rw new standards

Installation procedures in Installation procedures in HAEHAE

Ralph C Wigg

in collaboration with Mr Neil Dennis - AECOM

©2009

WARNINGWARNING

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 Topics – not necessarily in this order– 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 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 – Integrating Gas & Dust Standards – 60079 60079 seriesseries

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”

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61241-0 Combine 60079-0 General Requirements

61241-4 60079-2 Pressurization “p”








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61241-4 Combine 60079-2 Pressurization “p”








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No change 60079-10-1 Classification - Gases







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61241-10 Change number

60079-10-2 Classification - Dusts






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61241-10 Change number 60079-10-2 Classification - Dusts

61241-11 Combine 60079-11 Intrinsic Safety “i”





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61241-14 Combine 60079-14 Selection/Installation




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61241-17 Combine 60079-17 Inspection & Maintenance



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61241-18 Combine 60079-18 Encapsulation “m”


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61241-1 Change number

60079-31 Protection by Enclosure “t”

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61241-1 Change number 60079-31 Protection by Enclosure “t”

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Classification Standards ‘Road Classification Standards ‘Road Map’Map’

AS2430.1Gas/Vapour

General

AS2430.3Gas/VapourExamples

AS2430.2Dusts

AS/NZS60079-10

AS/NZS2430.3Series

AS/NZS61241-3

AS/NZS61241-10

AS/NZS60079-10-2

AS/NZS 60079-10-1

Pre 1999 1999/2004 2005

2010

2009

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Use of Standards - Gas/VapourUse of Standards - Gas/Vapour

Generalized MethodAS/NZS 60079-10-1

Annex ZB(AS/NZS 2430.3.5)

Other relevant Standards

e.g. API, IP, NFPA

ExamplesAS/NZS 60079-10-1

Annex ZA(AS/NZS 2430.3 series)

AS/NZS 60079-10-1 clause 5.4.6

(AS/NZS 2430.3.1)

AS/NZS 60079-10-1(AS/NZS 60079 -10)

‘First principles’ can be used in place of all examples.

Highlight examples are not mandatory.

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ATEX Principles - 2003ATEX Principles - 2003

ATmospherique EXplosive (French)Generalised directive to manage ignition risks for hazardous areas

European Union ‘regulation’ issue: Mandated through European member country legislationRisk 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 pathNot a certification schemeInitially based on preference of CEN and CENELEC standards but accepts Alternate Standards (IEC)

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AS/NZS (IEC) 60079-10-1:2009AS/NZS (IEC) 60079-10-1:2009

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 - Gas/Vapour Classifications - FutureFutureGas/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 ClassificationsDust 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 Current Hazard Management ApproachApproach 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 ClassificationsRisk 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 optionoption to the current prescriptive approach to allow choice of equipment for zones.

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IEC 60079-10: Enabling Risk IEC 60079-10: Enabling Risk AdjustmentAdjustmentClause 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 - Risk Adjustments - ImplementationImplementation Annexes to:

AS/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 OH&S 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’Installation Standards ‘Road Map’

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

AS/NZS 61241.1-2:2000

2004 2009

AS/NZS 61241.14 - Dust

AS/NZS 2381.1:1999

AS 2381.2 (Ex ‘d’)

AS 2381.6 (Ex ‘e’)

AS/NZS 2381.7 (Ex ‘i’)

AS/NZS 2381.8 (Ex ‘s’)

AS 1076.6 (Ex ‘n’)

AS/NZS2381.1 - Gas

AS/NZS (IEC) 60079-14

(IEC with amendmentsand annexes)

AS/NZS (IEC) 60079-17

Gas & Dust Selection & Installation

Gas & Dust Inspection & Maintenance

2005

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AS/NZS 60079-14 – IEC generated AS/NZS 60079-14 – IEC generated changeschangesFormat 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 EPL Assignment without risk adjustmentadjustment

Table 1Equipment Protection Levels where only zones are assigned

ZoneZone Equipment protection levels (EPLs)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’

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Equipment MarkingEquipment Marking

New marking including EPLs

Explosion Protected

Protection

Technique

Gas GroupDust Group

Temperature Class or

Maximum Temperature

Max. Temp @ Dust Depth

EPLG – Gas D – Dust

Ex

t

d IIB

Ex IIIC

T4

T130°C T500185°C

Gb

Da

Similar marking is also being implemented on mechanical equipment

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Alternate EPL markingAlternate EPL marking

Examples

H. ATHERINGTON LtdTYPE 250 JG 1Ex e px IIC 125 °C (T4) Gb alternate Ex eb pbx IIC 125 °C (T4)No. 56732GHI 02.0076 X

BEDELLE S.ATYPE A B 5Ex d I Mb alternate Ex db I

ABC companyType XYZSerial No. 123456Ex ia IIIC T120 °C Da alternate Ex ia IIIC T120 °CIP20N.A. 01.9999

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AS/NZS 60079-14 - AU itemsAS/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 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 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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North America progressing to IEC

IEC - LinksIEC - Links

CENELEC standards = IEC (parallel vote)

ATEXATEX

ATEXElectrical &

Non-electrical

CEN

ISO

IECEx - Electrical Equipment- Repair - Competencies (2010)

- Mechanical? (long term)

IECIEC

Cenelec

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IEC TC 31 Scope change IEC TC 31 Scope change (Mirrored in (Mirrored in Australia)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 2008To 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 StandardsNon 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 StandardsEN - 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 ElectricalIEC – 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

IEC 60079-2: Pressurisation – mechanical and electricalfor example

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Non Electrical - relationshipsNon 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 ForwardGoing Forward

Change is happening– be prepared and consider the issues

Communicate and put your views forward

Participation and support are desperately needed

Questions?

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rw new standards

Documents

electrical standards

asnzs standards

integrating gas dust

combine combine

mainstream iec standards

enclosure t

change number

installation procedures