Installation procedures in HAE

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Installation procedures in HAE

• Ralph C Wigg
• in collaboration with Mr Neil Dennis - AECOM

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WARNING

• This presentation should be consideredonly with
  the associated dialogue.
• It is important not to take statements contained
  herein literally but within the context in which
  they were delivered, understanding also that some
  of theinformation contained may not yet exist
  in AS/NZS published standardsand therefore
  subject to change.

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Topics not necessarily in this order

• Where are we with adoption of IEC standards
• Integrating Gas and Dust standards
• Classification standards update
• Risk adjusted classifications and applications
• Installation standards update
• Non Electrical developments
• Time frame for Introduction
• Non-electrical standards

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Adoption of IEC Standards

• 1991 Standards Australia Committee EL014
  decided to pursue the adoption of IEC standards
  for Hazardous Areas.
• 1996 Strategic plan developed, agreed and
  adopted.
• 1999 First IEC standards directly adopted
  without change
• 2009/2010 Last of the mainstream IEC standards
  adopted as AS/NZS standards

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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Integrating Gas Dust Standards 60079 series
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Classification Standards Road Map
Pre 1999
1999/2004
2005
2009
AS2430.1 Gas/Vapour General
AS/NZS 60079-10
AS/NZS 60079-10-1
AS2430.3 Gas/Vapour Examples
AS/NZS 2430.3 Series
2010
AS2430.2 Dusts
AS/NZS 61241-3
AS/NZS 61241-10
AS/NZS 60079-10-2
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Use of Standards - Gas/Vapour
First principles can be used in place of all
examples. Highlight examples are not mandatory.
AS/NZS 60079-10-1 (AS/NZS 60079 -10)
AS/NZS 60079-10-1 clause 5.4.6 (AS/NZS 2430.3.1)
Generalized Method AS/NZS 60079-10-1 Annex
ZB (AS/NZS 2430.3.5)
Other relevant Standards e.g. API, IP, NFPA
Examples AS/NZS 60079-10-1 Annex ZA (AS/NZS
2430.3 series)
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ATEX Principles - 2003

• ATmospherique EXplosive (French)
• Generalised directive to manage ignition risks
  for hazardous areas
• European Union regulation issue Mandated
  through European member country legislation
• Risk based (Risk categories introduced - Cat 1,
  Cat 2, Cat 3)
• Address electrical and non electrical issues
  (e.g. EN1127-1)
• Compliance to Standards deemed to meet objectives
  but not the only path
• Not a certification scheme
• Initially based on preference of CEN and CENELEC
  standards but accepts Alternate Standards (IEC)

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AS/NZS (IEC) 60079-10-12009

• IEC elements
• Gives support to Classification by Calculation.
• Calculation method is not mandated. Use of
  alternative models is accepted
• Qualitative guidance only
• Hypothetical volumes
• Average LEL, increased by dispersion profile
• Used for ventilation assessment not hazard
  radius
• Calculations conservative 2 or 3 orders of
  magnitude
• Hypothetical volumes and zones related but not
  deterministic
• Includes useful calculations for release rates
• Includes Mists information still unresolved

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Gas/Vapour Classifications - Future

• Gas/Vapour (60079-10-1)
• Further updates to mists (but still hard to
  define risks)
• Further advances on new computational tools.
• Revise calculations for hypothetical volume.
• Work towards recognizing other standards (IP 15,
  API-505 etc)
• Outstanding questions
• How big is a hazard(ous area)?
• How big is a leak?
• Do we need guidance on more catastrophic
  failures?
• Redefining zone 0 what is frequent and does
  it have meaning?

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Dust Classifications

• AS/NZS (IEC) 60079-10-1 due for adoption 2010.
• IEC 60079-10-2 due for publication mid 2009
• Emphasis on dust cloud hazard.
• Introduce dust groups
• IIIA (flyings)
• IIIB (non conductive)
• IIIC (conductive)
• Dust layers identified as a fire risk and may not
  be hazardous areas (subject to housekeeping
  conditions)
• May prefer to use Ex rated items for fire risk
  management and not explosion hazards

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Current Hazard Management Approach

• Current Classification and Apparatus is based on
  fault tree principles.
• Likelihood of hazard x Likelihood of ignition
  source ALARP probability of event.
• e.g. Zone 1 areas may be hazardous in normal
  operation and require apparatus with a high
  integrity from becoming an ignition source.
• Zone 2 areas are less likely to be flammable and
  electrical equipment has lower integrity from
  being an ignition source.
• Does not consider consequence.
• Apparent risk may be suggested by individuals
  fudging classifications.

