2007 UN ECE WP6 › ... › documents › 2007 › EquipmentExplosiveEnviron… · Assessment principles IECEx maintains a suite of Assessment documentation procedures, check lists

2007 UN ECE WP6

Geneva

6 November

Chris Agius

Secretary IECEx

A Global Solution for the Ex Field

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RISK

Risk is a Product of

Likelihood of an event occurring

AND

Consequences of that event occurring


What is Ex??????????????

In Short:

Ex can be considered as a means of ensuring the safe use of equipment in areas where there is a potentialfor an explosive concentration of gases and vapours or combustible dusts to be present.


Ex or Hazloc Equipment – Where ???IECEx


Ex / Hazloc Equipment – Where ???

Automotive refuelling stations or petrol stationsOil refineries, rigs and processing plantsChemical processing plantsPrinting industries, paper and textilesHospital operating theatresAircraft refuelling and hangarsSurface coating industriesUnderground coal minesSewerage treatment plants

Gas pipelines and distribution centresGrain handling and storageWoodworking areasSugar refineriesMetal surface grinding, especially aluminium dusts and particles.Oil and gas tankers, drilling ship and FPSO (Floating Production Storage and Off-Loading Vessels)

Ex equipment is frequently found in these locations:

What is IECEx?What is IECEx?

The single International IEC Scheme covering Certification to Standards that relate to Equipment for use in Explosive Atmospheres, to provide an Internationally accepted means of demonstrating claimed compliance with International Standards

IECEx is a “Conformity Assessment Tool”providing confidence that Products and Servicescovered by an IECEx Certificate meet specified requirements.

Why Have IECEx?Why Have IECEx?To eliminate or significantly reduce:

Multiple/Re-Testing/Assessments

Delays in accessing markets

Obstacles that prevent access to new products and technology by smaller markets.

Un-Safe Practices + Lost Production (Down time)

Initial aim “The facilitation of International Trade in Ex Products, Systems and Services”, while maintaining acceptable levels of Safety

IECEx Vision:

“To be the Global Centre of Excellence in the Ex field”


Who is the IEC?

The International Electrotechnical Commission

Founded in 1906 to promote international co-operation on all questions of standardization and related matters in the field of electrotechnology


IEC organization chart

IEC COUNCILNational Committees

IECQ

COUNCIL BOARD (CB)

CONFORMITY ASSESSMENTBOARD (CAB)Management of Certification

ManagementAdvisory Committees

EXECUTIVE COMMITTEE(IEC Officers)

Central Office(The Executive)

Industry Sector Boards

Technical Advisory Committees

Technical Committees (TCs)

STANDARDIZATION MANAGEMENT BOARD (SMB)Management of International Consensus Standards Work

IECEE

IECEx

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IEC Global Reach: 143 countries

IEC Members Affiliate Members

68 Members75 Countries in Affiliate Country Programme

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IECEx OriginsFormed as a result of demand from industry for an International Standardised approach to testing and Certification for the Ex field, now in operation for 10 years.Industry demand for a system that

Operates on a worldwide basisProvides for equity among all participants and MembersEnsures credibility by operating a single Ex Test lab and Ex Certification Body assessment system based on peer assessment principlesEnsures transparency of rules, procedures and systems

A single set of Rules and Operational procedures set by the industry itself (including regulators) to ensure industry and regulatory confidence in the IECEx system

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Fundamental Disciplines of Ex

Area Classification

Equipment Conformance

Installation Conformance

Maintenance, Repair + Overhaul

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Area ClassificationThe fundamental element of ExDetermines the likely occurrence + extent of areas affectedTakes into account items such as:-

• Chemical Characteristics of liquids, gases, dusts• Operating environment• Operational processes• Competence of Personnel• Others

IEC 60079-10 (Gases) and IEC 61241-10 (Dusts) Defined by the following code

• Zone 0• Zone 1 Gases + Vapours• Zone 2--------------------------------------------------------------------------------------• Zone 20• Zone 21 Dusts, Fibres• Zone 22

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Equipment ConformanceDoes Ex equipment match area classification, e.g. zone, T rating, Gas Grouping etc?Is Ex equipment certified or approved according to local regulations, is certification/approval current and valid, is it authentic?Compliance with correct Standards and SpecificationsDoes certification/approval documents match Ex products that are presented as certified?Have all environmental factors been covered, e.g. mechanical, corrosive, weather?Others, e.g. conditions. ”X”What about the letter “U” ?? ( IECEx NEM 07.0003U )

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Installation conformance

Confirmation of correct Ex equipment selection, e.g. matches area classification and so on?

