HB 239:2011

HB 239:2011

Handbook
Guidance on the repair and overhaul of electrical equipment for explosive atmospheres

HB 239:2011 This Joint Australian/New Zealand Handbook was prepared by Joint Technical Committee EL-023, Electrical Equipment in Mines. It was approved on behalf of the Council of Standards Australia on 8 December 2010 and on behalf of the Council of Standards New Zealand on 1 July 2011. This Handbook was published on 19 July 2011.

The following are represented on Committee EL-023: Australian Chamber of Commerce and Industry Australian Coal Association Australian Industry Group Consult Australia Department of Industry and Investment NSW Department of Mines & Petroleum (WA) Department of Mines and Energy (Qld) Electrical Apparatus Service Association Mining Electrical and Mining Mechanical Engineering Society National Association of Testing Authorities Australia Queensland Department of Environment and Resource Management Solid Energy New Zealand The Aviation and Marine Engineers Association University of Newcastle WorkCover New South Wales

Keeping Standards up-to-date

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HB 239:2011

Handbook
Guidance on the repair and overhaul of electrical equipment for explosive atmospheres

First published as HB 239:2011.

COPYRIGHT Standards Australia Limited/Standards New Zealand All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher, unless otherwise permitted under the Copyright Act 1968 (Australia) or the Copyright Act 1994 (New Zealand). Jointly published by SAI Global Limited under licence from Standards Australia Limited, GPO Box 476, Sydney, NSW 2001 and by Standards New Zealand, Private Bag 2439, Wellington 6140.

ISBN 978 0 7337 9891 7

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PREFACE
This Handbook was prepared by Standards Australia/Standards New Zealand Committee EL-023, Electrical Equipment in Mines. The objective of this Handbook is to provide practical guidance for the overhaul and repair of electrical equipment for explosive atmospheres. It contains performance-based information on process and procedures that have been part of AS/NZS 3800 that may not transfer to the revised 2011 version IEC 60079.19, the recognised international Standard for the repair and overhaul of explosion-protected electrical equipment. Additionally, information on the key processes for the repair of reeling and trailing cable is included. The Handbook offers additional guidance regarding techniques and special processes necessary to ensure consistent and reliable delivery of repaired and overhauled equipment and cables. Also included are appendices covering quality management systems, measurement and calibration, and history of equipment and service facilities approval schemes. The Handbook has been written to assist repair facilities, owners and operators of electrical equipment in explosive atmospheres.

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CONTENTS
Page SECTION 1 GENERAL 1.1 SCOPE ........................................................................................................................ 7 1.2 REFERENCED DOCUMENTS .................................................................................. 7 SECTION 2 DEFINITIONS 2.1 GENERAL .................................................................................................................. 9 2.2 ADDITIONAL DEFINITIONS ................................................................................... 9 SECTION 3 TECHNICAL PRINCIPLES AND PROCESSES 3.1 INTRODUCTION ..................................................................................................... 11 3.2 BACKGROUND ....................................................................................................... 11 3.3 COMPETENCIES ..................................................................................................... 11 3.4 SERVICE FACILITY RELATIONSHIPS WITH THE EXPLOSION-PROTECTED EQUIPMENT OWNER/OPERATOR ......................... 12 3.5 CONSULTATION WITH OTHER PARTIES: MANUFACTURERS AND REGULATORS................................................................................................ 13 3.6 DOCUMENTATIONVERIFICATION DOSSIER ................................................ 13 3.7 TRANSITION OF STANDARDS ............................................................................. 14 3.8 SELECTION OF SERVICE FACILITY.................................................................... 16 3.9 SERVICE FACILITY CAPABILITIES..................................................................... 16 3.10 WORK FLOW........................................................................................................... 17 3.11 COMMENTARY ON MATERIALS......................................................................... 27 3.12 COMMENTARY ON INSPECTION TECHNIQUES ............................................... 30 3.13 MECHANICAL REPAIR PROCESSES.................................................................... 31 SECTION 4 GENERIC TESTING PROCESSES FOR VERIFICATION OF EXPLOSION-PROTECTION TECHNIQUES 4.1 NON-DESTRUCTIVE TEST (NDT)......................................................................... 37 4.2 DIELECTRIC WITHSTAND (HIGH POTENTIAL OR HI-POT) TESTING ................................................................................................................. 37 4.3 INSULATION RESISTANCE................................................................................... 39 4.4 COMPONENT TESTING ......................................................................................... 39 4.5 TEMPERATURE MEASUREMENT........................................................................ 40 SECTION 5 OVERHAUL OF ROTATING MACHINES 5.1 GENERAL ................................................................................................................ 41 5.2 REPAIR/OVERHAUL ............................................................................................. 41 5.3 OWNER/OPERATOR RESPONSIBILITIES............................................................ 42 5.4 QUALITY-MANAGED ASSESSMENT STRATEGIES .......................................... 42 5.5 EVALUATION PROCEDURES FOR ROTATING MACHINES............................. 43 5.6 ADDITIONAL NOTES FOR COPY WINDING....................................................... 47 5.7 AFTER WINDING.................................................................................................... 47 5.8 REPAIR OF ROTORS .............................................................................................. 48 5.9 TEMPERATURE SENSORS .................................................................................... 48 5.10 ENCLOSURES.......................................................................................................... 48 5.11 SPECIFIC TESTS APPLICABLE TO ROTATING MACHINES............................. 49 5.12 SPECIFIC REQUIREMENTS FOR REPORTING ON ROTATING MACHINES .............................................................................................................. 50

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Page 5.13 SPECIFIC REQUIREMENTS FOR PACKAGING AND DESPATCH OF ROTATING MACHINES ......................................................................................... 50 5.14 REINSTALLATION RECOMMENDATIONS FOR ROTATING MACHINES .............................................................................................................. 50 SECTION 6 EX d FLAMEPROOF EQUIPMENT 6.1 INTRODUCTION ..................................................................................................... 51 6.2 OVERHAUL ............................................................................................................. 54 6.3 REPAIR..................................................................................................................... 54 6.4 RECLAMATION ...................................................................................................... 54 6.5 CATEGORIES OF REPAIR...................................................................................... 54 6.6 CHECKS AND REPORTING ................................................................................... 55 6.7 IN-SITU TEMPORARY REPAIR FOR HOLE OR THREAD .................................. 64 6.8 HYDROSTATIC PRESSURE TESTS....................................................................... 66 6.9 FINAL VERIFICATION ........................................................................................... 69 6.10 PACKAGING AND DESPATCH ............................................................................. 69 SECTION 7 EX e INCREASED SAFETY 7.1 INTRODUCTION ..................................................................................................... 70 7.2 OWNER/OPERATOR............................................................................................... 71 7.3 INSPECTION/OVERHAUL ..................................................................................... 71 7.4 SPECIFIC ISSUES FOR ROTATING MACHINES ................................................ 73 7.5 REPAIR..................................................................................................................... 74 7.6 FINAL VERIFICATION ........................................................................................... 75 7.7 PACKAGING AND DESPATCH ............................................................................. 75 7.8 REPORTING............................................................................................................. 75 SECTION 8 EX i INTRINSIC SAFETY 8.1 GENERAL ................................................................................................................ 76 8.2 OWNER/OPERATOR RESPONSIBILITIES............................................................ 78 8.3 INITIAL ASSESSMENT .......................................................................................... 81 8.4 OVERHAUL ............................................................................................................. 82 8.5 PASS/FAIL CRITERIA FOR OVERHAULED EQUIPMENT ................................. 84 8.6 COMPONENTS FORMING PART OF INTRINSICALLY SAFE EQUIPMENT.................................................................................................. 84 8.7 TESTING/ASSESSMENT ........................................................................................ 86 8.8 REPAIR..................................................................................................................... 87 8.9 RECLAMATION ...................................................................................................... 88 8.10 TESTING .................................................................................................................. 88 8.11 ALTERATIONS AND MODIFICATIONS .............................................................. 88 8.12 REPORTING............................................................................................................. 88 8.13 PACKAGING AND DESPATCH ............................................................................. 89 SECTION 9 EX m ENCAPSULATION 9.1 INTRODUCTION ..................................................................................................... 90 9.2 REPAIR/OVERHAUL PROCEDURES .................................................................... 90 SECTION 10 EX n NON-SPARKING 10.1 INTRODUCTION ..................................................................................................... 93 10.2 INSPECTION AND OVERHAUL ............................................................................ 94 10.3 ROTATING MACHINE SPECIFIC ISSUES ............................................................ 96 10.4 REPAIR..................................................................................................................... 96 10.5 FINAL VERIFICATION ........................................................................................... 97

