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

3. 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.

4. 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

5. 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

6. Integrating Gas & Dust Standards – 60079 series
General Requirements
Pressurization “p”
Classification - Gases
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

7. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
Classification - Gases
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

8. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
Classification - Gases
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

9. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

10. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

11. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

12. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

13. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

14. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

15. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

16. Integrating Gas & Dust Standards – 60079 series
Combine
General Requirements
Pressurization “p”
No change
Classification - Gases
Change number
Classification - Dusts
Intrinsic Safety “i”
Selection/Installation
Inspection & Maintenance
Encapsulation “m”
Protection by Enclosure “t”

17. Classification Standards ‘Road Map’
Pre 1999
1999/2004
2005
2009
AS2430.1
Gas/Vapour
General
AS/NZS
AS/NZS
AS2430.3
Gas/Vapour
Examples
AS/NZS
2430.3
Series
2010
AS2430.2
Dusts
AS/NZS
AS/NZS
AS/NZS

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

19. 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)

20. AS/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

21. Gas/Vapour Classifications - Future
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?

22. Dust Classifications AS/NZS (IEC) 60079-10-1 due for adoption 2010.
IEC 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

23. 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.

24. 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.

25. 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. …….”

26. Risk Adjustments - Implementation
Annexes to: AS/NZS , AS/NZS and AS/NZS
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

27. Installation Standards ‘Road Map’
2004
2005
2009
AS/NZS :2000
AS/NZS Dust
AS/NZS (IEC)
(IEC with amendments and annexes)
Gas & Dust
Selection &
Installation
AS/NZS :1999
AS/NZS Gas
AS (Ex ‘d’)
Gas & Dust
Inspection &
Maintenance
AS (Ex ‘e’)
AS/NZS (IEC)
AS/NZS (Ex ‘i’)
AS/NZS (Ex ‘s’)
AS (Ex ‘n’)
AS/NZS and 17 due mid-late 2009
Parallel with AS/NZS for two years

28. 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

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

30. Temperature Class or Maximum Temperature
Equipment Marking
New marking including EPLs Ex d
IIB T4 Gb
Temperature Class or Maximum Temperature
Explosion Protected
Protection Technique
Gas Group
Dust Group
EPL G – Gas D – Dust
Max. Dust Depth Ex t
IIIC
T130°C
T500185°C Da
Similar marking is also being implemented on mechanical equipment

31. 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
GHI X
BEDELLE S.A
TYPE A B 5
Ex d I Mb alternate Ex db I
ABC company
Type XYZ
Serial No
Ex ia IIIC T120 °C Da alternate Ex ia IIIC T120 °C
IP20
N.A

32. AS/NZS 60079-14 - AU items AS/NZS key items
Update cable requirements in line with AS/NZS
Note: IEC does not require SWA cables for zone 1.
Maintain options for conditions of control from AS/NZS
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)

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

34. AS/NZS 60079-19 - AU items AS/NZS key items
AS/NZS includes a number of the requirements now given in AS/NZS3800 as an extension to IEC
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 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
Likely publication date for the AS/NZS is the first half of depending on the situation with the standards development process in Australia.

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

36. IEC TC 31 Scope change (Mirrored in Australia)
Previously ( )
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.

37. 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

38. EN - Non Electrical Standards
EN 13980, EN 1710 – Underground coal mine equipment (priority)
Generic standards (Introduced for IEC consideration)
EN General
EN ‘fr’ - Flow restricting (limited breathing)
EN ‘d’ - Flameproof (as per electrical)
EN ‘c’ - Construction safety (increased safety)
EN ‘b’ - Ignition control (electro mechanical management systems)
EN ‘k’ - Immersion (as per electrical)
Future inherent safety being considered
Specific equipment standards e.g.
EN (Design of fans)

39. IEC – Non Electrical
Beginning with adoption/modification/restructure of EN standards
Already working on mining equipment standards as priority
IEC : general requirements – mechanical and electrical
ISO/IEC : Basic requirements for mechanical equipment (including ignition hazard assessment)
ISO/IEC xx: Mechanical equipment – constructional safety, control of ignition sources, liquid immersion
(combined elements from EN standards)
IEC : Flameproof – mechanical and electrical
for example
IEC : Pressurisation – mechanical and electrical

40. 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?

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