Doc No.

DWC-27-001
Kent W2V Revision: A
Date: 30/11/20
Page: 1 of 35

Kent Waste 2 Value

HAZARDOUS AREA CLASSIFICATION

Revision Status/Comment Originator Date

- Preliminary D Woolgar 30/10/20
A Issued D Woolgar 30/11/20

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL

AND SHALL NOT BE DISCLOSED TO A THIRD PARTY WITHOUT PRIOR WRITTEN PERMISSION

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CONTENTS

REVISION HISTORY ........................................................................................................... 4

CLIENT REVIEW RECORD ................................................................................................... 4
GLOSSARY OF TERMS........................................................................................................ 5
1 INTRODUCTION.......................................................................................................... 6
2 HAZARDOUS AREA CLASSIFICATION ........................................................................... 7
2.1 Zone Classifications...................................................................................................................... 8
2.2 Methodology for Hazardous Area Classification.......................................................................... 9
2.3 Modification Control..................................................................................................................10
3 HAZARDOUS PROPERTIES OF FLUIDS ........................................................................ 10
4 HAZARDOUS PROPERTIES OF SOLIDS ........................................................................ 11
5 AREA CLASSIFICATION .............................................................................................. 11
5.1 Feedstock preparation and pumping.........................................................................................11
5.1.1 Operation ..........................................................................................................................11
5.1.2 Area Classification.............................................................................................................11
5.2 Digesters.....................................................................................................................................11
5.2.1 Operation ..........................................................................................................................11
5.2.2 Area Classification.............................................................................................................12
5.3 Biogas Pipework.........................................................................................................................13
5.3.1 Operation ..........................................................................................................................13
5.3.2 Area Classification.............................................................................................................13
5.4 Digester Gas Mixing ...................................................................................................................13
5.4.1 Operation ..........................................................................................................................13
5.4.2 Area Classification.............................................................................................................13
5.5 Ammonia Stripper......................................................................................................................14
5.5.1 Operation ..........................................................................................................................14
5.5.2 Area Classification.............................................................................................................14
5.6 Ammonia Scrubber ....................................................................................................................14
5.6.1 Operation ..........................................................................................................................14
5.6.2 Area Classification.............................................................................................................14
5.7 Gas Storage (Combibag).............................................................................................................14
5.7.1 Operation ..........................................................................................................................14
5.7.2 Area Classification.............................................................................................................15
5.8 Digestate Separation and Transfer ............................................................................................15
5.8.1 Operation ..........................................................................................................................15
5.8.2 Area Classification.............................................................................................................15
5.9 CHP.............................................................................................................................................16
5.9.1 Operation ..........................................................................................................................16
5.9.2 Area Classification.............................................................................................................16
5.10 Flare ......................................................................................................................................16
5.10.1 Operation ......................................................................................................................16
5.10.2 Area Classification.........................................................................................................16
5.11 Natural Gas Boiler .................................................................................................................17
5.11.1 Operation ......................................................................................................................17

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5.11.2 Area Classification.........................................................................................................17

5.12 Biomethane Upgrade Unit ....................................................................................................17
5.12.1 Operation ......................................................................................................................17
5.12.2 Area Classification.........................................................................................................17
5.13 Grid Entry Unit ......................................................................................................................19
5.13.1 Operation ......................................................................................................................19
5.13.2 Area Classification.........................................................................................................19
5.14 Propane System ....................................................................................................................19
5.14.1 Operation ......................................................................................................................19
5.14.2 Area Classification.........................................................................................................19
5.15 Condensate Sump & Drain....................................................................................................20
5.15.1 Operation ......................................................................................................................20
5.15.2 Area Classification.........................................................................................................20
6 AREA CLASSIFICATION TABLES.................................................................................. 21
7 CONCLUSIONS.......................................................................................................... 25
8 REFERENCES............................................................................................................. 26
9 APPENDIX A: HAZARDOUS CLASSIFICATION DRAWINGS............................................ 27
10 APPENDIX B: FACTORS EFFECTING HAZARDOUS AREA CLASSIFICATION ................. 28
11 APPENDIX C: CLASSIFICATION OF MECHANICAL & ELECTRICAL EQUIPMENT ........... 30
12 APPENDIX D: CALCULATIONS................................................................................. 32

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REVISION HISTORY

Revision Description
- Draft issue for review prior to construction
A Issued with calculations, updated zones and Hazardous Area Drawings list

CLIENT REVIEW RECORD

Rev Description Date Reviewer(s) Company(s) Date Reviewed

- Preliminary 30/10/20 M Laubscher Seyspec PM
A Issued 31/11/20 M Laubscher Seyspec PM

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GLOSSARY OF TERMS

Acronym Description
AD Anaerobic Digestion
AIT Auto Ignition Temperature
EU ATEX Directives 100a and 137 relating to protection of personnel against fires &
ATEX
explosions
CHP Combined Heat and Power plant
DSEAR Dangerous Substances and Explosive Atmospheres Regulations 2002
LEL Lower Explosive Limit
NE Negligible Extent
UEL Upper Explosive Limit

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1 INTRODUCTION
This document is the Hazardous Area Classification for the Kent Waste to Value Plant.

The plant is located next to an existing chicken farm and will process chicken manure to produce
biogas by anaerobic digestion. A portion biogas is used in a Combined Heat and Power plant (CHP) to
produce heat and electricity for the Plant with the bulk of the biogas upgraded to Bio-methane and
injected to the local gas distribution network. The digestate is spread to land for beneficial use.

The plant consists of feedstock mixing and conditioning equipment that mixes the manure with
recovered liquids and pumps the slurry to the digesters. There are two primary plug flow digesters
with concrete roofs. The digester gas spaces are at low pressure, approx. 15mbar and fitted with
overpressure relief valves venting to atmosphere.