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Page 10.6 PACKAGING AND DESPATCH ............................................................................. 97 10.7 REPORTING............................................................................................................. 97 SECTION 11 EX tD (DIP) 11.1 INTRODUCTION ..................................................................................................... 98 11.2 INSPECTION AND OVERHAUL ............................................................................ 98 11.3 OVERHAUL ........................................................................................................... 100 11.4 FINAL VERIFICATION AND TESTS ................................................................... 100 11.5 PACKAGING AND DESPATCH ........................................................................... 101 11.6 REPORTING........................................................................................................... 101 SECTION 12 EX p PRESSURISED 12.1 INTRODUCTION ................................................................................................... 102 12.2 INITIAL INSPECTION........................................................................................... 102 12.3 ENCLOSURES........................................................................................................ 103 12.4 TEMPERATURE RATING..................................................................................... 103 12.5 OVERHAUL AND REPAIR PROCEDURES FOR PRESSURISED EQUIPMENT................................................................................ 104 12.6 GROUP I EXPLOSION PROTECTED TRANSFORMERS ................................... 105 SECTION 13 EX o OIL FILLED 13.1 INTRODUCTION ................................................................................................... 107 13.2 NON-SPARKING PROTECTION .......................................................................... 107 13.3 OIL CONDITIONING............................................................................................. 107 13.4 TESTING ................................................................................................................ 107 SECTION 14 EX v VENTILATED..................................................................................... 108 SECTION 15 EX s SPECIAL PROTECTION..................................................................... 109 SECTION 16 GROUP I HAZARDOUS AREA REELING AND TRAILING CABLES 16.1 SCOPE .................................................................................................................... 110 16.2 CABLE COMPONENTS......................................................................................... 110 16.3 GUIDANCE ON ASSESSING CABLE CONDITION............................................ 115 16.4 EVALUATION BEFORE REPAIR AND HISTORY RECORD............................. 115 16.5 PROCEDURE FOR HARD SOLDERING REELING AND TRAILING CABLES .............................................................................................. 118 SECTION 17 PRE-OVERHAUL INSPECTION (CODE C1) FOR GROUP I 17.1 PRE-OVERHAUL REQUIREMENTS.................................................................... 120 17.2 FLAMEPROOF....................................................................................................... 120 17.3 INCREASED SAFETY EQUIPMENT.................................................................... 120 17.4 PRESSURISED EQUIPMENT ............................................................................... 121 SECTION 18 COMPLIANCE OF LEGACY PLANT 18.1 GENERAL .............................................................................................................. 122 18.2 HISTORY................................................................................................................ 122 18.3 USING THE FACTS ............................................................................................... 122 18.4 ASSUMPTIONS...................................................................................................... 122 18.5 VERIFICATION DOSSIER .................................................................................... 122 18.6 FACT GATHERING ............................................................................................... 122

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Page APPENDICES A QUALITY MANAGEMENT SYSTEM COMPONENT ......................................... 125 B MEASUREMENT AND CALIBRATION IN Ex WORKSHOPS ........................... 131 C SAMPLE CERTIFICATES AND FORMS.............................................................. 153 D E HISTORICAL INFORMATION RELATING TO EQUIPMENT APPROVAL SCHEMES.................................................................. 190 HISTORICAL INFORMATION RELATING TO SERVICE FACILITY APPROVAL SCHEMES ......................................................................................... 195

HB 239:2011

STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Handbook Guidance on the repair and overhaul of electrical equipment for explosive atmospheres

S E C T I O N
1.1 SCOPE

G E N E RA L

This Handbook provides guidance for the repair and overhaul of explosion-protected electrical equipment used in hazardous areas (defined in AS/NZS 60079.0). The Handbook covers equipment with a Group I designation for coal mining; Group II where flammable gases and vapours may be present; and Group III which includes equipment used in the presence of combustible dusts. This Handbook details the methods of overhaul, repair, examination and the testing required to ensure safety and compliance with the relevant Standards for the different equipment explosion-protection techniques. It covers the several types of explosion-protection techniques currently in use and provides guidance for repair and overhaul service facilities. The soon to be published revision of AS/NZS 3800 (and IEC 60079-19 Edition 3) offer a performance-based approach to the overhaul of electrical equipment for use in hazardous areas. In many applications it was felt it was necessary to establish guidance to standardise the approach for inspection, repair and overhaul techniques and methods, and to provide a repository where expert knowledge can be accumulated from experience and disseminated for the benefit of stakeholders. The objective of this Handbook is to provide service facilities, equipment owner and/or operators and relevant regulatory authorities involved in the repair and overhaul of electrical equipment in hazardous areas with guidance to ensure safety and compliance with the relevant existing Standards. The Handbook also offers additional guidance on techniques and special processes necessary to ensure consistent and reliable delivery of repaired and overhauled equipment and cables. This document is to be read initially in conjunction with AS/NZS 3800 and IEC 60079-19 Edition 3, the recognized international Standard for repair and overhaul of explosionprotected electrical equipment. In anticipation of the soon-to-be published revised AS/NZS 3800 (and IEC 60079 Edition 3), where possible, reference to these documents has been quoted throughout the text. 1.2 REFERENCED DOCUMENTS AS/NZS 1299 1300 1747 1802 1972 Electrical equipment for coal minesFlameproof restrained plugs and receptacles Electrical equipment for coal minesBolted flameproof cable coupling devices Reeling, trailing and feeder cables used for miningRepair, testing and fitting of accessories Electric cablesReeling and trailingFor underground coal mining Electric cablesUnderground coal minesOther than reeling and trailing
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AS/NZS 2081 2290 2381 2802 3800 4761 4871 60079 61241 62013

Electrical equipment for coal and shale minesElectrical protection devices (series) Electrical equipment for coal minesMaintenance and inspection (series) Electrical equipment for explosive atmospheresSelection, installation and maintenance Electric cables-Reeling and trailing-for mining and general use (other than underground coal mining) Electrical equipment for explosive atmospheresRepair and overhaul Competencies for working with electrical equipment for hazardous areas (series) Electrical equipment for coal mines, for use underground (series) Explosive atmospheres (series) Electrical apparatus for use in the presence of combustible dust (series) Caplights for use in mines susceptible to firedamp (series)

AS/NZS ISO 9001 Quality management systems AS 60529 Degrees of protection provided by enclosures (IP Code)

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SECT ION
2.1 GENERAL

DEF I N I T I ONS

The Definitions in the standards listed in Referenced Documents apply to this document. 2.2 ADDITIONAL DEFINITIONS The following definitions also apply. 2.2.1 Verification Dossier A set of documents showing the compliance of electrical equipment and installations, including certificates, manufacturer instructions, records of previous repairs, overhaul and reclamation. 2.2.2 Metal spray (also known as thermal spray) A coating deposition technique in which melted droplets of material are sprayed onto a substrate material. The resulting coating is comprised of small pancake-like splats, often with voids and incomplete bonding. The technique allows deposition of materials dissimilar to the substrate and does not heat the substrate, but requires controlled application to ensure consistency of material and bonding. 2.2.3 Laser welding A metal joining technique using lasers to generate the melt heat and precisely deposit material at the required location. Laser welding offers control and high power input, reducing the size of the heat affected zones around the welds. 2.2.4 Solder Solder is metal alloy with a low melting point used to join materials through melting and physical keying onto the surface while cooling. Traditionally, solders were tin-lead alloys. However, environmental concerns with lead have seen restrictions on the use of lead in electrical and electronic equipment. As a consequence many recent solders have been formulated to be lead-free alloys. Many different lead-free formulations exist and these may not be compatible with each other. In addition, over time some lead-free solders have grown metallic (tin) whiskers, which in some instances have affected clearance distances in Ex i equipment. 2.2.5 Controlled temperature burn-out Removal of insulating materials (commonly varnishes, plastics and epoxy in windings) by heating. Temperatures are selected to melt and oxidise the insulating materials without comprising the magnetic properties or interlamination insulation of the iron core. 2.2.6 Final inspection The last inspection of an item while under the control or responsibility of the inspecting body. 2.2.7 Competent person Refer to AS/NZS 3800. A person who can demonstrate a combination of knowledge and skills to effectively, efficiently and safely carry out activities in hazardous areas covered by AS/NZS 4761. Competency in some cases may be limited to one or more specific types of protection techniques, e.g. Ex d, Ex i, and or activity (e.g. design, selection, installation, maintenance, testing and inspection). A competent person may also be referred to as a responsible person.

