_CLASSIFICATION AREA BOUNDARIES

. ~wil l ensure nooc curr ence of undue loss of l ight ends. Using a well-maintained systemtogether wi th go od house-kee ping standards, significant releases wil l occur onlyunder fault (i.e. abnormal) conditior~s.2. Liquefied f lammable gases and 'hot ' f luid sampling should always be into a closedsyst em wi th provision wi th venti ng to a safe place. Flammable atmospheres, therefore,are unlikely to exist other than under fault conditions.3 The boundary areas indicate d are suitable for use wh en syst em maintenan ce is of highstandard and releases of only a lo w order are anticipated. Should this no t be th e case,then t he basic l imits defined in Appendix I-para 1 shall b e applied.4. In sett ing the boundaries it has been assumed that same valve leakage may occurcreating a wetted ground condit ion.

5 1 OPEN SAMPLING INTO CONTAINERCASE A: INFREQUENT USE

APPLIES TO FLAMMABLE FLUIDSSAMPLED AT OR NEAR AMBIENTTEMPERATURE EXCLUDING LIQUEFIEDGASES)ADDITIONAL ANNULAR ZONESHDU1 U WETTE GROUN AREA Sphere of 1.5 m 5 ft.1 radius aroundE X C E E D A NOMINAL 5~ RADIUS SOH together wit h the space enclosed

by t he vert ical projection of the equatorGRDUND t o grou nd level shall be classifi ed ZoneI V E [ _ 2. Where a wetted ground area exists,

_ \5 a further annular vo lu me shall beincluded w i th a rad~u s f 4 .5m 15 f t . )of the vert ical axis of SOH and 2rn 6ft.) height above ground level.CASE B: FREQUENT USE APPLIES TO FLAMMABLE FLUIDSSAMPLED AT OR NEAR AMBIENT(Increased ground spillage build-u p area assumed) TEMPERATURE EXCLUDING LIQUEFIEDGASES)

on--dRad.

/ 1.5m Rad.GROUNDLLFVEL_ _ Q _-

Sphere of 1.5m 5 f t .) radios aroundSOH together w it h the space enclosedby t he vert ical projection of t he equatort o ground level plus the annular volumecontained wit hin the radius of 8 m 2 5ft.) of the vertical axis of SOH and 3m(10 ft.) height above grou nd level shallbe classif ied Zone 2.

5.2 SAMPLING INTO CLOSED SYSTEM DOES NOT APPLY TO LIQUEFIEDFLAMMABLE GASES.CASE A: FLAMMABLE LIQUIDS SAMPLED ATOR NEAR AMBIENT TEMPERATURE AJ Fre2uencies of Use.Treated as 5.1 Case A above All frequencies o f s u e . Sanipling pointsshall not exceed 6mr~1 i 4 ) bore forCASE B: LIQUEFIED GASES AND pressure opt0 2 0 bar 300 psi). AboveFLAMMABLE FLUIDS SAMPLED AT t is pressure bores s f ~ a l l f je t t~rot t ledTEMPERATURES ABOVE AMBIENT) d o w n t o 31nm (118 ) o r t lo~ lble alvesused.Zone 2 Area shall be as defined in Appendix I Para 1.


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CL SSIFIC TION RE BOUND RIES

DOC. NO. KOC-G-002

FOR P RTICUL R PPLIC TIONS

6 DRAIN POINTS FOR PROCESS WATER INOPEN OR WELL VENKATED LOCATION

I APPENDIX l lPage 42 of 7

6 1 IN REGULAR USE DISCHARGING INTOOPEN AT APPRO XIM ATEU ROU ND LEVEL

REV

CASE A: FLAMMABLE LIQUIDS

I D- om-

Applicable to heavier than airgaslvapour.

The space contained wi thi n thesurfaces of a vertica l cylinder of radius1.5m 5 ft.) fro m the SOH extendingut, from the around level t o 3m 10 f t . )I -above the SOH, shall be classifiedZone 1.

GROUND The surrounding area shall be classifiedLEVEL Zone 2 as defined in Appendix I, paraT 7

CASE B: LIQUEFIED FLAMMABLE GASES AND The space contained wit hin t he surfacePRESSURIZED FLAMMABLE FLUIDS of a vertical cylinder of radius 5m 16

ft.) from SOH extending up fromground level to 3m 10 ft.) above theSOH will be classified Zone 1.

6 2 DISCHARGING INTO CLOSED SYSTEMTREAT AS PIPELINE PLUS FITTINGS ASDEFINED IN APPENDIX Il l - SECTION 2

The surrounding area wi ll be classifiedZone 2 as defined in Appendi x I, Case1. Larger release is anticipated undersingle fault conditions e.g. incomple teclosure of isolating valve. Anadditional area of horizontal depth 15m10 ft. and height 3 m 10 ft.) shall beclassified as Zone 2 .

Will normally be contained within limitsof the classified zone applicable t o itsparent vessel or tank.


