Presented at the November 17, 2016, Arkansas STEPS Network Class

1. Hot Work

3. Hot Work Program
Hot Work - Any operation
or job which could provide,
become or create an
ignition source for any
flammable material:
Welding, Cutting, Brazing, Soldering
Acetylene burning
Arc welding
Metal chipping, sand blasting
Open flames
Electrical driven power tools
Or similar work (Cameras, flashlights,
and electronic equipment can create
hazards in flammable atmospheres

4. Prevention – Hot Work Permit
Flammable
Range
L.E.L.
10%
L.E.L.
L.F.L
U.E.L.
U.F.L
100%
Too Rich to
Explode
0.5% 5% 15%
Methane
Flammability / Explosive Range

5. • Hot Work
• Move the welding/cutting or move the hazard
(SWN requires > 100ft well bore & not less than 50ft from vegetation
or other combustibles)
• Remove combustible materials
• Confine the heat, slag, sparks with guards
• Protect combustibles that can’t be moved with fire blankets
• Fire Extinguishers-in a state of
readiness
• Fire Watch-required by OSHA
• Have extinguisher and be trained to use it
• Required for minimum of 30 minutes after completion of
welding and cutting
Hot Work Permit

6. Do any of these cause a spark?

7. CSB Dangers of Hot Work

8. Static Electricity Hazards

9. Explosion Kansas City

10. Hazardous (Classified) Locations
Jeremy Cox, CSP
SWN
William Brown, CSP
XTO
Presented By::

11. Training Objectives
By the end of this training, employee will be able to:
• Understand how to determine Hazardous (Classified) Locations
• Understand the differences between Class I, II, III hazardous
locations
• Understand the different kinds of conditions under which these
hazards are present
• Understand the three types of ignition sources
• Equipment design & construction considerations

12. Regulatory Agencies
• OSHA 1910.307
• NEC, articles 500-504 & 510- 517
• ANSI / API 500-1998

13. Hazardous Locations
• The National Electrical Code (NEC) defines
hazardous locations as those areas "where fire
or explosion hazards may exist due to
flammable gases or vapors, flammable liquids,
combustible dust, or ignitable fibers or
flyings."

14. Petroleum Refinery

15. Grain Elevator

16. Lumber Mill

17. Tank Battery

18. Gas Gathering Facility

19. Well Servicing

20. 3 Types of Class Locations
• Class I Locations
• Class II Locations
• Class III Locations

21. Class I Locations
• Class I Hazardous Location is one in which
flammable gases or vapors may be present in
the air in sufficient quantities to be explosive
or ignitable.

22. Typical Class I Locations
• Some typical Class I Locations are:
– Petroleum refineries, and gasoline storage and dispensing areas;
– Dry cleaning plants where vapors from cleaning fluids can be present;
– Spray finishing areas;
– Aircraft hangars and fuel servicing areas; and
– Utility gas plants, and operations involving storage and handling of
liquified petroleum gas or natural gas.
– All of these are Class I . . . gas or vapor . . . hazardous locations. All
require special Class I hazardous location equipment.

23. Class II Locations
• Areas made hazardous by
the presence of combustible
dust.

24. Typical Class II Locations
• Some typical Class II Locations are:
– Grain elevators;
– Flour and feed mills;
– Plants that manufacture, use or store magnesium or aluminum
powders;
– Producers of plastics, medicines and fireworks;
– Producers of starch or candies;
– Spice-grinding plants, sugar plants and cocoa plants; and
– Coal preparation plants and other carbon handling or processing
areas.

25. Class III Locations
• Areas where there are
easily-ignitable fibers or
flyings present, due to
the types of materials
being handled, stored, or
processed.

26. Typical Class III Locations
• Some type III locations include:
– Textile mills, cotton gins;
– Cotton seed mills, flax processing plants; and
– Plants that shape, pulverize or cut wood and
create sawdust or flyings.

27. Divisions (Conditions)
• In addition to the types of hazardous locations, the National
Electrical Code also concerns itself with the kinds of
conditions under which these hazards are present. The Code
specifies that hazardous material may exist in several
different kinds of conditions which, for simplicity, can be
described as:
– normal conditions
– abnormal conditions.

28. Divisions
• Division 1 - normal conditions
• Division 2 - abnormal conditions

29. Class I Location Groups
• The groups deal with the nature of the
hazardous substances.
• The gases and vapors of Class I Locations are
broken into four groups by the Code: A,B,C,&
D
• These materials are grouped according to the
ignition temperature of the substance, its
explosion pressure, and other flammable
characteristics.

30. Group A
• The only substance in Group A is acetylene.
• Acetylene makes up only a very small
percentage of hazardous locations.
Consequently, little equipment is available for
this type of location.
• Acetylene is a gas with extremely high
explosion pressures.