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2.2.8 Special processes Processes that cannot be fully verified by test, therefore requiring adherence to specific procedures to ensure tasks fulfil the processes satisfactorily.

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SECT ION

TECHN IC A L PR I NC I P L ES P R O CE SSES

AND

3.1 INTRODUCTION This Section describes aspects of the technical infrastructure of relevance to the repair and overhaul of Ex equipment, and the general processes of overhaul. Particular emphasis is placed on competencies, access to information (covering both documentation and postrepair marking of equipment) and the planning of workflow. Central to the efficient and effective delivery of overhauls and repaired equipment are relationships with significant stakeholders, such as the equipment owner, user and possibly the designer and manufacturer. 3.2 BACKGROUND Explosion-protected equipment and high integrity reeling and trailing cables are essential risk controls for the safe use of electricity within a hazardous area. Certified and approved explosion-protected equipment have passed rigorous compliance reviews of the original equipment design. The more recent (Type 5) certification schemes also include quality audits of the equipment manufacture. These programs aid to improve the compliance level of hazardous area equipment, while regular inspections and maintenance by the owner or operator assist to maintain the equipment in its as built condition. No item of engineered equipment can last indefinitely and it is generally acknowledged that failure of an explosion-protection technique is not self-revealing. In order to verify the continued integrity of the equipment, periodic overhaul of electrical equipment situated in hazardous areas is recommended to verify the integrity of the equipment safeguards. Hazardous areas are defined in AS/NZS 60079.0 as follows: In underground coal mines, hazardous areas are termed hazardous zones and are generally geographically defined in legislation. In operating areas the hazardous zone is considered to be zone 1 while ever ventilation is effective. However, on the loss of ventilation the hazardous zone is often considered to be zone 0. There are hazardous zones in mines that are not accessible to people, but which are considered to be zone 0. Because equipment usage affects its explosion-protection properties, the equipment is regularly removed from service and overhauled, as timetabled in AS/NZS 2290.1 for Group I applications. In Group II and III applications there is no published timetable for overhaul, and the equipment may be overhauled either periodically or on an as-needs basis. 3.3 COMPETENCIES Inspection, repair and the verification of compliance after overhaul of explosion-protected electrical equipment requires specialist knowledge and experience not generally achieved in general industrial equipment overhaul. AS/NZS 4761 details competency requirements for hazardous area equipment work, but these competencies should only be considered a starting point; experience working on the types of equipment overhauled is essential. Incorrect actions and/or conformity evaluation may impair or incorrectly diagnose the subsequent explosion-protected properties of that equipment. Therefore all work and verification activities should be performed by, or under the supervision of, a person who has a recognised competency for the particular explosion-protection technique. This person is often termed a competent person. Effective overhauls sometimes require use of specialist processes such as welding, metal spraying and non-destructive testing. It may not be possible for the overhaul workshop to possess the facilities or competencies for all techniques used in any particular overhaul, and
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it is common for these type of services to be subcontracted to specialist providers. Often, these specialist processes are supported by industry-based competence schemes that recognise individuals or approved suppliers. Whether these specialist processes are provided in-house or outsourced, the competent person should be aware of the presence and relevance of such schemes. They should take steps to ensure that operatives, who are engaged in all actions and processes that may affect the Ex properties of the equipment under overhaul, are appropriately skilled in the processes employed. Records supporting these steps should be kept, either as skills matrices for staff performing specialist tasks inhouse, or as part of the sub-contractor evaluation process. 3.4 SERVICE FACILITY RELATIONSHIPS PROTECTED EQUIPMENT OWNER/OPERATOR WITH THE EXPLOSION-

The repair and overhaul of equipment requires effective communication among a number of parties who have interests in the equipment. These can include the owner, the operator and the repair facility. These are explained in further detail below: (a) (b) (c) The equipment owner is the specifier and provider of instruction information. The operator typically has day-to-day involvement in using the equipment and may, through that involvement, identify issues demanding attention. The combination of owner/operator and Service Facility are typically responsible for identifying a suitable scope of work for equipment repair or overhaul and agreeing to any associated variations. Responsibilities between the owner/operator and Service facility are normally established through contractual relationships outside the scope of this document.

Facilities involved in repair and overhaul should consult with all parties to attempt to confirm that dossiers are maintained and reflect the current (rather than as-provided) status of the equipment. Clear communication ensures that (i) (ii) there is a holistic approach to the safety of the affected hazardous area installation (rather than a focus on individual items of equipment); documentation associated with the equipment is available and reflects the compliance status of equipment;

(iii) problems identified within the equipment are addressed; (iv) (v) necessary or desired upgrades are included; options in the repair process are discussed and agreed on;

(vii) the compliance status of returned equipment is clearly agreed; (viii) there is a timely delivery of post-overhaul documentation; and (ix) post-contractual disputes are minimised.

Consultation regarding the equipment verification dossier may highlight issues in the history of the equipment, recurrent or known failure modes, or environmental deficiencies that are relevant to the repair and overhaul of the equipment. In some cases, clients may ask the repair and overhaul facility not to proceed with some elements of the overhaul activity. In these cases there should be a clearly agreed scope of work. It is acknowledged that clients may employ alternative means of establishing explosion-protection; the omission of operations mandated in AS/NZS 3800 should be clearly justified and identified in post-overhaul documentation. Repair facilities should be careful in the assertion of compliance in such cases.

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3.5 CONSULTATION REGULATORS

WITH

OTHER

PARTIES:

MANUFACTURERS

AND

Other parties may provide information relevant to equipment overhaul and repair. Manufacturers, certification bodies and regulators may issue post-manufacture information updates or safety alerts. Facilities involved in the overhaul and repair of Ex equipment should be aware of the possible issue of additional information and ask for relevant information to be provided by the owner or operator. Normally this type of information is included in the relevant verification dossier. 3.6 DOCUMENTATIONVERIFICATION DOSSIER It is not unusual for a service facility to receive electrical explosion-protected equipment from an owner /operator with little to no information on the history of repair and overhaul, or known deficiencies within the delivered equipment. Therefore, it is important for the service facility to seek the necessary verification dossier and owner/operators instructions and guidance before proceeding. All hazardous area installations are required to have a verification dossier in accordance with AS/NZS 60079.14, which is mandated by AS/NZS 3000. For Group I, hazardous areas are typically predefined and the verification dossiers are established for individual explosion-protected plant items. Information normally available on the supply of equipment forms the basis for a dossier, which is kept up-to-date by the owner/operator so that the dossier reflects the current compliance status and service history of the equipment. (The implementation of this may vary between clients and industries and with the age of the installation.) Equipment certification regimes may affect the information available. Appendix D offers additional information on a range of equipment approval and certification systems currently in use in Australia. Recent obligations cited in the IEC Ex certification scheme include manufacturers information regardless of the Ex equipment Group. Some older equipment may only have been evaluated for compliance with national or international Standards and issued with a Certificate of Conformity attesting to the validity of the explosion-protection characteristics of the equipment. Other older equipment may only have regulatory approval. Approved equipment will generally be compliant with the national Standards at the date of issue, however alternative risk controls that were deemed equivalent were sometimes approved. In fact, compliance to Standards is a minimum requirement for certification and equipment may be designed and certified using more stringent specifications than those detailed in Standards. For these reasons a service facility should review the compliance specifications prior to repair or overhaul. In all cases, the preferred approach to overhaul is to refer to certification or approval documentation, including the drawings that identify the explosion-protected features of the equipment. In the event that the owner/operator cannot provide the verification dossier the workshop may be able to assist in gathering the relevant information. As previously mentioned, Group I equipment has a strong history of evaluating the suitability and compliance of explosion-protected equipment prior to use in a hazardous area, and has insisted that compliance documentation, including drawings, are maintained and used for the purposes of repair and overhaul to verify that the explosion-protected characteristics of the equipment are maintained as originally evaluated. Groups II and III do not have the same strong history of evaluation and maintenance of documentation and therefore could use an alternative approach. In circumstances where
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certificate documents are not available, then a service facility should liaise with the owner/operator who may elect to initiate the repair or overhaul of the explosion-protected equipment to achieve compliance with the relevant Standards. However, the more recent certification/approval scheme makes the provision of compliance documentation mandatory with the supply of the equipment (refer to AS/NZS 60079.0 Clause 30, Instructions). In instances of legacy equipment without compliance documents, steps taken to obtain the certificate documents should be recorded in the repair facility records. Figure 3.1 provides a flowchart as a guide to assist in determining whether a particular piece of explosionprotected electrical equipment can be satisfactorily repaired or needs to be replaced. Clearly, there are issues for service facilities (workshops) in establishing that they have all relevant documentation when overhauling legacy equipment, but there are also issues when overhauling recently-issued equipment. Recently-issued equipment will be accompanied by a comprehensive verification dossier, however, it is possible mine management practice is to hold multiple copies of the dossier. While the verification dossier is supposed to include details of maintenance and inspections performed over the operating life of the equipment, it is possible that all of this information is not present in the copy of the dossier provided to the service facility. Efforts should be made to confirm that the dossiers provided to the service facility include all relevant information, including shift inspection reports, outcomes from previous pre-overhaul inspections and the reports associated with any previous overhaul. The data in the verification dossier thats necessary for the repair or overhaul includes, but is not limited to, the following details: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Technical specification. Drawings. Type(s) of protection (explosion-protection).; Operating conditions, such as environment, supply (inverter), lubricants, duty, etc). Dismantling and assembly instructions. Certificate limitations (specific conditions of use), where specified. Marking (including Ex marking). Recommended methods of installation, operation, maintenance, repair or overhaul for the equipment. List of spare parts. Summary of previous history, including previous overhauls and any pre-overhaul inspections and repairs carried out.
NOTE: Manufacturers have and are likely to make small changes to identical equipment and have these certified to meet specific client requirements. In these instances the change may be in the form of a supplementary certificate/approval and the original drawing may well have been used but with a revision. Therefore, it is strongly recommended that if the repair house decides to make a copy of the documents for its work files, the equipment serial number should be documented to ensure correct reference for future overhauls or, more importantly, that incorrect reference material is not used.