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IPPENDIX I l l JDOC. NO KOC G 002

CLASSIFICATION AREA BOUNDARIES

Page 43 o 7 REV

FOR PARTICULAR APPLICATIONSOPEN OR FREELY VENTED T AN KS OR SU MP7 Typically used for receiving purgingand process drainage, bearing oilIN FREQUENT OR P ERMANENT USE leakage, an oil water separator and

similar duties.

NOTE:

The Zone 1 area shall extendhorizontally 8 m 25 ft.) in all directionsfrom the outer limits of the open topor cover vents) and vertically upwards

G R O U N from ground level, or from the tank topL EV E L if elevated, t o a height of m 6 t . ) ._ _K

The Zone area shall extendhorizontally 5m 50 f t . ) in alldirections from the outer limits of theopen top or cover vents) and verticallyupwards from the tank top if elevated,to a height of 3m 10 f t . ) .

All pits, sumps or ground depressions within Zone-2 area,wi ll automaticaily be classified as Zone-1


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DOC NO. KOC G 002 Page 44 of 70

8 -RELIEF VALVES AND-EMERGENCY BLOW OFF

REV 6

8 1 RELEASING TO ATMOSPHERE

LASSIFICATION AREA BOUNDARIES

GENERAL1. The criteria affecting the extent of classification of area around the relief valve in non-

enclosed area are too diverse t o specify . Individual engineering judgement is requiredfor specific cases, taking int o consideration the lower flammabi lity limit LFL) of therelease. But in no case the dimension shall be less than shown in this diagram.The calculation method to determine the distance to the L L shall be in accordance wi thAPI RP-521.

2. In general, a relief valve wi ll discharge only under abnormal conditions and theclassification roun d the point o f discharge is Zone 2, although to allow for smallleakages past the valves, Zone is proposed for 1.5m radius 5 ft. ) around thedischarge pipe tip. If, however , because of special process feature a particular reliefvalve is expected t o discharge frequently, t he whole classification shall become Zone 1.

R a d .

LENGTH-

8 2 DISCHARGING. . TO CLOSED SYSTEM.Treat as pipeline plus fitti ngs as defined i n theAppendix, section 2 .

i In the case of bo th heavier andlighter tha n Air Gases, a sphere of1.5m 5 ft.) radius around thedischarge pipe tip w ill be classifiedas Zone I and within asurrounding sphere of 5 m 16 f t . )radius Zone 2. Superimposedthereon will be an addition to theZone 2 area consis ting of aninverted cone wi th the apex at thedischarge point SOH)dimensioned as follows:Lighter Than Air GasesLength of Cone = 100 x

GROUND Discharge pipe dia.LLEVEL. _ Radius of Cone = 60 xDischarge pipe dia.

Heavier Than Air GasesLength of Cone = 260 x~ i s c h a r ~ eipe dia.Radius of Cone = 120 xDischarge pipe dia.

ii Where the height of the dischargepoint SOH) is less than 8m 25ft.) above ground level, th e conicalvolume below the 5 m 16 ft.)sphere wit hin a base radius of 8m2 5 ft.) will also be classified Zone2. Ref. ROSPA)If the discharge point i s vesselrnounted, it wil l normally becontained within limits of theC:lassifietf zorie ;rl)l~lic;tble t o itsparent vessel or tank.


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ORPARTICULAR APPLICATIONS

DOC. NO. K O C G 0 0 2 Page 45 of 7

9 VENT PIPES IN OPEN AIR-

REV

LOW CAPACITY DiSCHARGES AT LOW VELOCITY)

CLASSIFICATtON AREA BOUNDARIES

Some recommendations to be considered in the design of venting system:i The upper end of the pipe should discharge upwards in the open air, out of reach, be at

least 4 m 13 ft.) above ground level, and should no t be located wit hin 3m 10 f t . ) ofopen windows or other openings.

i There should be no entry to basement or below groun d areas vertically belo w or wi thinareas designated as Zone 2i i i) Vent pipes should be installed no closer than 3 m 1 0 ft.) to a boundary, unless it is a

solid wall w hich effectively for ms a limit to t he classified area.These provisions do not apply t o vent s associated wi th large, bulk storage tanks towhich the requirement of Appendix Ill Section 1 are appropriate.

9 1 FREQUENT R CONTINUOUS RELEASE These discharges occur in normaloperation, and so give rise to eitherZone 1 or Zone 0 taken as sphere tocover bot h heavier and lighter than air

3m Rnd . 3n. Rad. vapours) around the poin t of discharge.Since the quantities released are small,

1 . 5 Rad. 1 . 5 m Rad . - the classified areas do not require to beparticularly extensive.For both lighter and heavier than air

G R L l l l ~ D gases, a sphere of 1 .5m 5 ft.) radiusL - E V F L around the SOH will be classified Zone

Y YY ~ w. . 1 and area within a surrounding sphereof 3rn 10 ft.) radius Zone 2 TheseLIGHTER THAN A I R HEAV I ER THAN A I R Zone 1 and 2 will change to Zone 0and 1 respectively, if the duration ofrelease exceeds 10 00 hours per year.

