PIPELINE QRA SEMINAR

INOGATE PIPELINE QRA SEMINAR

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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
• Ignition sources
• Chemical reactions
• Oil soaked lagging on hot piping
• Pyrophoric iron sulphide (H2S & metal
corrosion)
• Electrical sparks and arcs
• Electrical motors and generators
• Switches, relays and other arching
components of electrical circuits
• Electrical wiring mal functioning
• Electrical welding
• Lighting fixtures
• Impressed cathodic protection system
• Mechanical sparks
• Lightning
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 FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
• Static electrical sparks • Flame
• Fuelling operations • Flaring
• Filling containers, tanks and • Fired equipment
pressure vessels • Gas welding and cutting
• High fluid exit velocities (high
pressure water sprays, gas jets) • Hot surfaces
• Drive belt operation • Fired vessels stacks
• Shot blasting • Engine exhaust
• Friction • Heat of compression

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INOGATE PIPELINE QRA SEMINAR
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• Definitions:

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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Ignition Probabilities (Liquids):

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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Ignition Probabilities (Gas Pipelines):

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
Item Leak Leak sizes in mm
rate pr
year
< 10 10 <25 25<50 50<75 75<100 >=100 N/A
Compressor, 9.19E-03 73% 14% 5% 0% 0% 0% 9%
Centrifugal
Compressor, 6.50E-02 81% 19% 0% 0% 0% 0% 0%
Reciprocating
Heat excahnger, HC 4.94E-03 75% 8% 8% 0% 0% 0% 9%
in shell
Heat excahnger, HC 2.92E-03 85% 8% 0% 0% 0% 0% 8%
in tube
Instrument 5.85E-04 79% 17% 2% 0% 0% 0% 1%
Piping steel, 5.87E-05 75% 5% 2% 2% 0% 10% 6%
3"< D <=11"
Piping steel, 2.00E-04 79% 13% 6% 1% 1% 0% 1%
D <=3"
Piping steel, 5.49E-05 64% 8% 0% 0% 0% 17% 11%
D > 11"
Pressure vessel, 2.21E-03 22% 0% 0% 11% 11% 0% 56%
horizontal, separator
Pressure vessel, 1.01E-03 100% 0% 0% 0% 0% 0% 0%
vertical, scrubber
Actuated Block Valve, 1.29E-03 87% 7% 0% 0% 7% 0% 0%
3” < D <= 11”
Actuated Block Valve, 1.29E-03 68% 9% 14% 0% 0% 0% 9%
D <= 3”
Actuated Block Valve, 8.04E-04 83% 17% 0% 0% 0% 0% 0%
D< 11”
Flanges, D <= 3” 3.95E-05 78% 10% 8% 2% 1% 1% 0%
Flanges, 5.56E-05 84% 5% 4% 1% 0% 6% 0%
3” < D <= 11”
Flanges, D< 11” 9.85E-05 85% 4% 0% 4% 0% 7% 0%

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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Aim of Zoning Classification (IP 15):
Avoid ignition of those releases that may occur from time to time
• Reduce to an acceptable minimum level the probability of coincidence of flammable atmosphere and an
electrical or other source of ignition
• Risk Target is 10-5 year
• IP 15 does not concern major releases (spread of flammables more than 30 m). These shall be
minimised by design and operation to an acceptable residual risk.
Hazardous area classification requires an interdisciplinary approach:
• Process
• Safety and loss prevention
• Electrical
Agreements reached on hazardous area classification should be formally recorded in a Hazardous
Area Dossier in supplement to hazardous areas drawings.

For the majority of releases the shape profile depends primarily on angle and location of the release.

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 FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Zoning:
Zone 0: The part of a hazardous area in which a flammable atmosphere is continuously
present or present for long periods

Zone 1: That part of a hazardous area in which a flammable atmosphere is likely to

occur in normal operation

Zone 2: That part of a hazardous area in which a flammable atmosphere is not likely
to occur in normal operation and, if it occurs, will only exist for a short period.

Non-Hazardous: areas that do not fall into any of the above.

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PROBABILITIES
Continuous grade release: A release that is continuous or nearly so, or that occurs
frequently and for short periods
If it is likely to be present for more than 1000 hours per year.

Primary grade release: a release that is likely to occur periodically or occasionally in

normal operations, i.e. a release which, in operating procedures is anticipated to occur
If it is likely to be present for between 10 to 1000 hours per year.

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 release may be of unknown size
e.g. fracture of a drain or unknown size e.g. corrosion hole.
If it is likely to be present for 1 to 10 hours per year.
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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Grade of Release:

Grade of release depends solely on frequency and duration.