3.7 TRANSITION OF STANDARDS The evolution of Standards is usually driven by a number of issues that relate to (a) (b) experience in the use of the Standards and the identification of deficiencies; changes and improvements to materials and process conditions; and
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(c)

specific application of equipment.

In fact, the updating of Standards is a regular and consistent process. The adoption of IEC Hazardous Area Standards as Australian and New Zealand Standards (AS/NZS) began in 1999 and the transition, particularly for the equipment Standards, is now complete. This means that the reference numbers for AS/NZS Standards have changed to match the adopted IEC Standard numbers. To further complicate the numbering, the original series numbers for Standards covering combustible dusts is undergoing another change in order to bring all Standards into the 60079 series. The following provides assistance in selection of Standards: TABLE 1 APPLICABLE STANDARDS FOR HAZARDOUS AREAS
Description of explosion protection technique Zone 0 Intrinsically safe, Ex ia Encapsulated, Ex ma Special protection, Ex s Zone 1 Intrinsically safe Special protection, Ex s Flameproof enclosure, Ex d Encapsulated, Ex m AS 2380.7 (see Note 1) AS/NZS 60079.11 Ex ib AS 1826 IEC 60079-33 Ex s (see Note 2) AS 2380.2 AS/NZS 60079.1 AS 2431 AS/NZS 60079.18 Ex mb AS 2380.4 AS/NZS 60079.2 Ex p AS 2380.6 AS/NZS 60079.7 Ex e Ventilation Powder filling Oil immersion Zone 2 Special protection Non-sparking Ventilation Pressurized rooms or pressurized enclosures AS 2380.9 AS 1826 Ex s IEC 60079-33 Ex s (see Note 2) IEC 60079-15 AS/NZS 60079.15 Ex n AS 1482 Ex v AS 2380.4 AS/NZS 60079.2 Ex p In accordance with the requirements for Zone 2 2nd Edition (2001) of IEC 6007915 is not acceptable In accordance with the requirements for Zone 2 In accordance with the requirements for Zone 2 (continued) AS 1482 Ex v AS/NZS 60079.5 Ex q AS/NZS 60079.6 Ex o In accordance with the requirements for Zone 1 AS 2380.7 (see Note 1) AS/NZS 60079.11 AS/NZS 60079.18 AS 1826 IEC 60079-33 (see Note 2) In accordance with the requirements for Zone 0 Applicable Standards and designated symbol Remarks

Pressurized rooms or pressurized enclosures Increased safety

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TABLE 1 (continued)
Description of explosion protection technique Zone 20 Intrinsically safe AS 2380.7 (see Note 1) AS/NZS 60079.11 Ex ia AS/NZS 61241.11 Ex iaD AS/NZS 60079.18 Ex ma AS/NZS 60079.31 Ex ta AS 1826 Ex s IEC 60079-33 Ex s (see Note 2) In accordance with the requirements for Zone 2 Applicable Standards and designated symbol Remarks

Encapsulated Dust enclosure protection Special protection Zone 21 Intrinsically safe

AS 2380.7 (see Note 1) AS/NZS 60079.11 Ex ib AS/NZS 61241.11 Ex ibD AS/NZS 61241.18 Ex mD AS 2236 DIP AS/NZS 61241.1.1 DIP A21 AS/NZS 61241.1 Ex tD A21 AS/NZS 60079.31 Ex tb AS/NZS 61241.4 Ex pD AS 2380.4

Encapsulated Dust enclosure protection

Pressurized enclosures Pressurized rooms Zone 22 Dust enclosure protection

AS/NZS 61241.1.1 DIP A22 AS/NZS 61241.1 Ex tD A22 AS/NZS 60079.31 Ex tc

NOTES: 1 2 Superseded Standard. Under development

3.8 SELECTION OF SERVICE FACILITY The owner or operator of the equipment requiring repair or overhaul should ensure that the service facility has available (either in-house or through subcontracts) all the equipment and facilities to allow completion of repairs and overhauls it attempts without compromising the quality and effectiveness of the repair or overhaul. Third-party quality and technical surveillance schemes assist the equipment owner/operator to achieve this requirement, with periodic reviews of service facilities against a specific standard, providing a higher level of confidence that inspections, repairs and tests are completed to the highest possible standards. The recently established ANZEx Service Facility Certification Scheme also ensures technical governance of the individual surveillance bodies and a consistent level of reporting service facility capabilities. Selecting a repair or service facility without the appropriate requirements increases the likelihood that the equipment may not be compliant with certification/approval documentation. 3.9 SERVICE FACILITY CAPABILITIES The service facility should possess all the equipment and facilities to do overhauls and repairs, and operate a management system that ensures the quality and effectiveness of overhauls and repairs. Appendix A identifies key elements of the management system.
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A service facility may subcontract work to an outside facility, provided that the service facility is responsible for the assessment of and compliance with the Standards and certification/approval documents. A workshop that requires recognition for the overhaul and repair of an Ex component must be able to satisfy the following basic requirements as required in MP 87.2 and they must have the in-house knowledge, skills, equipment and required competency to fully undertake the following: (a) (b) (c) (d) The initial assessment, inspection and tests to ascertain the incoming Ex condition and functionality. The ability to restore worn, failed or damaged equipment to its original compliance, and robustly retain this specification in future service. The final assembly, inspection, tests and reporting to ensure Ex compliance and functionality. Notwithstanding the capabilities of a subcontracted third party, the repair facility should conduct rechecks on the repair work and include this report documentation with all other job sheets for inclusion with the final report.

3.10 WORK FLOW 3.10.1 Overview In most cases the management of equipment sent to a service facility for overhaul will follow a common sequence of events. Typically, the equipment will be logged and inspection documentation prepared prior to an initial inspection to identify features demanding attention in the overhaul process. It is normal practice to allow the service facility to strip and quote, and to develop an agreed work scope based on its findings. The initial inspection by a competent person will result in a comprehensive report that should form the basis for the scope of works associated with the overhaul. This scope of works should be confirmed with the owner/operator prior to the commencement of works. Service facilities are reminded that in cases where significant work is required to restore a piece of equipment to the condition described by certification/approval documents, it may be more cost-effective to consider full replacement of the equipment. Assuming owner/operator acceptance of the scope of works, overhaul should proceed under the supervision of a competent person. Guidance on possible outcomes of the overhaul is provided in Fig 3.1, while guidance on specific techniques and methods of verification is provided in subsequent sections.

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Goods inward review for ex equip

Is equip ex?

No

Overhaul as nonex equipment

Remove ex marking

Yes

Does customer want non-ex OHaul?

No

Return as scrap

Yes Document equip details

Contact customer and request verification dossier

Advise customer unable to ex-OHaul Yes

Enter equip details in job system

No Are they available? No Is equip Group 1? No No

Yes
Do you have cert documents?