Biogas is collected from the roof space of the digesters and is distributed by overground steel
pipework with welded and flanged joints laid to falls with small bore condensate drains taken from
the low points to condensate sumps. The pipework distributes biogas to the gas mixing
compressors, CHP, Biomethane Upgrader, gas storage and flare.

The gas mixing system uses compressors in a plant room to raise the biogas pressure to about 1 bar
and return the gas through below ground welded PE pipe into the digester to provide mixing energy.

The biogas supplying the CHP is treated in a dedicated plant to remove condensate and hydrogen
sulphide. The clean biogas is fed by a gas booster to the CHP container to generate electricity for the
site.

Biogas for upgrading is treated in a dedicated plant to remove condensate and hydrogen sulphide.
The clean biogas is compressed and passed through a containerised membrane system to remove
carbon dioxide. The carbon dioxide is vented to atmosphere and the biomethane is cooled and
transferred to the Grid Entry Unit where the gas is conditioned with odourant, CV adjusted to
Network specification and pressure regulated to enter the Network. Gas not meeting the
specification is rejected and returned to the digester headspace.

The gas storage is a proprietary Combibag (fabric lined lagoon with dual membrane fabric roof) for
storing digestate and biogas. The Combibag operates at around 5mb and a gas blower is used to
raise the outgoing gas pressure to return biogas from storage to the system.

Surplus biogas is burnt in a proprietary flare which has a dedicated gas booster to supply the burner.

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The biomethane CV is adjusted by addition of propane from a tank farm of 2t bulk storage tanks.
Liquid propane is pumped to the Grid Entry Unit and vapourised for addition to the biomethane.

Natural gas is imported at the site through a commercial meter skid and piped to the main building
which contains a gas boiler for supplying the process hot water.

2 HAZARDOUS AREA CLASSIFICATION

This classification has been carried out in accordance with the guidance in References 1, 2 and 4. The
Area Classification is required for the purposes of compliance with the Dangerous Substances and
Explosive Atmospheres Regulations 2002 (DSEAR). The area classification is intended to highlight the
areas of the plant where a flammable atmosphere may be present and the classification of the
flammable zones associated with these releases.

Reference 1, BS EN 60079-10 clause 1 states that:

“for detailed recommendations regarding the extent of the hazardous areas in specific industries or
applications, reference may be made to the codes relating to those industries or applications”

Therefore Reference 2 has also been applied as this refers specifically to natural gas (which is similar
to biogas) and Reference 4, which has been prepared by the German Safety Agency for biogas
digesters operated at less than 100mbar, is used for direct examples of release types.

A hazardous area is defined as a three-dimensional space in which a flammable atmosphere may be

expected to be present at such frequencies so as to require special precautions for the control of
potential ignition sources. A flammable atmosphere is defined as a mixture of flammable gases,
vapours or powders with air in such proportion such that it will burn when ignited. Factors effecting
size and shape of any generated flammable area are discussed in Appendix B.

There are three basic grades of release defined in References 1 and 2, these being:

 Continuous; A release that is continuous or which is expected to occur for long periods
 Primary; A release that may be expected to occur periodically or occasionally during normal
operation
 Secondary; A release not expected to occur in normal operation, and, if it does occur, is likely to
do so only infrequently and for short periods

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The grade of release is used when deciding on the classification of a zone.

2.1 Zone Classifications

Zones are classified for gases and dusts as follows:

Zone Definition
0 Explosive atmosphere is present continuously or for long periods or frequently
(typically defined as >1,000 hours per year, Ref. 2) e.g. inside a vessel.
1 Explosive atmosphere is likely to occur in normal operation occasionally
(typically defined as 10 – 1000 hours per year, Ref. 2).
2 Explosive atmosphere is not likely to occur in normal operation, but if it does
occur, is likely to do so for short periods only.
Table 1: Zone Definitions for Gases and Vapours

Zone Definition
20 Explosive atmosphere is present continuously, or for long periods or frequently
for short periods, e.g. inside a vessel.
21 Explosive atmosphere is likely to occur occasionally in normal operation.
22 Explosive mixture is not likely to occur in normal operation, but, if it does occur,
will persist for a short period only.
Table 2: Zone Definitions for Dusts

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Release grades are related to Zone definitions as shown in Figure 1:

Identification of potentially explosive mixture

Identification & grading of source of release

Continuous - Primary - Secondary

Continuous Primary Secondary

Natural ventilation No ventilation Natural ventilation No ventilation

Zone 0 / 20 Zone 0 / 20

Zone 1 /121
Zone / 21 Zone 1 / 21 Zone 1 / 21 Zone 1 / 21

Zone 2 / 22 Zone 2 / 22 Zone 2 / 22 Zone 2 / 22 Zone 2 / 22

Figure 1: Release Grade & Zone Definition

NB: Natural ventilation may be replaced by forced ventilation depending on reliability and
availability.
2.2 Methodology for Hazardous Area Classification
The standard methodology for area classification is shown in references 1 and 2. Within these there
are two possible techniques that can be used. These are known as:
 Direct example
 Point source release
The direct example approach uses reference to worked examples (shown in references 1 and 2) for
generic industrial equipment. These examples can be applied directly to similar situations. Examples
of these are vessels, pumps, vessel vents and bunds. This methodology is relatively fast to apply
given that examples are contained in the guidance.

The point source release approach consists of a specific methodology to identify all possible release
points and their associated release rates. This can be applied to all situations including those for
which there is no direct worked example already available.

The direct example approach was used for this area classification as all situations were covered by
examples found within the guidance.

The Hazardous Classification of package equipment has been provided by the suppliers.

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2.3 Modification Control

Where area classification has been set for specific areas it is essential that strict modification control
be exercised to prevent:
a) Unsuitable equipment being installed in the area as a result of modification or repair
b) Unsuitable chemicals being brought into the area e.g. of a lower temperature classification
or gas group
c) Changes in operation e.g. definition of storage areas or moving of drum filling points
d) Changes in operating procedures

Any of the above could result in a breach of the Basis of Safety for operation of the plant.