31. • Acetylene is a well known fuel gas used almost universally
in gas welding.
• Even though it is very common, this gas is an extremely
dangerous material. Acetylene is so reactive, it should
never be allowed to come into contact with certain metals
such as unalloyed copper.
• Nor should it be stored or used at pressures greater than
15 psi.
Acetylene Cylinders

32. • Acetylene is so flammable, that the National Electric Code
has a special designation (its most stringent) for using
electrical equipment around acetylene.
 No other substance falls into this classification!
• Acetylene leaks, no matter how small can have serious
consequences.
The explosive range of the gas, when mixed with air, is from 2.5% to
82%, the widest of any commonly used gas.
Acetylene Cylinders

33. Group B
• Relatively small segment of classified areas.
• Includes Hydrogen and other materials with
similar characteristics.

34. Group C & D
• Are by far the most usual Class I groups.
• They comprise the greatest % of all Class I hazardous
locations.
• Common Group D flammable substances include:
– Butane, gasoline, natural gas, propane

35. Class II Groups
• Class II – “dust locations” contain:
– Groups E, F, & G
– These groups are classified according to the ignition
temperature and the conductivity of the hazardous
substance.
– Conductivity is an important consideration in Class II
location, especially metal dusts.

36. Group E
• Metal dusts are categorized in the Code as
Group E.
• Included here are aluminum and magnesium
dusts and other metal dusts of similar nature.

37. Group F & G
• Group F atmospheres contain such materials
as
– Carbon black, charcoal dust, coal and coke dusts
• Group G includes:
– Grain dust, flour, starch, cocoa, and similar types
of materials

39. International Electrotechnical
Commission (IEC)
• The IEC classification system, used throughout much
of the world outside of North America, varies from
the traditional NEC Class/Division system in that it
recognizes three levels of probability that a
flammable concentration of material might be
present.
• These levels of probability are known as:
– Zone 0, Zone 1, Zone 2

40. IEC Zone Definitions
• The Class definitions only apply to applications in the
U.S.
• The Zone standard classify the types of flammable
substances present as such:
– Zone 0, Zone 1, and Zone 2 are zones where
hazardous vapors and gases are present
– Zone 20, Zone 21, and Zone 22 are zones where
hazardous dusts or fibers are present

41. IEC Zone Definitions
• The hazardous location areas are defined by
taking into account the different dangers
presented by potentially explosive
atmospheres. This

42. IEC Zone Definitions

43. IEC Zone Definitions
This graphic is for illustration purposes only.

44. IEC Group Definitions
• The explosive characteristics of the air
mixtures of gases, vapors, or dusts vary with
the specific material involved. Materials have
been placed in groups based on their ignition
temperatures and explosion pressures.
Electrical apparatus for potentially explosive
atmospheres is divided into 2 groups per EN
50014:

45. IEC Group Definitions
• Group I — Electrical apparatus for mines
susceptible to firedamp (for use underground)
• Group II — Electrical apparatus for places with
a potentially explosive atmosphere, other
than mines susceptible to firedamp

46. IEC Group Definitions

47. IEC Ignition Temperature Class

48. IEC Protective Methods

50. Markings Explained

51. Intrinsically Safe Device Markings

52. Sources of Ignition
1. Arcs and Sparks
2. High Temperatures
3. Electrical Equipment Failure

53. Arcs and Sparks
• Use of electric, non-explosive tools, equipment and motors
• Sandblasting
• Breaking concrete
• Drilling
• Chipping, ripping, or cutting by impact
• Soldering
• Grinding & filing
• Carrying cellular phones, pagers, radios, or any other
equipment not labeled as safe for use in hazardous
atmospheres.
• Operation internal combustion engines
– (portable air compressors, generator, heaters..)
• Metal Tools (shovels, chisels, etc.)

54. High Temperatures
• Heat-Producing
Equipment
• Such as lamps and
lighting fixtures
• Cutting Torch
• Welding

55. Electrical Equipment Failure
• Shorting of an Electrical
Tool
• Equipment Failure

56. Equipment Design & Construction
• All equipment must be designed and
constructed to be suitable for the specific
Hazardous Location Class that it will be
installed in.

57. Equipment Design & Construction
Cont…
• Tools and Equipment we
use will be primarily Class
I Division I or Class I
Division II
• Tools and equipment
may be constructed for
either Class I Division I or
Class I Division II or not
rated at all.

58. Devices that are not rated…
• Are Mag’s flashlights “explosion-proof” or “intrinsically
safe”?
– Mag Instrument’s flashlights are general-purpose
flashlights. We have not had them tested or certified as
safe for special-purpose uses under any “intrinsically safe”
standard or under any of the various “explosion-proof”
standards that exist. We do not label our flashlights
“explosion proof” or “intrinsically safe” and we do not
warrant that they would be safe if put to such a special-
purpose use.
– Mag Flashlight Official Website

59. Equipment Design & Construction
Cont…
• Non-sparking hand tools we may use

60. LEL Bottle Rocket

61. Equipment Design & Construction
Cont…
• Brass shovel

62. Equipment Design & Construction
Cont…
• Measuring tools

63. Review of Three Types of Hazardous
Locations
• Class I
– gas or vapor
• Class II
– combustible dust
• Class III
– fibers and flyings