Obtain authority from customer and obtain

Do you have the copy of manufacturing Standard?

Yes Yes Create OHaul document from certification documents Create OHaul document from Standards requirements No

Do you have OHaul document?

No

Yes Strip, inspect and measure fill in detailson report

Go to

Are there any nonconformance?

Yes

Can they be resolved? Yes

No
Are any repairs required?

Yes

Quote/report to customer

No

Complete OHaul and document

Attached OHaul label

Carry out final inspection and dispatch with OHaul documents

Place copies of OHaul documents in job file

Close job and archive

FIGURE 3.1 SERVICE FACILITY MANAGEMENT OF EXPLOSION PROTECTED EQUIPMENT

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3.10.2 Initial inspection Equipment submitted for repair or overhaul should be subjected to a preliminary examination to identify work necessary to allow the equipment to be returned to its previously certified condition. This inspection should take into account the outcomes of previous pre-overhaul inspections (if available), owner/operator comments associated with the return, known deleterious conditions associated with the working environment and use, and relevant documentation including safety alerts, certification/approval documentation, asset manuals and history. The inspection should be conducted in an orderly manner, typically from equipment identification to external and final internal examination. Owner/operator comments may lead the inspector directly to significant non-conformance, however these may describe symptoms rather than identify root causes. Care should be applied to ensure that all areas of non-conformance arising from a failure are identified and documented. This should consider both the sequence of failure and consequential damage that may arise. Inspections should, where possible, be conducted in a sequence that minimises unnecessary work. Where other certified parts are attached to the equipment, the attached parts should be checked for compliance with their relevant certification/approval documentation. A checklist for initial inspections of equipment is provided for each protection technique in the relevant Sections of this document. 3.10.3 Failure analysis Failure analysis should be conducted during the initial inspection process and during the review of past history (based on information from the verification dossier, owner/operator comments and safety alerts) on this equipment and against equipment having similar features (design/construction/operating environment). Failures of not-obvious underlying causes should be also investigated, e.g. associated equipment (pump or fan) causing premature failure of primary drive (motor). 3.10.4 Determination of conformity Following the initial inspection, the repair facility should establish all areas where the equipment under inspection is not in conformance with the specification parameters agreed with the client and the certification/approval documents. In establishing conformity, consideration should be given to the measurement capability of the workshop equipment. 3.10.5 Determination of pass/fail criteria The competent person should establish and document pass/fail criteria for explosionprotected characteristics of the equipment that is to be repaired or overhauled. Pass/fail criteria will be determined by certification/approval documentation, verification dossier documentation, protection techniques and owner/operator specification. The range and precision of measurement equipment can then be determined to fulfil the inspection, test and verification activities. 3.10.6 Exceptional circumstances 3.10.6.1 General Occasionally, repairs to explosion-protection characteristics on large equipment can be safely completed in-situ without relocating the equipment to a service facility. Where repairs are required to a removable part that is well defined in certification/approval documentation, the removable part may be transferred to a service facility for repairs. Alternatively, in-situ temporary repair that can be completed safely and that ensures the robust ongoing maintenance of the explosion-protection characteristics may be considered.

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3.10.6.2 Repair and partial acceptance of component parts of explosion-protected equipment In the event of damage to a component part of explosion-protected equipment, it may be possible to repair a well defined part at a service facility and refit the repaired part to the main explosion-protected equipment that remained (isolated) in the hazardous area. This procedure is unlikely to be suitable for component parts that require dynamic testing of the equipment, such as balance and/or load testing of rotating machines, but more likely to be suitable for doors on enclosures, etc. Although the service facility may receive only a component part, it must endeavour to fulfil all the usual inspections, tests and reporting functions that would be completed if the whole equipment item had been submitted, e.g. hydrostatically testing a large flameproof door after structural repairs, with the door bolted to a mock enclosure. Similarly, if a piece of defined equipment is delivered to the service facility missing a component, say a potted gland that has been left attached to the cable at the installation site, the service facility may continue the repairs or overhaul on the equipment and then carry out inspection of the gland at reinstallation, or leave that activity to a competent person employed by the owner/operation. In all of the these situations, the service facility must clearly report what equipment components had been repaired, and the relevant final dimensions, tests and inspections that have been completed to verify the equipment components and the main equipment item when the repaired component has been reinstalled. 3.10.6.3 In-situ temporary repairs of component parts in explosion-protected equipment In-situ repairs may be undertaken with the support of the operator with local site safety provisions. It is preferable that hot work or work with non-explosion protected tools is completed outside the hazardous zone. The operator will need to undertake a specific safety risk assessment for the work completion and any residual risk that a temporary repair may entail. Temporarily repaired equipment must be scheduled for permanent restoration at the earliest possible opportunity. Should a service facility be contracted to undertake an in-situ temporary repair, although this will need to be completed with the necessary cooperation of the site operator, it is the role of the service facilitys competent person to verify that the temporary repair has sufficient integrity to ensure that the explosion-protected characteristics have not been impaired. The competent person may need to devise alternatative test procedures or increase the detailed (in-situ) inspection frequency to ensure that the temporary repair retains the necessary explosion-protection integrity while in-service. An example of a temporary thread repair for flameproof equipment is detailed in Section 6. 3.10.7 Resolution of Scope of Works 3.10.7.1 General In establishing a scope of works the following considerations are relevant: (a) The service facility should consult with the owner/operator in defining the scope of work required in the various categories after ensuring that the equipment is of an appropriate type, and certification/approval documentation is available in sufficient detail to carry out all checks and tests, as required by the appropriate Standard. Once a repair/overhaul procedure has been established and accepted by the owner/operator, the repair facility should ensure that no variation to the scope of work is conducted without first receiving written acceptance of the proposed change from the owner/operator.

(b)

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3.10.7.2 OverhaulNo repair Compliance with current certification/approval and equipment identification is established by carrying out all checks, measurements and tests as required by the overhaul Standard. The results should be recorded on the overhaul and examination report. In some cases equipment may be found to be fully compliant with the explosion-protected Standards, however documentation is not complete or adequate. The documentation issues should be addressed as outlined in Clauses 3.10.7.5 and 3.10.7.6. 3.10.7.3 OverhaulRepair The competent person should establish the actions necessary to restore the equipment to the agreed condition. This should consider: (a) (b) (c) Rectification of the explosion-protection characteristics. Replacement of component parts. Processes to strip, repair and reassemble equipment.

3.10.7.4 Compliance documentation essentials National Standards for repair and overhaul of explosion-protected equipment highlight the essential requirements to verify adherence to the original certification/approval documentation. Safety components, critical parts and dimensions are defined in the manufacturers documentation and certification/approval documents to enable verification of the integrity of the explosion-protected characteristics of the equipment. The owner/operator of the equipment is required by AS/NZS 60079.14 to maintain a verification dossier (refer to Clause 3.6) that retains the necessary reference documentation for the service facility to validate the explosion-protection characteristics of the equipment to be repaired and/or overhauled. 3.10.7.5 Management of documentation inconsistencies For some equipment, the repair facility may be able to assess the equipment as compliant, while documentation is inconsistent with current expectations, or incomplete. Where inconsistencies in documentation are found that do not affect the explosion-protection status of the equipment, these should be drawn to the attention of the owner/operator for rectification. These inconsistencies should be clearly identified in the concluding reports. 3.10.7.6 Deficiencies in compliance documentation Should the service facility be confronted with a situation where certification/approval documentation is not available but sufficient information is available to identify the type of protection and Standard to which the equipment was manufactured, the owner/operator of the equipment needs to be consulted to obtain all available information to aid service to validate the integrity of the equipments explosion-protection characteristics. It should be noted that this practice is unacceptable in Group I and some explosionprotection techniques. As stated in AS/NZS 3800, repair and overhaul without compliance documentation is not permitted for the following equipment: (a) (b) (c) Equipment for Group I applications. Equipment certified as intrinsically safe Ex i. Equipment certified as encapsulated apparatus Ex m.

Where multi-group (i.e. Group I/II) equipment cannot be validated against the relevant certification/approval documentation and alternate means of validation are used, the equipment label plate and overhaul and examination report need to clearly state that the equipment is not suitable for use in a Group I hazardous area.