Installation Standards complied with?

Conditions on certification been met?

Manufacturer installation instructions met?

Installation dossier complete?

Others

Time

Pe

Pe2

Time

Pe

Pe1

2

1

No sealinstalled

Increased explosionpressure caused byprecompression from 1

Pe2 = K Pe1

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Maintenance and Repair/Overhaul

Ex equipment and installations are NOT set and forget installations.Maintenance schedules must be included in any installation dossier or manualsDo maintenance and repair processes follow Standards and Ex equipment manufacturer requirements?Are personnel conducting maintenance or repairs competent, in Ex techniques, certification systems as well as general engineering?Are adequate and required records maintained?Others, e.g. facilities, equipment etc

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Supporting Asset ManagementSupporting Asset Management

“In 2006, Chevron spent approximately $30 billion on goods and services….”

Extract from websites

“The fourth largest publicly-traded integrated oil and gas company* and a world-class chemicals manufacturer, TOTAL operates in more than 130countries ……..”

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Confidence

End Users, e.g. Oil and GasChemical

The IECEx OfferingThe IECEx Offering

ManufacturersDistributors

Service Providers

Regulators, e.g.OSH

Coal Mining

Test+Cert. BodiesInspection Bodies

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IECEx Foundation

Equity Transparency Confidence

F O U N D A T I O N

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IECEx Core Assessment Areas

1.Ex Certification Bodies and Test Laboratories to gain acceptance as IECEx BodiesCompliance to ISO/IEC Guides + Standards (re

Guide 65, 17025, IECEx rules, Technical Guidance Docs

Technical capability – facility, personnelCompliance with IECEx procedures

2. Products and Services to demonstrate compliance with IECEx Scheme requirements

IEC StandardsIECEx Quality System requirementsIECEx rules, including marking.

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Assessment of IECEx Test Labs + Certifiers

Credibility of ExCBs and ExTLs - The FOUNDATION of the IECEx SchemeEVERY Applicant ExCB and ExTL MUST undergo the IECEx Structured assessment program, based on the well established Peer Assessment principles

IECEx maintains a suite of Assessment documentation procedures, check lists and forms, e.g.

IECEx OD 003: IECEx Assessment Manual (Initial, Surveillance + Re-assessment)IECEx TGDs (Technical Guidance Documents) for each Ex techniqueSite Assess. Reports, ISO/IEC Guide 65, 17025 Report forms

Final acceptance by way of formal voting by ALL Member CountriesFollowing acceptance, Surveillance + 5 year re-assessment.

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Summary of IECEx Assessment Records of ExCBs and ExTLs

Original Application

Information

+ Forms

Completed TGDs

+ Check Lists

Original Application

Information

+ Forms

Site Assessment Audit Plan, Reports + Notes, e.g. Follow Up Actions

Surveillance Schedule and Information

Summary Voting Report

Available to ALL IECEx Member Bodies

Surveillance information and reporting by IECEx Secretariat

IECEx Assessment Records Retained by Secretariat

Issued to Member Countries for formal Voting and acceptance

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IECEx Core Assessment Areas1. Ex Certification Bodies and Test Laboratories to gain acceptance as IECEx Bodies

Compliance to ISO/IEC Guides + Standards (re Guide 65, 17025, IECEx rules, Technical Guidance DocsTechnical capability – facility, personnelCompliance with IECEx procedures

2. Products and Services to demonstrate compliance with IECEx Scheme requirements

IEC StandardsIECEx Quality System requirementsIECEx rules, including marking.

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Operational Documents, e.g.

Full list of Operational Documents http://www.iecex.com/operational.htm

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Assessment of Product + Services

IECEx Scheme

IECEx Certified Service Facilities - Rules IECEx 03

IECEx Certified Equipment Rules IECEx 02

Covers New Ex Equipment that offers the Global Industry:

- IECEx Test Report, ExTR

- IECEx Quality Assessment Report, QAR

- With ExTR + QAR achieved, an IECEx “On-Line” Certificate of Conformity, CoC with listing on IECEx website

Covers Services involved in Ex Repair and Overhaul Facilities that address:

- Repair Facilities + Equipment + Systems

- Competence of Repair Staff

- An IECEx “On-Line” Certificate of Conformity, CoC dedicated to Ex Repair

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Core Elements of IECEx Equipment Certification

Initial Assessment of Manufacturer’s Quality System (factory audit)

On-going Surveillance (factory audits)

Testing of Samples (Type Test)

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Core Elements of IECEx Services Certification (Repair Workshops)

Initial Assessment of Repairer to IEC 60079-19 + IECEx Quality System Req.