3 HAZARDOUS PROPERTIES OF FLUIDS

The plant produces biogas which is a mixture of methane and carbon dioxide. Under normal
operation the composition will be about 60% methane and 40% carbon dioxide.

For this area classification, the properties of the biogas have been assumed to be the same as for
pure methane. However, as the vapour density of carbon dioxide is much greater than that of
methane, and of air, at certain compositions the vapour density of the biogas may be greater than
air. Following the upgrading process the product gas is methane.

The feeds to the process and the other products (liquid and solid) are non-flammable.

The properties of the hazardous fluids handled / found on the site are outlined in Table 3; taken
from Reference 3.

Chemical Name Flashpoint / Autoignition Relative density Gas Group and

LEL-UEL Temperature of gas or vapour Temperature
to air Class
Methane
4.4 – 17 % v/v 600°C 0.551 IIA T1
(Natural gas)
Propane 2.15 – 9.6% v/v 470°C 1.52 IIA T1
Hydrogen Sulphide 4 – 45.5 % v/v 260°C 1.19 IIB T3
Ammonia 15 to 33.6 % v/v 630°C 0.59 IIA T1
Lubricating Oils 180°C 330°C n/a - T2
Table 3: Hazardous Properties of Fluids

1
The relative density of biogas is 1.2 due to the carbon dioxide content (typically 40%).

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4 HAZARDOUS PROPERTIES OF SOLIDS

The solid material handled in the process is non-flammable.

5 AREA CLASSIFICATION
5.1 Feedstock preparation and pumping
5.1.1 Operation
Feedstock preparation and pumping consists of 2 bunkers which hold the manure. Manure is
conveyed to grinder to reduce particle size and discharged into a blending tank where it is mixed
with treated digestate to prepare a slurry.

The slurry passes through a grit settling system, the grit is washed and collected for removal from
site and the de-gritted slurry is pumped to the digesters.

The plant is located in a large shed. The area is naturally well ventilated.

5.1.2 Area Classification

The gas lines are not brought into the feeder building. The digestate, which has the potential to
release small amounts of biogas has been through a stripping process and therefore will not release
biogas.
There are no significant sources of release and the space is well ventilated.
The area can be classified as non-hazardous

5.2 Digesters
5.2.1 Operation
The digesters are externally insulated rectangular concrete tanks with heating coils on skids within
the digesters. The tanks are covered with a concrete roof with penetrations for the gas pipes and
service openings for mechanical mixers. The gas space is fitted with an over pressure relief valve.

The digester contents are mixed by recirculated biogas through low level nozzles and submersible
propeller mixers in tank. There are 4 steel fabricated service ports on the roof of each digester to
allow access to the mixers, the port has an internal baffle which enters the digestate and isolates the
service area from the main gas storage area. There are also penetrations for condensate return.

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The digestate overflows into an effluent chamber which is open to atmosphere and is aerated with
compressed air as it flows into the chamber. The effluent chamber is mixed with submersible mixers.

The biogas is collected in a header pipe on the digester roof and flows either to the gas mixing plant
room or to the biogas utilisation – CHP, BUU, Flare or storage – as demanded by the individual plant.

5.2.2 Area Classification

In normal operation the gas space inside the digesters will normally be above the Upper Explosive
Limit (UEL) for methane. However, if there are leaks of air into any of these tanks, then an explosive
vapour atmosphere could be formed above the level of the liquid. This is not likely to occur in
normal operation. The headspace inside the digester is not classified

The service ports can be opened under maintenance conditions which will allow entry of air. The
area below the service port is classified as Zone 2 and the area above the service port is classified as
Zone 2 for an extent of 3m horizontally and upwards. (Reference 4 Para 3.5)

The area around the pipe penetrations is well ventilated and is classified as Zone 2 NE as is the
general digester roof area. The inside of the biogas pipework is above the UEL for methane and is
not classified. The area around the biogas pipe is well ventilated and is classified as Zone 2 NE
(Reference 2 Table 1).

An explosive vapour atmosphere may be formed by a release from the Pressure Relief Valves on
each of the digesters. The PRV is a low pressure relief with a Zone 2 sphere of 3m diameter around
the PRV with a Zone 1 sphere of 1m radius at PRV. (Reference 4 Para 3.5)

The effluent chamber contains active digestate, the aeration of the digestate will cause the release
of entrained biogas and the oxygen will cause the methanogens to cease activity. However there
will be residual biogas released in the headspace of the effluent chamber which will classified as
Zone 1 (Reference 2 Para 5.4).
There will also be a Zone 1 around the opening of the effluent chamber extending for a radius of
0.5m (Reference 2 Para 7.4).

An explosive atmosphere will not normally occur around digestate sample or drain points because of
a) the small volume of digestate released and b) on contact with air the biologically active species
die and stop producing biogas.

The concentration of H2S in the raw biogas is up to 2000ppm, this is significantly below the LEL of
40,000ppm and therefore H2S is not considered as a potential source of hazardous areas.

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5.3 Biogas Pipework

5.3.1 Operation
Biogas is collected from the holding space in the roof of the digesters which maintains the biogas at
an approximate pressure of 5mbar. The biogas is piped to the Digester Plant Room and the biogas
utilisation – CHP, BUU, Flare or storage – by overground steel pipework laid to falls to return
condensate to the condensate sump.

5.3.2 Area Classification

Inside the biogas and biomethane pipes the methane concentration will be above the Upper
Explosive Limit (UEL). Therefore inside these lines will be designated a non-hazardous area.
The exterior above ground pipework contains flanged and screwed joints and there may be leaks of
methane from these joints. Therefore there will be a Zone 2 NE around any flanged joints on
pipework in freely ventilated areas (Reference 2, table 1).
Vent, purge and sample valves
 if plugged or capped Zone 2 NE
 if uncapped Zone 1 at radius 1 metre.

