2009 1 Installation procedures in HAE Ralph C

© 2009 1

Installation procedures in HAE Ralph C Wigg in collaboration with Mr Neil Dennis - AECOM

WARNING This presentation should be considered only 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 the information contained may not yet exist in AS/NZS published standards and therefore subject to change. © 2009 3

Topics – not necessarily in this order ª Where are we with adoption of IEC standards ª Integrating Gas and Dust standards ª Classification standards update ª Risk adjusted classifications and applications ª Installation standards update ª Non Electrical developments ª Time frame for Introduction ª Non-electrical standards © 2009 4

Adoption of IEC Standards ª 1991 – Standards Australia Committee EL 014 decided to pursue the adoption of IEC standards for Hazardous Areas. ª 1996 – Strategic plan developed, agreed and adopted. ª 1999 – First IEC standards directly adopted without change ª 2009/2010 – Last of the mainstream IEC standards adopted as AS/NZS standards © 2009 5

Integrating Gas & Dust Standards – 60079 series 61241 -0 60079 -0 General Requirements 61241 -4 60079 -2 Pressurization “p” 60079 -10 -1 Classification - Gases 61241 -10 60079 -10 -2 Classification - Dusts 61241 -11 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 6

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 60079 -2 Pressurization “p” 60079 -10 -1 Classification - Gases 61241 -10 60079 -10 -2 Classification - Dusts 61241 -11 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” 61241 -4 © 2009 7

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” 60079 -10 -1 Classification - Gases 61241 -10 60079 -10 -2 Classification - Dusts 61241 -11 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 8

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 60079 -10 -2 Classification - Dusts 61241 -11 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 9

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases Change number 60079 -10 -2 Classification - Dusts 61241 -11 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” 61241 -10 © 2009 10

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 11

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 Combine 60079 -14 Selection/Installation 61241 -17 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 12

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 Combine 60079 -14 Selection/Installation 61241 -17 Combine 60079 -17 Inspection & Maintenance 61241 -18 60079 -18 Encapsulation “m” 61241 -1 60079 -31 Protection by Enclosure “t” © 2009 13

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 Combine 60079 -14 Selection/Installation 61241 -17 Combine 60079 -17 Inspection & Maintenance 61241 -18 Combine 60079 -18 Encapsulation “m” 60079 -31 Protection by Enclosure “t” 61241 -1 © 2009 14

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 Combine 60079 -14 Selection/Installation 61241 -17 Combine 60079 -17 Inspection & Maintenance 61241 -18 Combine 60079 -18 Encapsulation “m” 61241 -1 Change number 60079 -31 Protection by Enclosure “t” © 2009 15

Integrating Gas & Dust Standards – 60079 series 61241 -0 Combine 60079 -0 General Requirements 61241 -4 Combine 60079 -2 Pressurization “p” No change 60079 -10 -1 Classification - Gases 61241 -10 Change number 60079 -10 -2 Classification - Dusts 61241 -11 Combine 60079 -11 Intrinsic Safety “i” 61241 -14 Combine 60079 -14 Selection/Installation 61241 -17 Combine 60079 -17 Inspection & Maintenance 61241 -18 Combine 60079 -18 Encapsulation “m” 61241 -1 Change number 60079 -31 Protection by Enclosure “t” © 2009 16

Classification Standards ‘Road Map’ Pre 1999/2004 AS 2430. 1 Gas/Vapour General AS/NZS 60079 -10 AS 2430. 3 Gas/Vapour Examples AS/NZS 2430. 3 Series 2005 2009 AS/NZS 60079 -10 -1 2010 AS 2430. 2 Dusts © 2009 AS/NZS 61241 -3 AS/NZS 61241 -10 17 AS/NZS 60079 -10 -2

Use of Standards - Gas/Vapour ‘First principles’ can be used in place of all examples. Highlight examples are not mandatory. Generalized Method AS/NZS 60079 -10 -1 Annex ZB (AS/NZS 2430. 3. 5) AS/NZS 60079 -10 -1 (AS/NZS 60079 -10) AS/NZS 60079 -10 -1 clause 5. 4. 6 (AS/NZS 2430. 3. 1) Other relevant Standards e. g. API, IP, NFPA © 2009 18 Examples AS/NZS 60079 -10 -1 Annex ZA (AS/NZS 2430. 3 series)