Grade does NOT depend on rate or quantity, ventilation or characteristics of the fluid.

Continuous grade release  Typically Zone 0

Primary grade release  Typically Zone 1
Secondary grade release  Typically Zone 2

“Typically” refers that it is ventilation dependent

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FREQUENCY ASSESSMENTS & IGNITION
PROBABILITIES
Fluid Categories:
Fluid Description
Category
A A flammable liquid that, on release, would vaporise rapidly and
substantially.
B A flammable liquid, not in Category A, but at a temperature
sufficient for boiling to occur on release.
C A flammable liquid, not in Categories A or B, but which can, on
release, be at a temperature above its flash point, or form a
flammable mist or spray.
G(i) A typical methane-rich natural gas.
G(ii) Refinery hydrogen.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – FLUID CATEGORY
Unstabilized Crude

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Stabilized Crude Natural gas SEPTEMBER 8-12, 2014 14
FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES

AREA CLASSIFICATION – APPROACH

• Point Sources Approach
3 Different approaches to zoning:
• Identify sources
• Direct Examples Approach • Determine grade
Based on experience and provides hazard radii for • Establish zone
typical installations. • Determine hazard radii
Open field: • Leak size
• Ambient temperature of max. 30°C • Pressure
• Wind speed 0.5 m/s – 2 m/s • Draw zone

• Risk Based Approach

• Risk target of 10-5 per year
• Unknown leak size
• Varying release size
• Consequences
• Exposure
• Approach is similar to risk
analysis
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 FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – RELEASE RATES

Continuous and primary grade release rates are normally well defined as they have been
designed for.
Secondary grade release rates/ leak holes are often unknown as they occur unintentionally
e.g. breakage of a flange, corrosion hole, fracture of a drain etc.
Secondary Grades of Release operates with LEVELS:

• LEVEL I 10-2 / release source year

• LEVEL II 10 - 10 / release source year
-2 -3

• LEVEL III 10-3 - 10-4 / release source year

The LEVEL to be used on a specific plant is based on the exposure of the most exposed
individual to flammable releases and the probability of ignition of those releases.

LEVEL frequencies are for the zone 2 boundary.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE: LEVEL

Exposure:
Exp = Pocc X Nrange
Pocc: Probability the worker is on site within the hazardous area.
Nrange: The time weighted average number of release sources which can affect the
individual during their time within the hazardous area.
Exposure is normally only calculated for the most exposed person and used for the
entire installation.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE: LEVEL

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE: LEVEL

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 HAZARDOUS
AREA CLASSIFICATION – POINT SOURCE
Flanges & Valves
Secondary Grade IR; Occupation and ignition
LEVEL I: 10-2 / year Pocc= 0.05 (Estimate)
LEVEL II: 10-2 – 10-3 / year Nrange= 5 (Table)
LEVEL III: 10-3 – 10-4 / year Exposure = 0.25 (Pocc x Nrange)
Pig = 0.03 (Table)
Calculation Example
Pig,total = 0.00037 (0.001185+0.0112) X 0.03
Flange d ≤ 3” : 3.95∙10-5 per year – 30 off = 0.001185
Flange 3”<d≤11”: 5.56∙10-5 per year – 10 off = 0.0112 From curve it is seen that we are at LEVEL 1
Natural Gas

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE

Pig Receivers
Pig receivers are likely to opened frequently and should normally be regarded as primary
grade release. The hazardous area should be classified as zone 1.

Provided that interlock systems are in place, the release that occurs from opening the
launcher/receiver will be minor and a hazard radius of 3 m is suggested in IP 15. If the
operating procedures include purging or water washing before opening the
launcher/receiver the nominal hazard radii can be reduced to 1.5 m.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE

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HAZARDOUS
AREA CLASSIFICATION – POINT SOURCE

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HAZARDOUS
AREA CLASSIFICATION – POINT SOURCE

At ground level INOGATE PIPELINE QRA SEMINAR

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 FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE -VENTILATION

• Natural ventilation and wind without stagnant zones.