5.4 Digester Gas Mixing

5.4.1 Operation
Biogas is drawn from the header pipe to the Digester Plant Room in the main building where the gas
is split into 2 streams, one for each digester, and the pressure is raised to about 500mbar by a
blower then distributed sequentially by actuated valves to the four mixing zones in the digester. The
pressurised gas flows through buried pipe back to the digester.

5.4.2 Area Classification

The Digester plant room contains the biogas boosters, condensate drop out pots, delivery header,
actuated valves and final connection to delivery pipework. A statistical analysis of the number and
type of fittings has been carried out to determine the gas release rate (Reference 2 Appendix 7
Section 1).
High and low level ventilation of 11.2m2 of effective natural ventilation distributed over the 2
external walls at high and low level to provide “more than adequate ventilation” (Reference 2
Appendix 7 Section 2).
The biogas pipework is a simple installation and is not confined or congested therefore the Digester
Plant Room is classified as Zone 2 NE (Reference 2 Appendix 7.4).

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5.5 Ammonia Stripper

5.5.1 Operation
Digestate is heated to 65°C, to volatise ammonia in the liquid, and sprayed into the top of the
stripper chamber against a counter flow of air which captures ammonia. The digestate is cycled
through 5 successive chambers and is then available for blending poultry manure or storing for use
as a fertiliser.

5.5.2 Area Classification

Ammonia is present in the stripping chambers but the process utilises high volume of air flow such
that the ammonia concentration is 12,000ppm which is below the LEL for ammonia.
Residual biogas will also be released by the digestate but the quantities are less than the ammonia
and the high air flow will maintain a concentration well below the LEL for methane.
The stripping process includes an air flush process after draining the digestate during shutdown
which maintains non-hazardous conditions.
The inside of the stripper chambers is classified as non-hazardous.
Leaks from the external stripper pipework and connections on the stripper chambers will release
stripping air which is below the LEL for ammonia.
The external area of the ammonia stripper is classified as non-hazardous.

5.6 Ammonia Scrubber

5.6.1 Operation
The ammonia rich air from the stripper is passed through a scrubber against a flow of dilute
sulphuric acid which removes the ammonia from the air to form ammonium sulphate solution. The
scrubbed air is returned to the ammonia stripper.

5.6.2 Area Classification

The ammonia concentration in the air is 12,000ppm which is below the LEL for ammonia.
The classification of the interior and exterior of the ammonia scrubber is non-hazardous.

5.7 Gas Storage (Combibag)

5.7.1 Operation
Digestate is transferred from the ammonia stripper to the centrifuge to be used for blending the
manure or to the Combibag for storage. Surplus biogas is stored in the gasholder above the
digestate storage.
The storage consists of a membrane liner in a shaped excavation to contain the slurry and a dual
membrane roof supported by an air blower to store the biogas. Mixing of the digestate is by

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submersible propeller mixers. The slurry is pumped in and out through pipes entering the base of
the storage. Gas is collected from take-off connections in the roof. There is a biogas over pressure
relief valve mounted at ground level.

5.7.2 Area Classification

In normal operation, the gas space inside the storage will normally be above the Upper Explosive
Limit (UEL) for methane. The headspace inside the storage is unclassified.
The space between the gas membrane and the outer membrane is maintained by a flow of air. A
small leak in the gas membrane will be dispersed by the air flow however the space will be
conservatively classified as Zone 2. The air exhaust from the gas holder will be classified as Zone 2
for an extent of 1m.
An explosive vapour atmosphere may be formed by a release from the Pressure Relief Valve which
releases biogas at 1.5mbar. The classification, which has been issued by the supplier of the relief
valve, and is in accordance with Reference 4 is:
 A Zone 1 for 1m around relief valve discharge;
 A Zone 2 for 2m around the Zone 1 (or 3m around the relief valve discharge).

There will be a Zone 2 NE around any flanged or screwed joint (including gas purge points and
instrument connections).

5.8 Digestate Separation and Transfer

5.8.1 Operation
Stripped digestate is transferred by to a centrifuge to remove solids. The centrate falls into a
transfer tank and is pumped to a buffer tank; some separated liquid is reused in the process and the
surplus pumped to the Combibag for eventual spreading to land. The centrifuge is mounted on an
elevated frame in the main building and is provided with an air extract system which discharges into
the stripping vessels. The cake is conveyed to trailers for removal from site.

5.8.2 Area Classification

The digestate has passed through the stripper so there will be no significant biogas or ammonia
releases.
Therefore the screen and digestate storage tanks are classified as non-hazardous.

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5.9 CHP
5.9.1 Operation
The CHP is a package unit consisting of a containerised CHP and gas pre-treatment. The pre-
treatment consists of a chiller unit to remove condensate and a carbon scrubber to remove H2S. The
container holds the gas booster, gas control valves, spark ignition gas engine, generator, lubrication
oil tanks, ventilation fan, distribution panel and control panel.

5.9.2 Area Classification

The CHP unit is supplied as package unit. The internal area has been classified as Zone 2 NE. This is
achieved by running the combustion air fan into the container before starting the engine and for a
cool down period after running. The excess airflow will disperse any gas leak inside the container.
During the cool down period the external gas valve is closed so there are no gas leaks when the
airflow stops.

The chiller and scrubber pipework is flanged pipework located externally and freely ventilated and
therefore is classified as Zone 2 NE. Sections of the pipework are insulated and the area under the
insulation is classified as Zone 2.

The lubrication oil is stored in a day tank within the CHP container where the temperature is below
the flashpoint. Oil mists could be released from a leak in the circulating oil pipework. Lubrication oil
falls into Release Category III which has been shown (HSL Report rr1107 Area Classification of Oil
Mists) to have little or no ignition risk therefore no hazardous area is associated with the lubrication
oil.