9.2 INFREQUENT RELEASE In the case of heavier tha n a ~ r apours,the space vertically belo w the 3m I 0ft.) sphere will be desrgnated one 2 orZone 1 as applicable

3n Rod n Rod For bo th lighter and he av~ er than alrgases, a sphere of 3 m 10 ft radiusaround the SOH wrll be classlf~ed one2

[ ,~n~jp~ j )n the case of he av~e r han alr vapotlrsVrL the space verttcally belo w the 3m 10

- - t t sphere will also bc des~


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APPENDIX l lCLASSIFICATION AREA BOUNDARIES


DOC. NO. KOC G 002 Page 46 of 7 0

10 FLARES AN D BURN PITS

REV

10 1 FLARES

I

Locations surrounding continuous or inte rmittent ignition sources such as flare tips may remainunclassified. There are no established hazardous area limits associated wi th the flares, exceptthe rules for the safe installation of the flares.For safe distances fr om process plan ts and other design guidance, refer to IP Mode l Code ofSafety Practice Part 3 Refining Safety Code .

When combust ion is taking placesaturated areas of sand with in the pitboundary will give of f vapours, fumesetc., hence the combusti on area itselfand the surrounding area with in adistance of 8m (25 ft.) from the pitedge wil l be classified Zone 1. Afurther area of 8 m (25 ft.) depth,encompassing the Zone 1 boundary,will be classified Zone 2

P I T E GE

1I FURNACES AND HEATERS

GENERAL. .I This section relates t o furnaces and process heaters whether fired by gas or oil, or

heated electrically. t is intended t o apply over the full range of process plants fro mlarge furnaces to relatively small units e.g. dryers, degassers, e tc. Furnacestheaters arecategor ized as being either Protected Fired or Unprotected Fired vessels or heatercontainments. A Protected Fired furnace or heater, is one so designed and equippedas to eliminate the vessel or containment as a source of ignition.A n Unprotected Fired heater or furnace, however, may constitute a source of ignitionunder certain operational conditi ons.

2 Unprotec ted Fired heatersJfurnaces mu st riot be located within hazardous areas (Zone1 & 2 associated wi th other process plant. They are suitable for installation only Inareas i n whic h normal industr ial standards are acceptable.


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APPENDIXDOC. NO. KOC G 002

_________ LCLASSIFICATION AREA BOUNDARIESFOR PARTICULAR APPLICATIONS

Page 7 of 7

GENERAL Contd...

REV

3. Protected Fired heaters are required when it is necessary for the installation to bewit hin the boundary of a Zone 2 area. Heaters shall not be positioned in Zone 1 areas.4 Protected Fired heaters, in this context, would be furnaces or heaters that:

I. Are thermally insulated and present no external surface tha t operates at atemperature above the ignition temperature of the gasivapour concerned.li. Have flue arrangements wi th the discharge located in an unclassified zone, andhave airfeed arrangements that wil l prevent flash back .

1.1 UNPROTECTED FIRED HEATERS / FURNACES Normal industrial risks are consideredacceptable. The space surrounding theCASE A: LOCATED OUTSIDE CLASSIFIED ZONES furnacelheater is UNCLASSIFIED . AARISING FROM OTHER PROCESS PLANT heater should be placed as for aspossible from the source ofhydrocarbon leak (SOH) but not lessthan 15 meters. Refer t o IP Code, Part3.

CASE B: LOCATED INSIDE CLASSIFIED ZONE NOT PERMISSIBLEARISING FROM OTHER PROCESS PLANT

1.2 PROTECTED FIRED HEATERS FURNACES The space surrounding the furnace1heater will be classified as Zone 2 .CASE A: LOCATED OUTSIDE CLASSIFIED ZONES The limit of the zone shall be set at aARISING FROM OTHER PROCESS PLANT horizontal distance of 3 m 10 t.) fromthe furnace exterior and extendupwards a distance of 8rn 2 5 f t .above the upper surface.

Note: The vertical height may bereduced if the induced conventionalupdraft is know or show n to be of alo w order, say < 0.6m/ s 2 f t ls) .r 2 m m i n . )


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DOC. NO. KOC G 002 Page 48 o f 7 REVpEiiiGTjCLASSIFICATION AREA BOUNDARIES

FOR PARTICULAR APPLICATIONSCASE B: LOCATED INSIDE A ZONE 2 AREAARISING FROM OTHER PROCESS PLANT

JND RY_ T NG U C L S S I F I E D R E _TO PR O C ESS P L N [

L D C L FLUE,2n nin*)L T E R N T I V E

P U S I T l U Nr

IIIL E :GRDUND LEVEL

Location within Zone 1 Area is not AcceptableNOTES1 In principle wh en a furnace heater is located in whole or in part with in an established

classif ied area, the Zone 2 area related t o the furnace, as defi ned in Subsect ion 11.2Case A, is simply superimposed o n t he exist ing classif ied zone, giving a resultantboundary that contains b oth volumes.

2 The note s included under are equally applicable t o this case.3 It mu st be appreciated that boundary l imits are not precisely quantif iable, hence sound

engineering judgement must be applied in establishing the f inal f or m of the classif iedzone.

4 . In the exarnples shown, the dash-shaded zort stloult i be included in th e classif iedspace t o achi

haz area classification

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