64. Review
Kinds of Conditions
• Division 1
– Normal Conditions
• Division 2
– Abnormal Conditions

77. Classify The Following
• Natural Gas Well Pad (under normal operations)
– Class I Division II
• Natural Gas Well Pad (during well servicing activity)
– Class I Division I
• Compressor Station
– Class I Division II
• Pipeline Pigging Operations
– Class I Division I

78. Classify The Following
Class I Division I

79. Classify The Following
Class I Division I

80. Questions

81. Atmospheric Monitoring

82. Definitions
• Hazardous atmosphere
– Atmosphere that may expose employees to risk of
death, incapacitation, impairment of ability to self-
rescue (i.e. unaided escape from permit space),
injury or acute illness from one or more following
causes:
• Flammable gas, vapor or mist in excess of 10% of Lower
Flammable Limit (LFL)

83. Definitions
• Hazardous atmosphere
– Airborne combustible dust at concentration that
meets or exceeds LFL
– Note: concentration may be approximated as
condition in which dust obscures vision at distance
of 5 ft or less
– Atmospheric oxygen concentration <19.5% or
>23.5%

84. Definitions
• Hazardous atmosphere
– Atmospheric concentration of any substance for
which dose or PEL could result in employee
exposure in excess of dose or PEL
• Note: atmospheric concentration of any substance not
capable of causing death, incapacitation, impairment of
ability to self-rescue, injury or acute illness due to
health effects is not covered

85. Definitions
• Hazardous atmosphere
– Any other atmospheric condition that is IDLH
– Note: for air contaminants which OSHA has no
dose or PEL, other sources of information, such as
MSDSs that comply with 29 CFR 1910.1200,
published information & internal documents can
provide guidance in establishing acceptable
atmospheric conditions

86. Definitions
• Immediately Dangerous to Life and Health
(IDLH)
– Condition that poses immediate or delayed threat
to life or cause irreversible adverse health effects
or interfere with individual’s ability to escape
unaided from permit space

87. Testing Protocol
• Before employee enters space, internal
atmosphere shall be tested, with calibrated
direct-reading instrument, for following
conditions in order given
– Oxygen content
– Flammable gases & vapors
– Potential toxic air contaminants

88. Atmospheric Monitoring
• Oxygen
– An atmospheric
oxygen
concentration below
19.5% (deficiency), or
above 23.5%
(enriched)

89. Atmospheric Monitoring
– Flammable gases & vapors
• LEL / UEL
• % LEL verses % Volume

90. Atmospheric Monitoring
• Toxic Gases
– An atmosphere concentration of any toxic
compound above the permissible exposure limit
established by OSHA, NIOSH or ACGIH

91. Atmospheric Monitoring
• Carbon Monoxide

92. Atmospheric Monitoring
• Hydrogen Sulfide

93. Atmospheric Monitoring
• Gas Monitor Alarms
• Provide an alarm at the appropriate exposure
limits for the monitored substance(s).
 Real-Time concentration
Short-Term Exposure Limit (STEL)
Time-Weighted Average (TWA)

94. Atmospheric Monitoring
• Types of Monitor Sensors
– Electrochemical (EC) Oxygen Sensors
– Catalytic (CAT) Oxidation Sensors
– Infrared (IR) Sensors
– Photo Ionization Detector (PID) Sensors

95. Atmospheric Monitoring
• Other Sensor Characteristics to Consider
based on your workplace needs may include:
➤ Monitor design that allows gas intake from both the top and front
of the monitor.
➤ The contaminant concentration measurement range, minimum
detection limit and resolution.
➤ Environmental conditions during use (range of temperature,
pressure and relative humidity).
➤ Sensor replacement procedures (on site versus manufacturer
replacement).
➤ Warranty period.

96. Atmospheric Monitoring
• Sensor Issues
– Sensor Drift (CAT)
– Zeroing
– Saturation
– Environmental Exposure
– Battery Life

97. Atmospheric Monitoring
• Maintenance
– As part of good operating practices, gas monitors
should be bump tested every day before use. A
bump test is defined as a qualitative function
check where a challenge gas is passed over the
sensor(s) at a concentration and exposure time
sufficient to activate all alarm indicators to
present at least their lower alarm setting.

98. Atmospheric Monitoring
• Docking Stations
• Data Log Capabilities & Benefits

99. Atmospheric Monitoring
• Atmospheric Monitoring Best Practices
– Spot Checks vs Continuous Monitoring
– Pump vs natural aspirated monitors
– Flow rate through hose on pump models
– Calibration & Bump Testing

101. Lightning Safety
• Postpone outdoor activities if
thunderstorms are imminent. Lightning
can travel 5-10 miles away from the
thunderstorm and strike the ground with
blue sky overhead. The storm doesn’t
have to be overhead in order for you to
be struck. 15 miles is SWN’s weather
action plan shut down
• Move to a sturdy shelter or vehicle. Do
not take shelter in a small shed, under
isolated trees, or in a convertible-top
vehicle. Stay away from tall objects such
as trees or towers or poles.
• If in your vehicle when lightning strikes –
don’t touch a metal surface. You are
safer in a vehicle than being outdoors.