5.10 Flare
5.10.1 Operation
The flare is a package unit by Flare Products designed to burn up to 1000m 3/h of biogas when there
is surplus gas. It is designed to burn all of the biogas.

5.10.2 Area Classification

Although the flare is designed to ignite flammable atmospheres, a hazardous area is not likely to
occur around the flare in normal operation.
The manufacturer has classified the flare skid as Zone 2 for a radius of 1 metre around the pipework.

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5.11 Natural Gas Boiler

5.11.1 Operation
The standby boiler is a package unit provided by Viessmann. It has a modulating Riello burner and
provides heat for the digestion and ammonia stripping process.

The boiler is installed in the main building. The natural gas is supplied by steel pipe at a nominal
100mbar to the boiler area. A gas booster located close to the burner raises the pressure by 45mbar.
The boiler area within the building is provided with ventilation from wall louvres.

The boiler is fitted with twin safety shut off valves and valve proving system which verifies the valves
before starting the ignition process.

The gas supply pipework within the building is not confined (not within 1m of 3 surfaces)

5.11.2 Area Classification

The boiler is located internally in a well ventilated area. The classification is Zone 2 NE due to the
combustion air ventilation.
The gas pipework is classified as Zone 2 NE as it is not a confined installation.

5.12 Biomethane Upgrade Unit

5.12.1 Operation
The biogas upgrade unit is a package unit supplied by DMT. It consists of biogas pre-treatment to
remove condensate, NH3 and H2S and a containerised membrane treatment system.

Treated biogas is compressed to 8bar and passed through membrane filters to remove carbon
dioxide which is vented at high level. The resultant biomethane is cooled to around 30°C and
transferred to the Grid Entry Unit through a short length of above ground pipe.

There are also high level vents for sample gas and biomethane pressure relief valves.

5.12.2 Area Classification

The upgrade plant is supplied as package unit and a classification has been prepared by the supplier.
There is a Zone 2 area extending approximately one metre around the container and the gas
conditioning equipment. There is a Zone 1 area at the high level vents starting above 7.38 metres
extending up to 11 metres in diameter. There are also Zone 2 areas at the high level vents starting

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above 5.8 metres extending 7 metres in diameter and above 7.38 metres extending 10 metres in
diameter.
The container plant room is classified Zone 2.

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5.13 Grid Entry Unit

5.13.1 Operation
The Grid Entry Unit is a packaged unit in a self contained kiosk located close to the BUU. It carries
out several discrete operations.
Firstly the gas is dosed with propane to increase the CV to the local gas network operator’s
specification and the pressure regulated down to 2bar to match the local gas network operating
pressure.
Then the gas is analysed against several parameters to confirm that contaminants are within
specification. If not, the gas is rejected to the flare.
Compliant gas is then odourised and passes through a remotely operated valve under the control of
the local gas network who can stop the flow under specified conditions.

5.13.2 Area Classification

The Grid Entry Unit is supplied as package unit and the supplier has provided zoning information.
There are Zone 1 areas around the openings in the container extending 0.5 metres and Zone 2 areas
extending 2.5 metres at low level. There are also Zone 1 and Zone 2 areas around the high level
vents starting at a height of 2.25 metres and extending 5 metres.
The analyser, regulator and ROV room are classified as Zone 1.
The external pipework is operating at 2bar in an outdoor, freely ventilated location so it classified as
Zone 2 NE (Reference 2 Table 1).

5.14 Propane System

5.14.1 Operation
The Propane System is a packaged unit supplied by FloGas and is situated on a concrete pad in a
compound close to the Grid Entry Unit.

The propane is stored in 6no 2tonne vessels. Liquid propane is pumped through an underground
pipe to a vapouriser in the GEU

5.14.2 Area Classification

The propane system is supplied as package unit. The supplier has provided zoning information.
There are Zone 1 and Zone 2 areas extending 1 metre around the propane pumps and Zone 2 areas
around the tanker connection pipework. The zones are all contained within the concrete pad for the
equipment.

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5.15 Condensate Sump & Drain

5.15.1 Operation
The gas pipes carrying the saturated biogas (between the digesters and the biogas users) are laid to
falls with condensate drains running to a condensate sump.

The lines are operated at a maximum pressure of 15mbar (the release pressure of the digester over-
pressure valve). The drain lines run under gravity and discharge below low water level which
provides a water seal against the operating pressure of the gas lines.

When the collected condensate reaches the overflow level it flows by gravity to the process sump.
The overflow drain incorporates a water seal to separate the interior of the condensate sump from
the process sump.

5.15.2 Area Classification

Under normal operating conditions the biogas will be contained within the condensate pipes by the
water seal. However there could be biogas in the headspace of the condensate sump which will
therefore be classified as Zone 1 (Reference 2 Para 5.4).
There will also be a Zone 1 around the top of the condensate sump extending for a radius of 0.5m
(Reference 2 Para 7.4).

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6 AREA CLASSIFICATION TABLES

Flammable
No. Source of Release Area Materials fluid Ventilation Zone Type Zone Extent Comments
Working Type,
Temp °C degree,
& Pressure availability
1. Feedstock Main Building Non-hazardous No sources of
preparation & release
pumping
2. Primary digesters & Digesters Biogas 40°C Natural Unclassified Digester headspace Space is above UEL
Effluent Chamber 5mbar Medium 3m horizontally and
Good Zone 2 vertically around
service ports
Zone 1 1m radius around the
relief valve discharge
Zone 2 3m radius around the
relief valve discharge
Zone 2 NE around pipe joints
Zone 2 NE around purge valves Must be capped
Zone 1 Effluent chamber
headspace
Zone 1 0.5m radius around the
opening.
3. Above ground Process area and Biogas 40°C Natural Zone 2 NE around joints Inside pipe above
biogas pipework Main Building 5mbar Medium UEL
Good Zone 2 NE around purge valves Must be capped or
plugged