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 v Risk based (Risk categories introduced - Cat 1, Cat 2, Cat 3) v Address electrical and non electrical issues (e. g. EN 1127 -1) v Compliance to Standards deemed to meet objectives but not the only path v Not a certification scheme v Initially based on preference of CEN and CENELEC standards but accepts Alternate Standards (IEC) © 2009 19

AS/NZS (IEC) 60079 -10 -1: 2009 IEC elements: Gives support to ‘Classification by Calculation’. v Calculation method is not mandated. Use of alternative models is accepted v Qualitative guidance only v Hypothetical volumes v Average LEL, increased by dispersion profile v Used for ventilation assessment – not hazard radius v Calculations conservative – 2 or 3 orders of magnitude v Hypothetical volumes and zones related but not deterministic v Includes useful calculations for release rates v Includes Mists information – still unresolved v © 2009 20

Gas/Vapour Classifications - Future Gas/Vapour (60079 -10 -1) Further updates to mists (but still hard to define risks) v Further advances on new computational tools. v Revise calculations for hypothetical volume. v Work towards recognizing other standards (IP 15, API 505 etc) v Outstanding questions: How big is a hazard(ous area)? v How big is a leak? v Do we need guidance on ‘more catastrophic failures’? v Redefining zone 0 – what is ‘frequent’ and does it have meaning? v © 2009 21

Dust Classifications ª AS/NZS (IEC) 60079 -10 -1 due for adoption 2010. ª IEC 60079 -10 -2 due for publication mid 2009 ª Emphasis on dust cloud hazard. ª Introduce dust groups IIIA (flyings) v IIIB (non conductive) v IIIC (conductive) v ª Dust layers identified as a fire risk and may not be hazardous areas (subject to housekeeping & conditions) ª May prefer to use Ex rated items for fire risk management and not explosion hazards © 2009 22

Current Hazard Management Approach ª Current Classification and Apparatus is based on fault tree principles. ª 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. v Zone 2 areas are less likely to be flammable and electrical equipment has lower integrity from being an ignition source. v Does not consider consequence. ª ‘Apparent risk’ may be suggested by individuals ‘fudging’ classifications. © 2009 23

Risk Adjusted Classifications ª Accepted in the next edition of IEC standards v Progressively to all aspects of hazardous area standards. (2006 to 2011) ª Fits other frameworks (ATEX, AS/NZS 4360 etc) ª Guidance is beyond IEC scope – not defined in IEC standards. Application may be country dependent – Australian approach may vary to other countries ª As an option to the current prescriptive approach to allow choice of equipment for zones. © 2009 24

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. ……. ” © 2009 25

Risk Adjustments - Implementation ª Annexes to: AS/NZS 60079 -10 -1, AS/NZS 60079 -10 -2 and AS/NZS 60079 -14 Guidance on when, and process required v Not a prescriptive approach – no specific examples v ª Relationship to OH&S regulations to be considered ‘Reasonably Practicable’ v ‘Minimize risk’ approach v Roles of designers to eliminate risks at design stages v © 2009 26

Installation Standards ‘Road Map’ 2004 2005 2009 AS/NZS 61241. 1 -2: 2000 AS/NZS 61241. 14 - Dust AS/NZS (IEC) 60079 -14 AS/NZS 2381. 1 - Gas (IEC with amendments and annexes) AS/NZS 2381. 1: 1999 Gas & Dust Selection & Installation AS 2381. 2 (Ex ‘d’) 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’) ª AS/NZS 60079 -14 and 17 due mid-late 2009 ª Parallel with AS/NZS 2381. 1 for two years © 2009 27 Gas & Dust Inspection & Maintenance

AS/NZS 60079 -14 – IEC generated changes Format and sequence of items – new to AS/NZS v Merging Gas and Dust into one standard v Introduces Equipment Protection Levels (EPL) to match risk adjusted classifications. v Introduce Dust Groups (non conductive, fibres) v Introduce Ex ‘ic’ (intrinsic safety – zero fault tolerance) v New calculations for Ex ‘i’ energy parameters (reducing limits where both inductance and capacitance are encountered) v Thermistors or type tests required for both VVVF and soft starting of motors (all protection techniques) v 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) v Ex p considers different designations for different release conditions © 2009 28