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For all other equipment, the recognized service facility needs to make every effort to obtain the certification/approval documentation prior to carrying out any repair. The effort to obtain the information needs to be fully documented, and included in the verification dossier for the equipment. Where the nameplate, and a copy of the original Standard to which the equipment was manufactured are available to determine the protection technique, the equipment may be repaired by or under the supervision of a competent person working in a recognized service facility. The owner/operator should recognize that service facilities are not explosion-protected equipment test authorities that test and verify the design compliance to Standards. Rather, they perform a quality service of returning equipment to a functional condition and validating the explosion-protection features typically set out in the equipments compliance documentation. The owner/operator may elect for a key item of explosion-protected infrastructure to be repaired or overhauled with limited availability of the equipments design characteristics, but must retain the responsibility to ensure ongoing safe use of the equipment. Typically, a risk assessment is carried out prior to the repaired equipment being installed. The risk assessment may identify that the overall consequence of reinstating this equipment is acceptable when full and detailed compliance documentation is not available for ongoing validation of the explosion-protection characteristics of the equipment. It is typical in contemporary OHS management that alternative proof of compliance must be available and it must demonstrate an equivalent or greater level of safety to AS, NZS or IEC Standards. Should a risk assessment be undertaken, it would be advisable to retain a copy of the report within the verification dossier for the equipment. The owner/operator may seek the assistance of the service facilitys expertise during the risk assessment. It may also be beneficial that this risk assessment be undertaken, prior to completion of the repair and overhaul, because some outcomes of the risk assessment may be required to be installed within the equipment while it is stripped down, e.g. the installation of additional temperature sensors. Should copy winding on motors be considered, refer to Section 5. Additional reporting requirements and special compliance label marking are required for repaired or overhauled explosion-protected equipment that has not been validated against original certification/approval documentation (refer to Clauses 3.10.13 and 3.10.14). 3.10.7.7 Insufficient information Where insufficient information is available to satisfy the requirements in Clause 3.10.7.6 or for equipment excluded from the alternative means of verification described in Clause 3.10.5, the equipment needs to be brought into line with the current applicable Standard. If this is the case, proof of compliance with the current Standard needs to be sourced. A certificate of conformity or other means that may be acceptable to the local regulatory authority should be obtained. Alternative management techniques as outlined in AS/NZS 2381.1 may be considered. This will require consultation with the owner/operator and lies outside the scope of the overhaul repair Standards.

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3.10.8 Changes to equipment 3.10.8.1 Changes to equipment described in certificate documents Changes to equipment described in certificate documents are defined as alterations. For such changes, the following should apply: (a) (b) The service facility should obtain the necessary certification/approval documentation. The service facility should sign an undertaking that the equipment still complies with the original certificate.

3.10.8.2 Changes not described in certificate documents, affecting the explosionprotection characteristics of the equipment Changes to equipment that affect the explosion-protected properties of the equipment that are not described in certificate documents are defined as modifications. Where such changes are performed, the service facility should attempt the following: (a) (b) (c) If the original certificate holder is still trading, the certificate holder should be notified prior to any work being undertaken. The service facility should attempt to obtain the necessary certification/approval documentation. Refer to Section 18 for certification options. The service facility should inform the owner/operator that the equipment no longer complies with the original certificate and that an application for a new certificate should be made. If the owner/operator does not wish to proceed with re-certification, the service facility may continue to repair or overhaul the equipment but should provide a report and clear statement that it is no longer suitable for use in a hazardous area and also remove the Ex marking from the equipment.

NOTE: Modifications that affect the explosive protection parameters of the equipment are not allowed, by AS/NZS 3800.

3.10.8.3 Changes not described in certificate documents, not affecting the explosionprotection characteristics of the equipment Some changes to equipment may not affect the explosion-protected properties of the equipment. Such changes can be considered providing that the following is applied: (a) Any proposed change not covered by the certificate should be assessed by a competent person who has independently verified qualifications and experience (e.g. units of competency 407 and 705 in AS/NZS 4761). The competent person should provide an assessment statement demonstrating that an equivalent level of safety is achieved according to the applicable Standard. The assessment may determine that additional testing is required under the applicable Standards. The assessment should, where possible, include consultation with the certificate holder. The assessment on internal equipment changes should demonstrate the following: (i) (ii) Adequate internal relief area to eliminate potential for pressure piling. Adequate techniques used for all arc fault limitation, electrical circuit protection and surface temperature limitation under normal and expected overload conditions.

(b) (c) (d) (e)

(f)

All documentation pertaining to the change, resultant tests and engineering assessments should be recorded and retained by the service facility.

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(g)

The equipment owner/operator and certification/approval holder should be advised of the alteration.

Changes not affecting explosion-protected properties may include the following: (i) (ii) An alteration to the equipment such as the addition, removal or relocation of hinge supports, mounts and glands. Replacement of internal electrical equipment by a component of similar physical size and identical or better rating, such as power contactors, overloads, control and monitoring apparatus.

(iii) To minimise the possibility of pressure piling occurring, the internal volume should not be increased by more than 10% in total from the original free volume when replacing internal components. (iv) Alterations to the layout form or function of the internal electrical arrangement under the following provisions: (A) The enclosure is of simple geometry, i.e. only square, rectangular or cylindrical with a taper not exceeding 10% and no overall internal dimension exceeding any other bymore than 4:1. The internal equipment is arranged so that at least 20% of each plane area cross-section is free to permit unimpeded gas flow to eliminate the potential for pressure piling. (Separate relief areas may be aggregated provided that each area has a minimum dimension of 12.5 mm in any direction.)

(B)

3.10.9 Repair Repair and reclamation activities must not degrade the explosion-protection technique. It is typical to use Ex-specific repair and reclamation processes and these are documented in the specific Ex technique Sections of this Handbook. When undertaking a repair or reclamation, the process would normally involve initial assessment of the equipment against compliance documents and drawings to determine the extent of repair or reclamation required. Depending on the extent of work, the competent person can determine a viable method of repair that will achieve not only immediate compliance, but also maintain compliance after the equipment is returned to service. 3.10.10 Verification of repair When selecting a repair process there are generally two paths to ensuring compliance. The first path is to complete the repair and then test the viability of the repair. The alternative path, for those processes that cannot be readily tested, is to follow a precise application method that ensures a consistent viable repair. For example, structural welding on a flameproof enclosure would require a hydrostatic pressure test to verify the integrity of the enclosure, however where actual testing is not applicable such as replacement of coatings, compounds or varnishing (e.g. the application of conformal coatings after component replace on intrinsically safe printed circuit board, Ex m compound replacement, vacuum impregnation of Ex e winding or the assemble of compression glands) the repair and assembly must consistently follow a manufacturers or workshops method of work to ensure the in-service viability of the repair when the equipment is installed in a hazardous area. After repair or reclamation, irrespective of the verification path, a thorough inspection must be completed to ensure the integrity of the repair and that compliance with certification/approval is retained. Verification should be against documented criteria. The results of the verification process and inspections must be recorded, including actual measurements that can be verified against the original measurements.

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3.10.11 Justification for the omission of verification tests If the competent person considers that a test or verification process detailed in Standards cannot be fulfilled, or is inappropriate for an item of explosion-protected equipment, then it is appropriate for the competent person to document that information in the compliance report and ensure the owner/operator is fully cognisant of the approach prior to returning the equipment to service. The reasons, justifications and considerations should be thoroughly documented in the job file. In these circumstances, alternative means to verify compliance as required by Standards and certification/approval should be undertaken. 3.10.12 Final inspection The final inspection is to be undertaken by the competent person to confirm that the specifications have been achieved and the equipment has been verified and tested for compliance. A detailed report identifying the scope of work undertaken, reclamation work completed, and measurements and tests undertaken is to be completed and forwarded to the owner/operator and a copy retained by the service facility. 3.10.13 Equipment compliance reporting As the work, tests and inspections on the equipment are being finalized, a report must be completed by the service facility and must include supporting documentation that will be provided to the equipment owner/operator for inclusion in the equipments verification dossier. Reporting requirements are specified in Appendix A. It is important that the owner/operator has an opportunity to review the completed work and verification report from the service facility prior to the installation of the equipment. A typical repair and overhaul must define the exact item of equipment, initial inspection finding, parts replaced, repairs completed, method of repair, statement of compliance and disclosure of final critical dimensions or observation that describe the explosion-protection characteristics. In all instances it is highly recommended that the work-scope and acceptance criteria are agreed prior to the work proceeding. At the completion of the repair and overhaul, the owner/operator should ensure a detailed report is received from the repair house identifying: (a) (b) (c) (d) Original condition of product, complete with dimensional and clearance data. Scope of work identified and agreed on. New dimensional data where repairs to these areas have been undertaken. Tests results.