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Flammable
No. Source of Release Area Materials fluid Ventilation Zone Type Zone Extent Comments
Working Type,
Temp °C degree,
& Pressure availability
4. Digester Gas Mixing Main Building Biogas 40°C Natural Zone 2 NE within plant room High and low level
500mbar Medium ventilation provided
Good to meet “More than
adequate” criteria
Zone 2 NE around drain valves Must be capped or
plugged
5. Ammonia Stripper Process Area Ammonia 65°C Natural Non-hazardous Ammonia & Biogas
Biogas Medium concentration below
Good LEL
6. Ammonia Stripper Process Area Ammonia 65°C Natural Non-hazardous Ammonia & Biogas
Biogas Medium concentration below
Good LEL
7. Gas Storage Lagoon Biogas Ambient Temp Mechanical Unclassified Storage headspace Space is above UEL
(Combibag) 1mbar Medium Zone 2 Between inner & outer
Good roof membranes.

Natural Zone 1 1m radius around the

Medium relief valve discharge
Good Zone 2 3m radius around the
relief valve discharge
Zone 2 NE around pipe joints
Zone 2 NE around purge valves Must be capped

8. Digestate Main Building Non-hazardous No sources of

Separation and release

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Flammable
No. Source of Release Area Materials fluid Ventilation Zone Type Zone Extent Comments
Working Type,
Temp °C degree,
& Pressure availability
Transfer

9. CHP and gas pre- Plant Area Biogas Ambient Temp Natural Zone 2 NE around gas
treatment 5mb Medium treatment area
Good Zone 2 Below pipe insulation

100mb Mechanical Zone 2 NE within CHP Refer to supplier’s

High container HAC
Good
10. Flare Plant Area Biogas Ambient Natural Zone 2 1m around pipework
5-100mb Medium
Good
11. Natural Gas Boiler Main Building Methane Ambient Natural Zone 2 NE around pipework Not confined
Medium Zone 2 NE at boiler Local ventilation for
Good combustion air

12. Biomethane Plant Area Biogas Ambient Natural Zone 2 1m around gas pre-
Upgrade Unit 5mb Medium treatment equipment Refer to supplier’s
to Good and container HAC
8bar Zone 1 11m radius at 7.3m
Methane high around vent
Zone 2 7m radius at 5.8m high
and 10m radius at 7.3m
13. Grid Entry Unit Plant Area Methane 35°C Natural Zone 1 In equipment rooms Refer to supplier’s

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Flammable
No. Source of Release Area Materials fluid Ventilation Zone Type Zone Extent Comments
Working Type,
Temp °C degree,
& Pressure availability
2bar Medium Zone 1 0.5 around container HAC
Good vents
Zone 2 3m around container
vents
Zone 1 5m radius at 2.25m
around high level vents.
Zone 2 NE around external
pipework.
14. Propane System Propane compound Propane Ambient Temp Natural Zone 1 1m radius around tank Within compound
12bar Medium vents and pumps
Good Zone 2 1m radius around pipe Refer to supplier’s
joints HAC
15. Condensate Sump Digester Biogas Ambient Temp Natural Zone 1 Within sump and 0.5m
5mbar Medium around top of sump
Good

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7 CONCLUSIONS
1. All new equipment for use in the hazardous areas should comply with the following ratings:
 Temperature Class T1 and Gas Group IIA based on the methane as the potential
explosive source.
 All equipment located in hazardous areas should be suitable for use in the given
classification; all new equipment to be ATEX rated.

2. ATEX requires an inventory of all equipment located within the hazardous areas.

3. DSEAR/ATEX requires that formal inspections are carried out on all equipment installed
within hazardous areas in line with BS EN 60079-17. Following the creation of a suitable
database, inspection schedules should be created and formal inspections be carried out by
suitably trained personnel. Any faults discovered during the inspections, will require logging
and the corrective actions will require prioritising and planning, prior to re-inspection. All
equipment within the hazardous areas will require re-inspection at a maximum interval of 3
years.

4. The hazardous area classification is based on the design at time of preparation, if the design
is updated this report and accompanying drawings should be updated.

5. If new projects are implemented the hazardous area classification should be revisited. This
report and accompanying drawings should be updated as required.

6. Restrictions on ignition capable personal equipment, i.e. Mobile phones, car key fobs,
pocket calculators, torches, cigarette lighters/matches etc., should be put in place for people
who access any of the hazardous areas.

7. Information relating to the site’s hazardous areas and the required precautions should be
conveyed to visitors, contractors and staff through site information points, and via site
inductions.

8. Signage should be installed adjacent to hazardous areas to inform personnel of the extent of
these areas.

9. If any of the feeds to the process or other products are shown to be flammable then the
area classification will need to be reviewed and updated.

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10. The operator should implement rigorous operating and maintenance systems. This should
ensure that adequate and regular inspection and maintenance activities are defined and
executed by trained and competent personnel. Moreover the operator should also ensure
that their management systems monitors the operating, inspection and maintenance
activities and ensures active management intervention if these are missed or curtailed.

8 REFERENCES
1. BS EN 60079-10-1:2009 Explosive atmospheres – Part 10-1: Classification of areas –
Explosive gas atmospheres
2. Institution of Gas Engineers; Hazardous Area Classification of Natural Gas Installations;
IGEM/SR/25 Edition 2; Communication 1748
3. BS EN 60079-20-1:2010 Material characteristics for gas and vapour classification — Test
methods and data
4. Safety Standards for Agricultural Biogas Installations. Bundesverband der
landwirtschaftlichen Berufsgenossenschaften e.V. Germany
5. Institute of Petroleum; Area classification code for installations handling flammable fluids,
Model Code of Safe Practice, Part 15, 3rd Edition; July 2005; Energy Institute (Inst
Petroleum).
6. 191012-PID-001 to 020 Revision 7 - Plant Piping & Instrumentation Diagrams

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9 APPENDIX A: HAZARDOUS CLASSIFICATION DRAWINGS

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 1 revB

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 2 revB

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 3 revB

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 4 revB

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 5 revB

Green Create W2V Kent Biomethane Plant – Hazardous Areas LUT-211-001 Sheet 6 revB

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10 APPENDIX B: FACTORS EFFECTING HAZARDOUS AREA CLASSIFICATION

Release Phase: The phase of material released (liquid, vapour, dust or two-phase) affects the size
and shape of the flammable zone.