EPL Assignment without risk adjustment Table 1 Equipment Protection Levels where only zones are assigned Zone Equipment protection levels (EPLs) 0 ‘Ga’ 1 ‘Ga’ or ‘Gb’ 2 ‘Ga’, ‘Gb’ or ‘Gc’ 20 ‘Da’ 21 ‘Da’ or ‘Db’ 22 ‘Da’, ‘Db’ or ‘Dc’ © 2009 29

Equipment Marking New marking including EPLs Ex Explosion Protected Ex d IIB Protection Technique Gas Group Dust Group t IIIC T 4 Temperature Class or Maximum Temperature T 130°C Gb Max. Temp @ Dust Depth T 500185°C EPL G – Gas D – Dust Da Similar marking is also being implemented on mechanical equipment © 2009 30

Alternate EPL marking Examples H. ATHERINGTON Ltd TYPE 250 JG 1 Ex e px IIC 125 °C (T 4) Gb alternate Ex eb pbx IIC 125 °C (T 4) No. 56732 GHI 02. 0076 X BEDELLE S. A TYPE A B 5 Ex d I Mb ABC company Type XYZ Serial No. 123456 Ex ia IIIC T 120 °C Da IP 20 N. A. 01. 9999 © 2009 alternate Ex db I alternate Ex ia IIIC T 120 °C 31

AS/NZS 60079 -14 - AU items AS/NZS key items ª Update cable requirements in line with AS/NZS 2381. 1 Note: IEC does not require SWA cables for zone 1. ª Maintain options for conditions of control from AS/NZS 2381. 1 ª Maintain ANZEx or IECEx equipment certification preference ª Add guidance on cable gland selection ª Maintain AS 1482 for Ex ‘v’ – building ventilation ª Maintain references for specific applications e. g. fuel dispensers, spray booths ª Add guidance on equipment certification review processes (Conformity Assessment Documentation) © 2009 32

AS/NZS 60079 -17 - AU items AS/NZS key item ª 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. © 2009 33

AS/NZS 60079 -19 - AU items AS/NZS key items ª AS/NZS 60079 -19 includes a number of the requirements now given in AS/NZS 3800 as an extension to IEC 60079 -19 ª A “guide” is being worked on that will include a lot of the information currently given in AS/NZS 3800 that will become supplementary to AS/NZS 60079 -19 to ‘fill the gaps’ ª AS/NZS 3800 is intended to continue to be in use for a period of at least 2 years after the publication of AS/NZS 60079 -19 ª Likely publication date for the AS/NZS is the first half of 2010 depending on the situation with the standards development process in Australia. © 2009 34

IEC - Links CEN ATEX Electrical & ATEX Non-electrical ISO Cenelec IECEx - Electrical Equipment - Repair - Competencies (2010) - Mechanical? (long term) IEC North America progressing to IEC CENELEC standards = IEC (parallel vote) © 2009 35

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. © 2009 36

Non Electrical Standards ª CEN mechanical standards initially developed in response to ATEX by non electrical groups ª Specific European mechanical standards - generally based on ignition risk assessment rather than technically specific. ª Category (or zone) rating variable based on assessments ª Modified gas/dust criteria to electrical standards (to be reviewed in IEC) ª ISO responsibility but IEC holds relevant expertise in hazardous areas. ª ISO and IEC working together in the non electrical field under IEC TC 31 © 2009 37

EN - Non Electrical Standards ª EN 13980, EN 1710 – Underground coal mine equipment (priority) ª Generic standards (Introduced for IEC consideration) v v v v ª 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. v EN 14986 (Design of fans) © 2009 38

IEC – Non Electrical ª Beginning with adoption/modification/restructure of EN standards ª 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 © 2009 39

Non Electrical - relationships ª Consider impact on/input from existing recognised standards API and ISO TC 67 oil industry standards – co-adopted v Other than EN standards? v AS 2809 (road tankers), AS 2229 (fuel dispensers), API 610, ASME PTC 9 etc ? ? ? v ª Certification schemes v ª Extension to IECEx – Does industry need or want it? New competencies and inspection regimes – are these warranted? © 2009 40

Going Forward Change is happening – be prepared and consider the issues Communicate and put your views forward Participation and support are desperately needed Questions? © 2009 41