• Typically air velocities will not be less than 0.5 m/s and will frequently be above 2 m/s.
• Where a facility is classified as an open area, the hazardous area classification of previous
slides applies without further ventilation considerations.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE VENTILATION – ENCLOSED AREAS

• Area where natural ventilation does not provide a minimum of 12 air changes per hour.
• 12 acph is defined as adequate ventilation (10 minutes persistence 2. grade release).
• Displacement ventilation.
• Dilution ventilation.
• Localised Exhaust Ventilation (LEV).
• Forced draught fan (acoustic enclosures).
• Over- and under-pressurisation

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
AREA CLASSIFICATION – POINT SOURCE VENTILATION – ENCLOSED
AREAS

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT
As a general policy, electrical equipment should not be located in a hazardous
area if it is possible to place it in a non-hazardous area, nor should it be
placed in a Zone 1 if it can be placed in Zone 2.

Correct selection of equipment requires three factors to be taken into

account:

• Zone in which the equipment will be used.

• Sensitivity to ignition of the gases or vapour likely to be present, expressed

as gas group.

• Sensitivity of the gases or vapour present to ignition by hot surfaces,

expressed as a temperature classification.

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 FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT
Type Protection
o Oil filled
apparatus.
p Pressurised
q Powder filled
d Flame proof
e Increased safety
ia Intrinsically safe “ia”
ib Intrinsically safe “ib”
n Non incendive
M Encapsulated
Functionality/concept
The equipment is submerged in oil preventing an flammable atmosphere to occur in the area where sparks are likely to occur.
The equipment is pressurised with a protective gas to prevent ingress of flammable gasses or liquids.
The overpressure can be made with or with out constant flushing of the protective gas.
By filling the housing with a finely grained powder, an arc within the housing is unable, with correct use, to ignite the
potentially explosive atmosphere outside.
The enclosure is designed to withstand an explosion and prevent its propagation.
The enclosure shall be able to withstand an internal pressure of 12 bar.
Enclosure in which there is no spark or hot surface in normal operation.
Limit the energy within the system so that even under fault conditions a spark or thermal effects cannot occur.
Limit the energy within the system so that a spark or thermal effects cannot occur considering 1 fault.
Type n protection has several implementation types:
nA: non sparking
nC: hermetically sealed enclosure
nL: energy limited
Parts that could ignite a potentially explosive atmosphere by means of sparks or heat are potted soas to prevent ignition of
the potentially atmosphere. This is achieved by encapsulating the components in a compound resistant to physical -
especially electrical, thermal and mechanical - and chemical influences.
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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT

For ”o”, ”d”, ”i” and ”n” there

is a material subgroup
division:
• IIA
• IIB
• IIC

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 FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT - SUMMARY

Protection Zone 0 Zone 1 Zone 2

Code Category 1 Category 2 Category 3 (ATEX)
(ATEX) (ATEX)
Flame proof ’d’
Pressurized ’p’
Powder filled ’q’
Oil filled ’o’
Increased safety ’e’
Intrinsic safe , ia ’ia’
Intrinsic , ib ’ib’
Non incendive ’n’
Encapsulating ’m’

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT –TYPICAL PRACTICE

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT –TYPICAL PRACTICE

• Instrumentation for use in hazardous areas shall be suitable for at least Zone 1
• Instrumentation for use in unclassified areas, which is required to remain
energised during an emergency, shall also be suitable for Zone 1.
• Instrument ”electrical systems” shall by preference be intrinsically safe (IS).
• Equipment shall comply with at least temperature Class T3, Group IIB.
• Instrument ”electrical systems” shall by Equipment comply with at least temperature
Class T3, Group IIB.
• All electrical apparatus located outdoor, shall be certified according to EU directive
94/9/EC (ATEX) and shall as minimum be certified for Equipment Group II Category 2G,
Explosion group IIB, temperature class T3.

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FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT –DOCUMENTATION

To aid maintenance and demonstrate that ignition hazards have been properly addressed,
an inventory of equipment installed in a hazardous area should be maintained, including:
• Type of protection
• Temperature class
• Subgroup of apparatus
• Location
• Marking

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 FREQUENCY ASSESSMENTS & IGNITION PROBABILITIES
EX EQUIPMENT

Battery Rooms
• Battery rooms should be adequately ventilated in order to assist in the dispersion of
hydrogen.
• Electrical apparatus thus may need to be suitable for use in zone 1 hazardous areas with
apparatus of subgroup IIC T1 class suitability for hydrogen unless there is dilution by LEV.

Non-electrical Equipment
• IP 15 is designed for selection and location of fixed electrical equipment.
• However hazardous area classification is a good basis for deciding what equipment
may be used at any particular location.
• This is in accordance with the ATEX Directives, which apply equally to electrical and
non-electrical capable of causing an ignition of a flammable atmosphere.

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END OF FREQUENCY
ASSESSMENTS & IGNISTION
PROBABILITIES

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