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Risk Adjusted Classifications

• Accepted in the next edition of IEC standards
• Progressively to all aspects of hazardous area
  standards. (2006 to 2011)
• Fits other frameworks (ATEX, AS/NZS 4360 etc)
• Guidance is beyond IEC scope not defined in IEC
  standards. Application may be country dependent
  Australian approach may vary to other countries
• As an option to the current prescriptive approach
  to allow choice of equipment for zones.

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IEC 60079-10 Enabling Risk Adjustment

• Clause 4.2 Objectives
• .. Subsequent to the completion of the
  area classification, a risk assessment may be
  carried out to assess whether the consequences of
  ignition of an explosive atmosphere requires the
  use of equipment of a higher equipment protection
  level (EPL) or may justify the use of equipment
  with a lower equipment protection level than
  normally required. The EPL requirements may be
  recorded, as appropriate, on the area
  classification documents and drawings to allow
  proper selection of equipment. .

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Risk Adjustments - Implementation

• Annexes toAS/NZS 60079-10-1,AS/NZS 60079-10-2
  and AS/NZS 60079-14
• Guidance on when, and process required
• Not a prescriptive approach no specific
  examples
• Relationship to OHS regulations to be considered
• Reasonably Practicable
• Minimize risk approach
• Roles of designers to eliminate risks at design
  stages

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Installation Standards Road Map
2004
2009
2005
AS/NZS 61241.1-22000
AS/NZS 61241.14 - Dust
AS/NZS (IEC) 60079-14 (IEC with amendmentsand
annexes)
Gas Dust Selection Installation
AS/NZS 2381.11999
AS/NZS2381.1 - Gas
AS 2381.2 (Ex d)
Gas Dust Inspection Maintenance
AS 2381.6 (Ex e)
AS/NZS (IEC) 60079-17
AS/NZS 2381.7 (Ex i)
AS/NZS 2381.8 (Ex s)
AS 1076.6 (Ex n)

• AS/NZS 60079-14 and 17 due mid-late 2009
• Parallel with AS/NZS 2381.1 for two years

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AS/NZS 60079-14 IEC generated changes

• Format and sequence of items new to AS/NZS
• Merging Gas and Dust into one standard
• Introduces Equipment Protection Levels (EPL) to
  match risk adjusted classifications.
• Introduce Dust Groups (non conductive,
  conductive, fibres)
• Introduce Ex ic (intrinsic safety zero fault
  tolerance)
• New calculations for Ex i energy parameters
  (reducing limits where both inductance and
  capacitance are encountered)
• Thermistors or type tests required for both VVVF
  and soft starting of motors (all protection
  techniques)
• Ex e and Ex n HV motors - special risk factor
  controls on start up (based on nett risk
  considering voltage, No. of starts,
  environmental, IP rating etc)
• Ex p considers different designations for
  different release conditions

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EPL Assignment without risk adjustment

• Table 1
• Equipment Protection Levels where only zones are
  assigned

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Equipment Marking

• New marking including EPLs

Ex
d
IIB
T4
Gb
Temperature Class or Maximum Temperature
EPLG Gas D Dust
Explosion Protected
Protection Technique
Gas Group Dust Group
Max. Temp _at_ Dust Depth
t
Ex
IIIC
T130C
T500185C
Da
Similar marking is also being implemented on
mechanical equipment
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Alternate EPL marking

• Examples

H. ATHERINGTON Ltd TYPE 250 JG 1 Ex e px IIC 125
C (T4) Gb alternate Ex eb pbx IIC 125 C
(T4) No. 56732 GHI 02.0076 X
BEDELLE S.A TYPE A B 5 Ex d I Mb alternate Ex
db I
ABC company Type XYZ Serial No. 123456 Ex ia IIIC
T120 C Da alternate Ex ia IIIC T120
C IP20 N.A. 01.9999
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AS/NZS 60079-14 - AU items

