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Cataloging risks
Hazardous area classification is a rigorous method of determining where an explosive environment
may be present. The codes and standards used in this process provide guidance for selecting,
building, and installing electrical equipment in that area. In general, hazardous areas (HAs) are
defined by:
In the field
By design, natural gas-fired power plants are fueled by an extremely combustible substance. But
fuel lines and the turbine deck are hardly the only HAs in the plant. The prerequisites for developing
an area classification for a gas-fired plant are understanding the characteristics of all of hazardous
materials present in it and defining where those materials exist (or may spread due to a leak). This
allows mapping out the plants HAs.
Each HA should be classified according to applicable industry codes and standards. For example,
electrical area classifications explain how to select and install electrical equipment and wiringright
down to the wiring methodto minimize the likelihood of ignition of a flammable or explosive
mixture.
Disclaimer: The guidelines mentioned in this article describe approaches used by Burns and Roe
Enterprises Inc. The information is provided solely to educate power plant designers and staff. Burns
& Roe is not responsible for classifications prepared by others using these guidelines.
Ram K. Saini, PE, is senior principal engineer for Burns and Roe Enterprises Inc. He can be
reached at 201-986-4339 or rsaini@roe.com. Charles Emma, PE, is principal engineer and can be
reached at 856-638-6920 or cemma@roe.com.
The National Electrical Code (NEC), NFPA 70, defines hazardous (classified) areas as those where
fire or explosion hazards may exist due to the presence of flammable gases, vapors, or liquids,
combustible dust, or ignitable fibers. Electrical area classification (EAC) is the process of
determining the existence and extent of hazardous locations in a facility containing any of those
substances. The result of the process is usually called the EAC of the facility. In the context of
electrical equipment, the following termsarea classification, hazardous locations, hazardous
(classified) locations, and classified areasare all synonymous with EAC. In the following
guidelines, the term EAC is used to avoid confusion with other nonelectrical classifications.
The approach described in this article focuses on a combustion turbine-generator (CTG) plant,
although the same methods are applicable to any type of power plant and its systems.
Group A: Acetylene
Group B: Hydrogen
Group C: Cyclopropane, ethyl ether
Group D: Acetone, butane, propane, hexane, natural gas, fuel oil
Division 1: Denotes areas where flammable or combustible concentrations exist under normal
operating conditions or are highly likely to exist under other conditions.
Division 2: Denotes areas where flammable or combustible concentrations exist under abnormal
operating conditions or are not likely to exist under other conditions.
Nonclassified or unclassified: Denotes areas where the presence of hazardous material is so
infrequent that Electrical Area Classification is deemed unnecessary.
Auto-ignition temperature
The auto-ignition temperature (AIT) of the hazardous material in a facility must be known to
complete its EAC. NFPA 497 provides AIT values for various combustible substances.
A typical area classification for propane gas would be: Class I, Division 2, Group D, 450C AIT. Here:
Obviously, a facilitys EAC must be known before any electrical equipment can be specified,
designed, or installed. On many CTG power projects, special-purpose mechanical equipment with
long lead times (motors and instrumentation and control systems and components, for example)
must be specified and ordered early. Failure to determine the EAC for the facility and such
equipment in a timely fashion can result in unsafe installations, rework, confusion, delays, and cost
overruns.
operator interfaces. Careful evaluation of all data in accordance with established techniques, along
with the application of sound engineering judgment, should produce a consistent and safe
classification.
The NEC calls for each room, section, or area of a facility to be considered individually in
determining its classification. Eschewing this approach in favor of classifying an entire facility using a
broad-brush approach (a process referred to as blanket classification) almost always leads to a
more dangerous and ultimately more costly facility. This is especially true for a power plant, which
normally contains several different process, support, and maintenance areas. A properly conducted
EAC, in a well-designed and constructed facility, might result in a few Division 1 areas and several
much larger Division 2 and nonclassified areas.
Although many other companies and industry organizations have written specific procedures for
Area Classification, the NFPA Recommended Practices for Classification are most applicable to
power plants. NFPA 497 covers Class I areas containing gases, vapors, and liquids, and NFPA 499
covers Class II areas containing dusts. These practices assume the ability to identify and locate
sources of hazardous material.
The sources can be necessarily open process points or unintentional leaks in the process. Once
sources are located, the practices provide guidance in determining the degree of the hazard
(Division 1 or Division 2) and its extent. They also provide diagrams for typical situations that give
recommended distances from the source for the extent of a hazardous location. Although the
diagrams take into account pressure, volume, flow rate, ventilation, building construction, and certain
process operations, it must be remembered that they are only typical and require sound engineering
for application to specific situations.
b. European standards
International Electrotechnical Commission (IEC) standards
IEC 79-10 (Part 10): Classification of Hazardous Areas
IEC 79-14 (Part 14): Electrical Installations in Explosive Gas Atmospheres
IEC 79-15 (Part 15): Electrical Apparatus with Type of Protection n
c. CTG vendor documentation
Major CTG vendors often supply Area Classification documents pertaining to their systems and
equipment.
d. Other
Numerous other materials are available for reference through industry sources.