This document should be filed in the verification dossier and supplied to the repair house for reference at the next repair or overhaul.
NOTE: Refer to Appendix C for sample report forms.

A more comprehensive disclosure will be required if the equipment is repaired without validation to certification/approval documents. This report documentation should include all of the following: (i) (ii) A repair and overhaul report. A statement that the repair and overhaul has been carried out in accordance with the relevant manufacturing Standard.

(iii) A statement that conformance of the equipment with the certificate of conformity cannot be guaranteed.
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(iv)

A statement that any special conditions of use have not been identified or considered in the repair or overhaul.

3.10.14 Equipment compliance labelling Repaired and overhauled equipment should be marked with the appropriate marking as detailed in national or international repair and overhaul Standards on the main equipment in a visible place. This marking should be legible and durable, taking into account all relevant environmental conditions. The marking should include the following: (a) (b) (c) (d) (e) The relevant symbol (see below). The repair and overhaul Standard number used for compliance verification. The name of the repairer or their, registered trademark and workshop certification No., The repairers reference number relating to the job. The date of the overhaul/repair.

The marking may be on a plate permanently attached to the repaired equipment. In the event of subsequent repairs, the earlier repair or overhaul plate should be removed, and a record made of all the markings on it. If an earlier plate has been removed and it had an inverted triangular symbol (as shown below), then the symbol on subsequent plates should also be an inverted triangular unless the repairer restores the whole equipment to full conformity with the certification/approval documents. Equipment that after repair or overhaul conforms neither to the certification/approval documents nor to the explosion-protected requirements in Standard should have all its marking details relating to the explosion-protected characteristics removed with the agreement of the owner/operator. The standardized symbols for marking cover two categories depending on the method of validating compliance of the explosion-protected equipment. Where the repair or reclamation is in accordance with Standards and the repairer has sufficient evidence of full compliance with the certification/approval documents and the manufacturers specification, either one of the following marks is to be used.

Where the repair or overhaul is validated in accordance with Standards but not the certification/approval documents, the following mark is to be used, provided that (i) the equipment altered during repair or reclamation has been judged by the repairer to still comply with the restrictions imposed by the overhaul Standard and the explosion-protection technique Standards to which it was manufactured. but the repairer has insufficient evidence of full compliance with the certification/approval documents; or

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(ii)

the Standards to which the previously certified equipment was manufactured are not known, but the requirements of the overhaul Standard and the current edition of the relevant explosion-protect ion technique Standards have been applied, but the repairer has insufficient evidence to assert full compliance with the certification/approval documents, then an assessment, by a competent person who has the appropriate units of competency (typically UTE NES 407 in accordance with AS/NZS 4761) has been conducted to verify compliance with the relevant level of safety prior to release of the equipment by the repairer.

In these situations the certification/approval labels should not be removed.

NOTE: The markings are required for the benefit of subsequent repairers and the only difference between the markings is the method of compliance.

Equipment that after repair or reclamation does not conform with the above should have its original manufacturers certification/approval label removed or altered to give a clear indication that the equipment is not certified, until a supplementary certificate is obtained to cover the repair or overhaul. If the equipment is returned to its owner before the supplementary certification is obtained the record described in the repair report should indicate that the equipment is not in serviceable condition and is not to be used in an explosive atmosphere area. It is advisable that this report does not look similar to a compliance report. Where changes mean the equipment no longer complies with the original certification/approval, the marking relating to the certificate of conformity or approval should be struck out on the compliance plate so that the equipment is not accidentally returned to service in a hazardous area. 3.10.15 Pre-delivery inspection It is advisable that the pre-delivery inspection be undertaken by a competent person that is not directly associated with the repair or overhaul so that a fresh set of eyes are used to confirm that the specifications have been achieved, documentation has been completed and the equipment has been verified and tested for compliance. This operation is normally undertaken prior to despatch of equipment. The equipment can then be packed for safe dispatch. The owner/operator should be advised that the equipment may be returned with conditions to be fulfilled prior to energising (the removal and blanking of ports, addition of lubrication fluids) to ensure maintenance of explosion-protected characteristics. 3.11 COMMENTARY ON MATERIALS 3.11.1 Introduction It is important to verify that materials used in repair and overhaul are as per original design specifications, or where permitted, compatible with original materials, in order not to introduce an inferior repair. For example, brazing on flamepaths is considered inappropriate due to likely dislodgement after thermal cycling. Replacement parts and reclamation materials must be suitable for their intended use and operating environment (e.g. the use of aluminium, lead-free solders, UV-sensitive materials, heat resistance and FRAS rating are some of the important issues to be considered).
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The following items are typical examples of materials requiring special consideration when undertaking repair and overhaul of explosion-protected equipment. 3.11.2 Aluminium and light alloys AS/NZS 60079.0 gives guidance on the chemical composition of aluminium components permitted in hazardous areas. The use of aluminium or light metal alloys in Group I applications should be avoided where practical. The use of light metal alloys or aluminium is only permitted if it complies with AS 3584 or AS 4871.1. 3.11.3 Cast irons Cast irons are commonly used engineering materials with higher carbon contents than steels. Their use is widespread on account of their low cost, ease of casting and ease of machining. Grades of cast iron are distinguished by their microstructure, which is determined by chemical composition and heat treatment. Different heat treatments after casting can yield different grades of cast iron from a common composition, although small additions of alloying elements are included to promote the formation of preferred structures in commercial foundries. Metallographic analysis is required to distinguish between grades of cast iron. The various grades of cast iron are described in AS 1830, AS 1831, AS 1832, AS 1833 and AS 2027. Grey cast irons (flake graphite cast irons) belong to a specific grade of cast iron requiring special attention, because they have very different properties to spheroid graphite or SG irons. Grey cast irons have microstructures containing flakes of graphite. The presence of graphite flakes causes the fracture surface to be grey in colour and can cause the metal to be very brittle. The incidence of brittle failure is promoted by in-service damage or preexisting manufacturing stresses and may be initiated by an apparently minor stress. The use of grey cast irons demands higher care in high-integrity applications such as explosionprotected enclosures. Some explosion-protected enclosures include components of grey cast iron and consequently, service facilities must be aware of the materials of construction. Components contributing to the explosion-protected properties of an enclosure that are suspected of being grey cast iron may be confirmed by one of the following means: (a) (b) (c) Reviewing materials of construction listed in the manufacturers drawings. Contacting the manufacturer to confirm the materials of construction. Undertaking metallurgical microstructural analysis. This may involve cutting a sample, or in-situ polishing and replication, or visual examination using a metallurgical microscope.

Where components contributing to the explosion-protected properties of an enclosure are suspected (or have been confirmed by one of the means above) of being grey cast iron, the service facility must perform additional verification work. All such enclosures should be over-pressure tested, or magnetic particle tested, irrespective of the category of work performed at time of repair or overhaul. 3.11.4 Corrosion inhibitors (grease) and their application Where required, only suitable lubricants or corrosion inhibitors should be used on flanges, spindles, push-button operators and the like (refer to AS/NZS 60079.1). Some lubricants have extremely low flashpoints and under conditions of a temperature increase, spark or internal explosion could enhance flame propagation or aid flame transmission through a flamepath. It is standard industry practice to obtain the material safety data sheet (MSDS) from the manufacturer or supplier with all chemicals and compounds used in commercial and industry environments. The MSDS will define the necessary characteristics to be considered, such as flashpoint, toxicity and corrosives. A
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further important aspect that may not be readily determined from the MSDS is the chemical/compounds reaction to insulation materials, conformal coating or reduction in comparative tracking index. Two corrosion inhibitors are commonly used with explosion-protected equipment, mostly to protect flamepath surfaces from corrosion. One inhibitor is a fluid type and the other is a thicker grease, however both are lanolin-based and thixotropic in performance. A thixotropic gel displays a reduced viscosity on the application of a finite smear, but recovers its original viscosity when the smear action is discontinued, thus the gel maintains a self-restoring compound. AS/NZS 60079.1 states that A corrosion inhibiting grease may be applied to joint surfaces before assembly. The grease, if applied, should be of a type that does not harden because of ageing, does not contain an evaporating solvent and does not cause corrosion of the joint surfaces. Verification of suitability should be in accordance with the grease manufacturers specifications. Overcoating with this product is not recommended because it can lead to exfoliation of any rusted areas. It is recommended that it is applied then wiped off to leave a smear coating with just a greasy feel. The thicker grease is recommended in damp areas to limit moisture ingress at flamepath joints. However, this should not be a substitute for a properly designed moisture barrier required to achieve specific IP compliance. Caution also needs to be taken to ensure that the corrosion inhibitors application does not contribute to a variation in enclosure reference pressure. Operators are cautioned that silicon-based corrosion inhibitors and lubricates can be detrimental to gas detectors, d.c. commutators and binding of bolts. Some corrosion inhibitors may still exhibit an approval number from the former Mines Department approval scheme, however these approvals have not been supported for over a decade and no verification occurs that the current product retains the same composition to the previously approved inhibitors. Therefore, the service facility needs to verify that the compound is suitable for use in a hazardous area. 3.11.5 Insulation materials When selecting insulation materials the following should be taken into consideration: (a) (b) (c) (d) (e) (f) (g) Dielectric strength. Temperature rating. Sheath hardness. Comparative tracking index (CTI). Physical properties (strength, moisture resistance, etc). Chemical properties (anti-embrittlement and suitable resistance to environmental contaminants, etc). Solid flow properties (resistance to material flow from a gland).