Release Rate: The rate at which a material is released affects the size of flammable zone generated.

Release Temperature: The temperature at which a material is released may affect the behaviour of
the release in terms of its buoyancy and the potential for condensation as well as vaporisation rate
of a liquid pool.

Ventilation: The amount and availability of ventilation affect the size and frequency of occurrence of
a flammable mixture. This is of importance where the release occurs inside a room or building. The
presence of ventilation has a major effect on the size of the flammable zone. For outside locations or
in open plant structures the ventilation is classified as “natural” and therefore has 100% availability.

Flammability Limits: Gases and dusts are only flammable over a limited range of compositions. The
limits are known as the upper and lower flammability or explosive limits and are specified under the
conditions that they have been measured. For common materials they are generally stated as being
in air at 25°C but may also be specified under other conditions.

The flammability limits affect the potential size of zone formed. These limits may vary widely
depending on the material. Limits also vary with temperature and pressure, generally increasing as
pressure and temperature increase. The effect is limited at conditions close to atmospheric pressure
and ambient temperatures and therefore tends only to be significant inside pressure vessels.

Minimum Ignition Energy: The minimum ignition energy is a measure of how easy a particular
flammable mixture is to ignite by a spark or flame. The lower the MIE, the easier it is to ignite the
material. This is taken into account by the “Gas Group” of the area classification.

This applies equally to dusts, where MIE is generally used to specify the level of precautions needed
for control of electrostatic ignition sources.

Auto Ignition Temperature: The Auto Ignition Temperature is a measure of how easy it is to ignite a
mixture without the presence of a flame e.g. from a hot surface such as a motor casing. This is taken
into account in the “Temperature Classification” of the equipment. AIT for gases is normally
measured in glass equipment and may be less with other materials e.g. steel. Hence a safety factor
of 2/3 is normally applied.

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Layer Ignition Temperature: For dusts, the Layer Ignition Temperature is a measure of the ease of
ignition for a layer of the material on a flat, hot surface and is the temperature at which smouldering
or combustion occurs. Generally the LIT decreases as the layer thickness increases. Standard tests
are carried out in the EU with a 5mm thick layer.

Conductivity: For dusts and non-conductive liquids conductivity is a measure of the potential for the
material to become charged and thus cause a static electricity ignition hazard. This may also be
expressed as Relaxation Time i.e. the time taken for a charge to dissipate.

Location: The location of a release is important in terms of the grade of the release. A release in a
confined area e.g. a pit or other poorly ventilated area may result in a higher grade of release than
one occurring outdoors.

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11 APPENDIX C: CLASSIFICATION OF MECHANICAL & ELECTRICAL

EQUIPMENT
Electrical and mechanical equipment intended for use in Hazardous Areas is classified according to
the maximum surface temperature that it can generate and the ignition energy. The maximum
surface temperature is important because it relates to the AIT of the flammable materials present. A
surface temperature close to the AIT or MIT of a hazardous material indicates a significant possibility
of ignition. A safety factor of 2/3 is usually applied to the AIT hence, a material with an AIT of 300°C
would require equipment with a temperature classification of T3 (200°C).

Maximum Surface Class

Temperature (°C)
450 T1
300 T2
200 T3
135 T4
100 T5
85 T6
Table 4: Temperature Classifications

The ignition energy or “Gas Group” relates to the potential ignition energy of the equipment in
terms of spark energy. This is important to ensure that electrical equipment is safe for use with
various gases. Gases are grouped into three categories based MIC (Minimum Ignition Current) or
MESG (Maximum Experimental Safe Gap), which are defined below.

MESG – Maximum gap between the two parts of the interior chamber which under test conditions
prevents ignition of the external gas mixture through a 25mm long flame path when the internal
mixture is ignited for all concentrations of the tested gas or vapour in air.

MIC – Minimum current in resistive or inductive circuits that causes the ignition of the explosive test

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Gas Group Definition

One determination Adequate When
IIA MESG >0.9mm or MIC > 0.9
IIB 0.55>MESG<0.9mm or 0.5>MIC<0.8
IIC MESG < 0.55 or MIC < 0.5
Determination both MESG and MIC required when:
IIA 0.8<MIC<0.9 need to confirm by MESG
IIB 0.45<MIC<0.5 need to confirm by MESG
IIC 0.5<MESG<0.55 need confirm by MIC
Table 5: Gas Groups

Equipment Category (according to the ATEX directive)

The equipment category defines the level of protection that the equipment provides against ignition
sources. Equipment is categorised 1, 2 or 3 with category 1 equipment providing the highest level of
protection. The equipment category is related to the zone in which it may be used by the following
table:

Category Zone Suitability

1 0 / 20 1 / 21 2 / 22
2 X 1 / 21 2 / 22
3 X X 2 / 22
Table 6: Equipment Category suitability for Hazardous Zones
X means not suitable for this zone

Protection Against Dusts

Protection is also provided against dusts by the resistance of the equipment to dust ingress. This is
defined by the IP rating of the equipment as defined in BS EN 60529 which defines various standards
of protection including that against dust ingress. The required levels of protection are:

Zone 20 IP6X
Zone 21 IP6X
Zone 22 Non-conductive dusts IP5X
Conductive dusts IP6X