On-going Surveillance

(Site audits)

Assessment of Competency of persons

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The “IECEx Way” for Ex Certification

ExCB

Country A

ExCB

Country B

ExCB

Country C

ExCB

Country D

Common Rules and Procedures adopted by ALL ExCBs and ExTLs

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IECEx “On-Line” Certification System

Original Master Controlled version of the IECEx Certificate sits on the IECEx WebsiteSeparate areas to cover both

IECEx Certified Equipment ProgramIECEx Certified Service Facilities Program

Also provides for the On-Line Registration of issued IECEx Test ReportsIECEx Audit Reports

Full Reports not shown on the website due to commercial in confidence information but Registration System provides declaration by the issuing IECEx Certifier that Reports exist and were issued according to the IECEx process

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Meaning of an IECEx Certificate Meaning of an IECEx Certificate of Conformity (IECEx CoC of Conformity (IECEx CoC ““EquipmentEquipment””))

Question: What does an ExCB Certify when issuing an IECEx CoC covering Equipment?

Answer: The manufacturer’s capability to consistantly produce the product/equipment, listed on the certificate to be in compliance with the standards also listed on the Certificate.

IECEx 02: 2006 Clause 5.1 Extract:IECEx 02: 2006 Clause 5.1 Extract:“The certificate will attest that the equipment’s design conforms to the relevant IEC standards and that the manufacturer is manufacturing the product under a quality system and associated quality plan(s), meeting the requirements of this Scheme and under the surveillance of an ExCB”.

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Registration of

Issued ExTR

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Registration of

Issued QAR

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Commonality: IECEx and National Systems

Product Testing

Initial Factory Inspection

Ongoing Factory Inspection, surveillance

Issuing a National Ex Certificate

Issuing an IECEx Certificate

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Full Acceptance at National Level

Acceptance of Ex Product + Services to Market

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Certificates and Reports

Reports and Certificates Issued since commencement in late 2003

0

1000

2000

3000

4000

5000

2003 2004 2005 2006 Sep-07

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Question

In noting that IECEx is a voluntary Scheme developed and run by industry and government, why are so many certificates being issued and the scheme growing at a rapid pace???

The question answers itself –

“A voluntary Scheme developed and run by the industry and government it serves to cater to the needs of its industries”.

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LATEST NEWS - IECEx Conformity Mark

Draft Regulations approved by CAB

Documentation in place for

Rules for Licensing

Terms and Conditions

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IECEx Management and Governance Structure

Set Policy and Approve Basic Rules IECEx 01IECEx 01

Day to Day Management of Scheme and Rules of Procedures IECEx 02, IECEx 03

Ensure common approach to testing and assessment, e.g. Standard Test Report Forms, ExTRs, Decision Sheets

IECEx ExTAGTesting and Assessment Group

all ExCBs and ExTLs represented

IEC ExMCManagement Committee ExMC

Member Countries

CONFORMITY ASSESSMENT BOARD (CAB)

IECEx Marks CommitteeManagement of the IECEx

Conformity Mark System

Deal with day to day operation of the IECEx Conformity Mark System

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ItalyIndiaJapanKorea, Republic ofNetherlandsNorwayNew ZealandRomaniaRussian Federation

IECEx Scheme Managing Committee:- Experts from

SingaporeSloveniaSouth AfricaSwedenSwitzerlandUnited KingdomUnited States of AmericaSerbia & Montenegro

AustraliaCanadaChinaCzech RepublicDenmarkFinlandFranceGermanyHungary

Others Planning to Join

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People Technical Quality

Guide

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Meaning of an IECEx Certificate Meaning of an IECEx Certificate of Conformity (IECEx CoC of Conformity (IECEx CoC ““ServicesServices””))

Question: What does an ExCB Certify when issuing an IECEx CoC covering Repair Workshops?

Answer: The repairer’s capability to consistantly carry out repair and overhaul activities in compliance with IEC 60079-19 and IECEx Scheme requirements, within the scope listed on the IECEx certificate.

IECEx 03: 2005 Clause 5.1 Extract:IECEx 03: 2005 Clause 5.1 Extract:“The IECEx Certified Service Facilities Program provides the means for Service Facilities to obtain an IECEx certificate that is intended to provide the international Ex community with confidence that such Service Facilities undertake repair and overhaul work in accordance with the technical and quality system requirements of the IECEx Service Facilities Program…..