• AS/NZS key items
• Update cable requirements in line with AS/NZS
  2381.1
• Note IEC does not require SWA cables for zone 1.
• Maintain options for conditions of control from
  AS/NZS 2381.1
• Maintain ANZEx or IECEx equipment certification
  preference
• Add guidance on cable gland selection
• Maintain AS 1482 for Ex v building
  ventilation
• Maintain references for specific applications
  e.g. fuel dispensers, spray booths
• Add guidance on equipment certification review
  processes (Conformity Assessment Documentation)

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AS/NZS 60079-17 - AU items

• AS/NZS key item
• AS/NZS 60079-17 includes a new Annex for guidance
  on fitness for purpose assessments for
  heritage (legacy) plant.
• Most of the other requirements (for the AS/NZS
  adoption) are the same as current standards.

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AS/NZS 60079-19 - AU items

• AS/NZS key items
• AS/NZS 60079-19 includes a number of the
  requirements now given in AS/NZS3800 as an
  extension to IEC 60079-19
• A guide is being worked on that will include a
  lot of the information currently given in
  AS/NZS3800 that will become supplementary to
  AS/NZS 60079-19 to fill the gaps
• AS/NZS3800 is intended to continue to be in use
  for a period of at least 2 years after the
  publication of AS/NZS 60079-19
• Likely publication date for the AS/NZS is the
  first half of 2010 depending on the situation
  with the standards development process in
  Australia.

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IEC - Links

• IECEx
• Electrical Equipment
• Repair
• Competencies (2010)
• Mechanical? (long term)

• CENELEC standards IEC (parallel vote)

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IEC TC 31 Scope change (Mirrored in Australia)

• Previously ( 2003 - 2008)
• To prepare and maintain international standards
  relating to the use of electrical apparatus
  including area classification, the selection and
  installation, inspection and maintenance, repair,
  overhaul and modification of electrical apparatus
  where there is a hazard due to the possible
  presence of explosive atmospheres of gases,
  vapours or mists.
• From 2008
• To prepare and maintain international standards
  relating to equipment for use where there is a
  hazard due to the possible presence of explosive
  atmospheres of gases, vapours, mists or
  combustible dusts.

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Non Electrical Standards

• CEN mechanical standards initially developed in
  response to ATEX by non electrical groups
• Specific European mechanical standards -
  generally based on ignition risk assessment
  rather than technically specific.
• Category (or zone) rating variable based on
  assessments
• Modified gas/dust criteria to electrical
  standards (to be reviewed in IEC)
• ISO responsibility but IEC holds relevant
  expertise in hazardous areas.
• ISO and IEC working together in the non
  electrical field under IEC TC31

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EN - Non Electrical Standards

• EN 13980, EN 1710 Underground coal mine
  equipment (priority)
• Generic standards (Introduced for IEC
  consideration)
• EN 13463 - 1 General
• EN 13463 - 2 fr - Flow restricting (limited
  breathing)
• EN 13463 - 3 d - Flameproof (as per electrical)
• EN 13463 - 5 c - Construction safety (increased
  safety)
• EN 13463 - 6 b - Ignition control (electro
  mechanical management systems)
• EN 13463 - 8 k - Immersion (as per electrical)
• Future inherent safety being considered
• Specific equipment standards e.g.
• EN 14986 (Design of fans)

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IEC Non Electrical

• Beginning with adoption/modification/restructure
  of EN standards
• Already working on mining equipment standards as
  priority

IEC 60079-0 general requirements mechanical
and electrical
ISO/IEC 80079-0 Basic requirements for
mechanical equipment (including ignition hazard
assessment)
ISO/IEC 80079-xx Mechanical equipment
constructional safety, control of ignition
sources, liquid immersion (combined elements from
EN standards)
IEC 60079-1 Flameproof mechanical and
electrical
for example
IEC 60079-2 Pressurisation mechanical and
electrical
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Non Electrical - relationships

• Consider impact on/input from existing recognised
  standards
• API and ISO TC67 oil industry standards
  co-adopted
• Other than EN standards?
• AS 2809 (road tankers), AS 2229 (fuel
  dispensers),API 610, ASME PTC9 etc ???
• Certification schemes
• Extension to IECEx Does industry need or want
  it?
• New competencies and inspection regimes are
  these warranted?

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Going Forward

• Change is happening be prepared and consider
  the issues
• Communicate and put your views forward
• Participation and support are desperately needed
• Questions?