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12 APPENDIX D: CALCULATIONS

Calculate number of simultaneous sources of release. - IGEM/SR/25 Appendix 7.1

Identify no of Secondary sources

under Nomal conditions Nsn Max interval between inspection to maintain Zone 2 in months Tmax
under Adverse conditions Nsa Actual interval between inspections in months Tactual
Time between inspection normal Tsn No of releases considered under Normal conditions Xn
Time between inspection adverse Tsa No of releases considered under Adverse conditions Xa

ITEM Nsn Nsa f(i) Tmax Tactual Tsn Tsa Nsn.f(i).Tsn Nsa.f(i).Tsa TABLE 7
flex pipes and bellow in Adverse 0 4 0.01 2 2 0.167 0.167 0.0000 0.0067
Regulator diagphragm 0 0.005 4 2 0.167 0.167 0.0000 0.0000 Sum Nx.f(i).Tx X
Rising stem valve 8 0.005 4 2 0.167 0.167 0.0067 0.0000 <0.001 1
Rotating stem valve 40 0.001 6 2 0.167 0.167 0.0067 0.0000 <0.01 2
Screwed union 0 0.001 6 2 0.167 0.167 0.0000 0.0000 <0.05 3
Screwed fitting, sealed 16 8 0.0008 6 2 0.167 0.167 0.0021 0.0011 <0.1 4
Flange, flexible pipes in Normal 108 8 0.0005 6 2 0.167 0.167 0.0090 0.0007 >0.1 Z1
. >1 Z0
Sum Nx.f(i).Tx 0.0245 0.0084

From Table 7 Xn = 3
Xa = 2

No of releases under normal conditions = 3

Consider 1 at inlet pressure of 5mb and 2 at outlet pressure of 500mb
No of releases under adverse conditions = 2
Consider 1 at inlet pressure of 5mb and 1 at outlet pressure of 500mb

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Calculate release rate under adverse conditions at 5mb and 500mb. – IGEM/SR/25 Cl 5.2.2.2

Area of Orifice 2.5 mm2

Diameter of Orifice 1.78 mm
Operating Pressure OP 0.005 bar
Temp in pipe 35 Celsius
Methane proportion 60 %
Molecular Weight M 27.23 g/mole
Gas Pressure P 0.005 bar (=OP or OP+10% for relief valve)
Coeff of Discharge Cd 0.8 1 for relief valve otherwise 0.8
Area of Orifice A 2.5E-06 m 2
Temp in pipe (Kelvin) T 308

Flow Rate G 0.0001 kg/s

0.063 g/s

Area of Orifice 2.5 mm2

Diameter of Orifice 1.78 mm
Operating Pressure OP 0.5 bar
Temp in pipe 35 Celsius
Methane proportion 60 %
Molecular Weight M 27.23 g/mole
Gas Pressure P 0.5 bar (=OP or OP+10% for relief valve)
Coeff of Discharge Cd 0.8 1 for relief valve otherwise 0.8
Area of Orifice A 2.5E-06 m 2
Temp in pipe (Kelvin) T 308

Flow Rate G 0.0006 kg/s

0.631 g/s
Total release under adverse conditions 0.063 + 2 x 0.631 = 0.694g/s

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Calculate release rate under normal conditions at 5mb and 500mb. – IGEM/SR/25 Cl 5.2.2.2

Area of Orifice 0.25 mm2

Diameter of Orifice 0.56 mm
Operating Pressure OP 0.005 bar
Temp in pipe 35 Celsius
Methane proportion 60 %
Molecular Weight M 27.23 g/mole
Gas Pressure P 0.005 bar (=OP or OP+10% for relief valve)
Coeff of Discharge Cd 0.8 1 for relief valve otherwise 0.8
Area of Orifice A 2.5E-07 m 2
Temp in pipe (Kelvin) T 308

Flow Rate G 0.0000 kg/s

0.006 g/s

Area of Orifice 0.25 mm2

Diameter of Orifice 0.56 mm
Operating Pressure OP 0.5 bar
Temp in pipe 35 Celsius
Methane proportion 60 %
Molecular Weight M 27.23 g/mole
Gas Pressure P 0.5 bar (=OP or OP+10% for relief valve)
Coeff of Discharge Cd 0.8 1 for relief valve otherwise 0.8
Area of Orifice A 2.5E-07 m 2
Temp in pipe (Kelvin) T 308

Flow Rate G 0.0001 kg/s

0.063 g/s
Total release under normal conditions 0.006 + 2 x 0.063 = 0.132g/s
Total of normal and adverse gas release 0.132 + 0.693 = 0.826g/s. Gas release < 1g/s so zone of negligible extent is possible with sufficient ventilation.

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Calculate ventilation requirements for “More than Adequate” airflow

IGEM SR/25 Appendix 7.2

Buoyancy Driven
Area of ventilation A 11.4 m2
-0.5 2
More than Adequate A> 7762xGxL 3.63 m Gas Release in kg/s G 0.000826 kg/s
Distance between louvre centres L 3.113 m
Adequate A> 1964xGxL-0.5 0.92 m
2
Height of enclosure H1 3.866 m
Hourly mean windspeed U10-50 4.25 m/s p59 SR25
-0.5 2
Inadequate A< 1964xGxL 0.92 m
For Nat Gas lower area of Bouyancy or Wind Driven is sufficent
-0.5 2
Poor A> 694xGxL 0.32 m For Biogas Wind Driven is preferable if SG is close to 1

Wind Driven

Area of louvres Sheltered

0.33 -1
No of ventilated walls More than Adequate Poor Factor 4xGx(U10-50xH1 ) 0.00049757
4 A 2.82 1.13 0.57
3 A 4.84 1.44 0.97
2 A 10.05 4.03 2.02
1 A 31.70 12.69 6.32

Required free area of ventilation on 2 walls is 10.05m2 which is greater than 11.4m2 of proposed louvres.
Therefore area is classified as Zone 2 NE.

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