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Repair Workshop Scheme Rules

IECEx 03 - Scheme General Rules of Procedure

OD 013

Processing of Applications from Workshops

OD 014

Quality Requirements for Repair Workshops

OD 015

Additional Tech requirements to IEC 60079-19

OD 016

Procedures for assessing ExCBs seeking to Join

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IECEx Repair Certification

Assessment of Qualifications and Work History

Technical Interview is conducted

Witness assessment of Skills.

Assessment of Key Competent Persons Include

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Assessment of Persons – IECEx Repair

Experience with Ex test requirements(1f)

What documents are required for overhaul to remain within certificationWhat records are required?

(1e)

Experience with Ex certification requirements/Standards

(1d)Working with / assessing engineering drawings(1c)Experienced in Ex techniques (1b)Experience in explosive atmosphere work(1a)Qualifications and work historyItem

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Explain where the Ex techniques are used (refer to 1b above for techniques claimed)

(2c)

Understanding of MESG, Ignition Temperature, LEL, UEL, Gas groups, Zones 0,1,2 and 20, 21, 22

(2b)

What is a hazardous atmosphere?Explosive Gas , Dust Cloud, Layer of dust, conductive dust and non-conductive dust

(2a)

Technical interviewItem

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Can show how test status is maintained throughout the repair/overhaul process

(3e)

Understands what to do if a piece of calibrated equipment is found to be faulty or out of calibration

(3d)

Use of calibration status, historyUnderstanding of measurement traceability

(3c)

Use of specific electrical test equipment(winding resistance, insulation, surface temperature, winding temperature, current, voltage)

(3b)

Use of specific mechanical test equipment(shaft/hole diameter, depth, pressure, transfer measurements, flatness, threads, etc)

(3a)Assessment of skills (see 2b above)Item

Guide

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IECEx Competencies for Persons

Based on draft proposalExMC/296/CD

Possible extension to the IECEx Scheme

Needed to support Service Facilities Scheme.

Verification of competency needs to be consistent and transportable.

IECEx Certification of Persons – NEW !!

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SLOVENIA *SIQ

SWEDEN*SP

SINGAPORE*TÜV SÜD PSB

UNITED KINGDOM*Baseefa*ITS *SIRA Cert*FM UK

UNITED STATES*UL*FM

NETHERLANDS*KEMA

GERMANY*PTB *DEKRA/EXAM *TUV Nord*TUV Rheinland*TUV SÜD PS*IBExUHUNGARYBKIBKIITALY * CESIKOREA*KOSHA*KGSNORWAY*DNV*NEMKORUSSIANANIO-CCVE

AUSTRALIA*ITACS *SIMTARS *TestSafe

CANADA*CSA International*QPS

CZECH Republic*FTZUCHINA*CQMDENMARK*UL Int./ DEMKO A/S

FINLAND*VTT

FRANCE*LCIE*INERIS

Sept. 2007: 34 IECEx Certifiers ExCBsIECEx 02 - Certified Equipment Program

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UNITED KINGDOM *Baseefa*SIRA Cert

NORWAY *NEMKO

AUSTRALIA : *SIMTARS

Set 2007: IECEx Certifiers ExCBsIECEx 03 - Certified Service Facilities (Repair) Program

New IECEx Program

Others under assessment

NETHERLANDS *KEMA, Quality

IECEx On-going workWG1 - Revision of Scheme Rules, IECEx 02WG2 - Preparation + Maintenance of Technical Guidance Docs.WG3 - Evaluation of AssessorsWG4 - Technical Reference for Assessments of ExCBs and ExTLsWG5- Quality System RequirementsWG6- Review of ExCB, ExTLs Assessment Process.WG7- Introduction of IECEx Mark (replaced by new ExMarkCo)WG8- Regulatory RecognitionWG9- Ex Proficiency TestingWG10- Introduction of Ex Repair and Overhaul, IECEx 03 + ODsWG11- Certificates issued to DistributorsWG12- Investigation of IECEx Expansion into Competency Assess.

Board of Appeal IECEx Internet site: www.iecex.comExTAG - Common Approach to Testing/Cert. + ExTAG WGs

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IECEx Confidence

Ex Equipment Ex Service Facilities Competent PersonsTraditional Program New Program, 2007 under development

Copyright

Standardisation

Confidence via StandardisationConfidence via Standardisation

Participation in IECEx provides real benefits

Technical Requirements

Conformity Assessment

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IECEx Continual strive to be the Global Centre of

Excellence in the Ex Field

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Conclusion

Further Information may be obtained from

www.iecex.com

QUESTIONS