The ignition gas cabinet, with screwed couplings and glands, in the turbine auxiliary equipment
area.
Gas relief points above the turbine building roof.
Fuel oil system
Fuel oil transfer pipe joints and coupling in the fuel oilunloading area and forwarding pump
stations.
Fuel oil tank piping, pump blocks, filling and suction valve blocks, vents, indicators, alarm
switches, oil piping (both outdoor and at the combustor), burners, and heaters.
Open process points, sample points, and sumps.
Hydrogen gas system
Hazardous
materials and where they typically exist in a power plant. Source: Burns and Roe Enterprises Inc.
Note 1: Adequately ventilated per NFPA 497 means a ventilation rate that affords either six air
changes per hour, 1 cfm per square foot of floor area, or another similar criterion that prevents
accumulated vapor-air concentrations from exceeding 25% of the lower flammable limit. Note 2: If
vent pipes are being discharged in an otherwise nonhazardous area, they should be discharged
outdoors at a minimum distance of 10 feet (for natural gas) and 15 feet (for hydrogen) from any
electrical equipment, light fixture, etc. Note 3: A continuously operated exhaust fan in the battery
room is required to remove any accumulation of hydrogen gas discharged from the batteries. Loss of
electrical power to the fan should be alarmed in the plant control room. Note 4: Ammonia detectors
should be installed around the diked area and connected to the plants distributed control system. A
deluge water spray system should be installed for automatic/manual actuation; its alarm should be
sent to the fire alarm panel in the plant control room.
These guidelines should be used as a minimum requirement for Classification of Electrical Areas
where such materials are located and processes are performed. Sound engineering judgment
should be applied to determine if additional areas, not mentioned in the table, should be identified.
Equipment manufacturers recommendations for the Area Classification of specific equipment should
be followed, especially if they are more stringent than the guidelines provided in the table.
When there is more than one leakage source in an area (for example, a manifold serving several
instruments or valves), or if there are several pieces of equipment with potential leak sources, the
area should be boxed out as an overall three-dimensional shape covering the limits of the extreme
leakage points. To avoid undue expense, take precautions to verify that boxing in overall areas, or
extending classified areas to recognizable boundaries, does not include electrical equipment that
would otherwise not be included in the hazardous area.
A listing of all the flammable and combustible materials used in the facility, as well as their
pertinent properties (flash point, ignition temperature, density, etc.) and how and where the
materials are handled.
Brief descriptions of the process and its O&M and cleaning details.
A list (including dates and/or editions) of all the codes, standards, references, practices, and
other data used to prepare the classification.
A discussion of all the assumptions made during the analysis.
A listing of each room or area and its determined area classification, along with the rationale
for making the determination.
A complete set of EAC drawings indicating all of classified areas process equipment, normal
and leakage sources, and boundaries.
3.Hazardous area
classification for the area around a combustion turbine-generator, including the hydrogen manifold
and connections. Courtesy: Burns & Roe Enterprises Inc.
4.Hazardous area
classification for the roof above a hydrogen-cooled generator. Courtesy: Burns & Roe Enterprises
Inc.
5.Hazardous area
classification for the area around the ammonia vaporizer skids and fuel gas valves and devices at a
combined-cycle power plant. Courtesy: Burns & Roe Enterprises Inc.
Explosion-proof and dust-ignition proof equipment is required in Division 1 areas and for
certain types of equipment in Division 2 areas.
Equipment approved by Underwriters Laboratories or by another appropriate agency is
preferred in hazardous locations.
It is preferable to locate electrical equipment outside the hazardous area.
General-purpose equipment is permitted for certain applications in Division 2 areas.
Purging and pressurization of enclosures are permitted to prevent the entrance of flammable
and combustible material, provided that specific rules in NFPA 496 are followed.
Instrumentation enclosures may be the general-purpose type if they are part of intrinsically
safe systems and if they are installed per NEC Article 504.
Rigid metal conduit is the allowable wiring method in Division 1 areas.
Cable trays and cables, under certain conditions, are permitted in Division 2 areas.
Electrical equipment must have temperature ratings or operating surface temperatures below
the AIT of the hazardous substance present.
Disclaimer: The guidelines discussed in this article describe approaches used by Burns and
Roe Enterprises Inc. The information is provided solely to educate power plant designers and
staff. Burns and Roe is not responsible for classifications prepared by others using these
guidelines.