Grading of Source of Release

Each item of process equipment (e.g., tank, pump, pipeline, and vessel)
should be considered as a potential source of release of flammable material.
If the item cannot contain flammable material it will clearly not give rise to a
hazardous area around it. The same will apply if the item contains a
flammable material but cannot release it to atmosphere (e.g., an all-welded
pipeline is not a source of release).
If it is established that the item may release flammable material to the
atmosphere (as will be the case with most items) it is necessary, first of all,
to determine the grade of the source of release in accordance with the definitions by establishing the likely frequency and duration of release.
By means of this procedure each item will be graded as continuous,
primary, secondary, or multigrade.
The source grade should be estimated by considering operational openings
to atmosphere and the possibility of releases under all (normal and
abnormal) operating conditions of the plant, installation, or process.
Releases are categorized as follows:
Continuous grade of release: A release that is continuous or is expected to
occur for long periods. Examples of continuous grade of release include
1 Surface of a flammable liquid in a fixed roof tank
2 Surface of an open reservoir (e.g., oil/water separator)
Primary grade of release: A release that can be expected to occur periodically or occasionally during normal operation. Examples of primary grade of
release include
1 Seals of pumps, compressors, or valves that are expected to release
flammable material, particularly during start-up
2 Water drainage points on vessels that contain flammable liquids
3 Sample points from which analytical samples are drawn
4 Relief valves, vents, and other openings, which that are expected to
release during normal operation
Secondary grade of release: A release that is not expected to occur in
normal operation, and if it does occur, is likely to do so only infrequently for
short periods. Examples of secondary grade of release include
1 Seals of pumps, compressors, or valves that are not expected to
release flammable material during normal operation
2 Flanges, connections, and pipe fittings where release of flammable
materials is not expected during normal operation
3 Relief valves, vents, and other openings that are not expected to
release during normal operation
A continuous grade of release normally leads to a zone 0, a primary grade to
zone 1, and a secondary grade to zone 2.

Extent of Zone
Quite a number of factors can influence the extent of the zone. If the gas is
lighter than air, it rises on release and can become trapped in the roof space,
or if the gas is heavier than air, it will fall and spread at ground level. This
has an impact on the location of the site; is it on a hill or in a hollow?
The extent of zones depends mainly on the following parameters:
1. Release rate of flammable material. The extent may increase with
increasing release rate (see release velocity).
2. Release velocity. Due to an improved dilution for release of flammable
gases, vapors, and/or mists in air, the extent of a hazardous area may
decrease if, with constant release rate, the release velocity increases
that which causes turbulent flow.
3. Concentration of flammable gases vapors and/or mists in the released
mixture. The extent may increase with increasing concentration at the
release source.
Ventilation. With an increased rate of ventilation, the extent of a hazardous
area may be reduced. The extent may also be reduced by an improved
arrangement of the ventilation system.
5. Obstacles. Obstacles may impede the ventilation and thus may enlarge
the extent of the zone. On the other hand some obstacles, for example
dikes and walls, may limit the movement of a cloud of an explosive gas
atmosphere and thus may reduce the extent.
6. Boiling point of flammable liquids (initial boiling point for liquid
mixtures). For flammable liquids, the concentration of the released
vapor is related to the vapor pressure at the relevant maximum liquid
temperature. The lower the initial boiling point, the greater the
vaporpressure for a given liquid temperature and hence the greater
the extent of the hazardous area.
7. LEL. The lower the LEL, the larger the extent of the hazardous area may
be.
8. Flash point. An explosive gas atmosphere cannot exist if the flash point is
significantly above the relevant maximum temperature of the flammable
liquid. The lower the flash point, the larger the extent of the hazardous area
may be. Some liquids (such as certain halogenated hydrocarbons) do not
possess a flash point although they are capable of producing an explosive
gas atmosphere; in these cases, the equilibrium liquid temperature
corresponding to saturated concentration at LEL should be compared with
the relevant maximum liquid temperature. (Note: In special conditions the

mist of a flammable liquid may be released at a temperature below the flash

point and may therefore produce an explosive gas atmosphere.)
Relative density. The horizontal extent of a hazardous area may increase
with increasing relative density. Where the relative density is less than
unity, the vertical extent may increase with a decrease in relative
density.
10. Liquid temperature. The extent of a hazardous area may increase with
increasing temperature of process liquid provided the temperature is
above the flash point. Note that the liquid or vapor temperature after
the release may be increased or decreased by the ambient temperature or other factors (e.g., a hot surface).
When sources of release are in an adjacent area, the migration can be prevented by
1 Physical barriers
2 Static overpressure in the area adjacent to the hazardous area
3 Purging the area with a significant airflow
4 2.3.5.1 Procedure for Determining the Type and Extent of
Zones
5 After establishing the grade of the release source, it is necessary to
determine the release rate from the item, and furthermore, the other
necessary factors that may influence the type and extent of the
hazardous area, as mentioned in previous sections.
It is rarely possible by cursory examination of a plant or plant design to
decide which parts of the plant can be matched to the three zonal definitions
(zones 0, 1, and 2). A more objective approach is therefore necessary and
involves the analysis of the basic possibility of an explosive gas atmosphere
occurring. Sincean explosive gas atmosphere can exist only if a flammable
gas, vapor, or mist is present with air, it is necessary to decide if any of these
flammable materials can exist in the area concerned. Generally speaking
such materials (and also flammable liquids and solids that may give rise to
them) are contained within process equipment that may or may not provide
a totally enclosed containment. To discover the cause of an explosive gas
atmosphere existing in an area, it is necessary therefore to determine how
the items of process equipment containing flammable materials can release
them to atmosphere.
1 Once the likely frequency and duration of release (and hence the grade
of source of release), the release rate, concentration, velocity,
ventilation, and other factors that affect the type of zone and/or extent
of the hazardous area have been determined, there is then a firm basis
on which to determine the likely presence of an explosive gas
atmosphere in the surrounding areas. This approach therefore requires

detailed consideration to be given to each item of process equipment

that contains a flammable material and could therefore be a source of
release. In some cases there may be other considerations (e.g.,
consequential damage) that may call for a different classification but
these considerations are outside the scope of this book.