3.11.6 Plastics and rubber When sourcing plastic materials, care needs to be taken to ensure the selected material will not introduce an electrostatic discharge hazard into hazardous areas. AS/NZS 60079.1 defines acceptable material parameters that may be introduced into a hazardous area that possess a risk of significant electrostatic charge accumulation. When these limits are exceeded the material must be verified by a test authority as acceptable for use in a hazardous area.
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Materials must also be verified as being fire retarding. Therefore, materials rated as FRAS (fire retarding anti-static materials) should be used wherever possible. In some hazardous area installations ventilation is restricted and personnel may be exposed to fumes from burnt plastics and/or rubber compounds. Consequently, it is important to consider the toxicity of any by-products. This might occur when a material is exposed to excessive heat. 3.12 COMMENTARY ON INSPECTION TECHNIQUES 3.12.1 General The fundamental inspection skills of a competent person are based on their familiarity with the equipment subjected to overhaul, the operating environment of that equipment and their understanding of common failure modes for the equipment and environment. An eye for detail and for conditions that dont look right may lead the inspector to identify otherwise unnoticed forms of equipment failure. While there is a tendency in some industries to use checklists in a tick and flick manner, careful inspection may identify signs of heat stress in cables and insulation, or traces of dust or moisture inside enclosures that demand further investigation. In many items of equipment, the explosion-protection properties are highly dependent on precise dimensional characteristics that are required to be confirmed or determined during overhaul. Overhaul facilities should be familiar with the conduct of a range of measurements, covering dimensional, thermal, electrical and electronic quantities. The following subclauses offer some guidance on the selection and use of a range of commonly used measuring equipment. For further guidance please see Appendix B. 3.12.2 Mechanical inspection techniques and equipment 3.12.2.1 General A surprising number of Ex protection techniques are dependent upon mechanical inspections and determinations of critical quantities. Mechanical inspections are one of the key determining factors where repairs are to be undertaken, especially when testing is not typically expected (e.g. maintenance for the IP rating) or testing is not conducted unless a mechanical flaw is detected. However, many explosion-protection techniques are almost wholly dependent on critical linear dimensions being met, such as the performance of Ex d equipment, but also linear clearances also relevant in Ex e and Ex i equipment. Fortunately, in Australia, there is a comprehensive technical infrastructure, and a number of types of common measuring equipment that are described in Australian Standards. Many factors contribute to a reliable measurement, and these are handled in some detail in HB 86.1. It is good practice to perform before-and-after confirmations of equipment performance to establish continued suitability of the measuring equipment. All measurement equipment used to determine the explosion-protected characteristics of repaired or overhauled equipment will need to be periodically calibrated so that they are traceable to SI units of measurement. Calibration activities are aligned with the expected scale and range of measurement to be undertaken in the compliance verification of explosion-protected equipment.

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3.12.2.2

Inspection and maintenance of IP rating

IP-rated equipment is very prevalent in industry environments and the IP characteristics of this equipment may also contribute to its explosion-protection properties. While an IP rating is achieved through a certification type test and is therefore a property of the design (not a property of individual items of equipment) ., During overhaul, the components and arrangements necessary to the IP rating may be affected. There is typically no requirement for a workshop to perform the reasonably complex IP testing on an overhauled item of equipment. Nonetheless, a workshop must verify the IP rating to its best ability and local means. Inspection of the mechanical parts for degradation, erosion of mechanical surfaces, or loss of elasticity or damage to O-rings or gaskets is an essential activity. However, tests may be devised to indicate the viability of the equipments IP rating by verifying the short-term retention of a pressure slightly above, or a vacuum slightly below, atmospheric pressure applied to the enclosure via a convenient access point. 3.12.2.3 Length measuring techniques and devices The application of length-measuring equipment needs to be carefully considered to determine an accurate portrayal of the equipment condition and that the measured results are repeatable. It is unlikely that service facilities will need laboratory-grade measurement instruments, but the industry-grade instruments typically used in a service facility still require careful handling, regular calibration and correct application. 3.12.3 Electronic inspection techniques Electronic inspection and repair techniques are highly specialized and have been developed by equipment manufacturers utilizing specialist skills and equipment, therefore it may be necessary to refer to the OEM for guidance. The circuit design and component list may be held as the intellectual property of the manufacturer and unless these items are available, repair of electronic equipment should not be undertaken. 3.13 MECHANICAL REPAIR PROCESSES 3.13.1 General This Section provides guidance on the applications of a range of commonly-used mechanical repair processes. For many techniques, achieving repairs of an integrity appropriate to the high-risk application of explosion-protection demands additional care beyond that encountered in basic workshop practice. Any reclamation should be carried out by competent personnel, skilled in the processes to be employed and using good engineering practices. Operators of reclamation techniques (e.g. welding, metal spraying) must show their level of competence by undertaking a practical skills test in the technique before being permitted to utilize the technique for the first time, then every three years thereafter. If the operator has not used the technique in the previous six months they should undertake a re-test. If any proprietary process is used, the instructions of the originator of the process should be followed. All reclamation should be properly documented and records retained. Such records include: (a) (b) (c) (d) Identification of the component part. Method of reclamation. Details on any dimensions that differ from those in relevant certification/approval documents or the original dimensions of the component part. Drawings showing reclamation details including material removed and replaced.
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(e) (f)

Date. Name of the organization carrying out the reclamation.

If the reclamation is carried out other than by the owner/operator or service facility, the owner/operator and service facility should be provided with a copy of the record. A reclamation procedure that would result in dimensions or other integral aspects affecting explosion-protection integrity being different from those given in relevant certification/approval documents is considered inappropriate without additional certification. In the event of any uncertainty regarding the permissibility (from an explosion-protection safety point of view) of an intended reclamation procedure, the advice of the manufacturer or certifying authority should be sought. It will be necessary to carry out tests afterwards to verify that the reclamation procedure is acceptable. 3.13.2 Welding 3.13.2.1 General Workshops are reminded that Ex equipment enclosures may be subjected to extreme service conditions. Weld repairs must ensure that the mechanical properties of the repaired item are not significantly altered by the methods of repair. Weld repair is a common technique used for both rectifying defects and imperfections and for deposition of additional metal prior to machining. However, welding techniques can have a significant impact on the properties of the repaired item. Every effort must be made to ensure controlled welding conditions. In particular, the heat employed in welding can cause internal stresses that cause distortion in adjacent structures. Welding on mounting structures as well as on enclosures can cause distortion that impacts on the integrity and functionality of enclosures, and close tolerance dimensions should be rechecked after the completion of welding. 3.13.2.2 Materials of construction

Materials of construction will determine the approach to repair of explosion-protected enclosures. Some materials, such as cast iron, SG iron and phosphor-bronze have limited weld-ability. Before attempting any weld repair the suitability of the materials of construction must be established from relevant certification/approval documents. 3.13.2.3 Quality welding principles High-integrity welded construction is qualified through a two-step process. The procedure (combining configuration, consumables and welding parameters) is qualified through the creation of a test piece that is destructively tested. Other welding personnel may then be qualified (by using the same qualified procedure) to create a test piece that is examined non-destructively, through macroscopic examination or through destructive testing. This is detailed in AS/NZS 3992:1998. Some configurations have been used so extensively that further weld qualification is not required, just welder qualificationrefer to Table 2.1 in AS/NZS 3992. Because of the unique nature of many weld repair configurations, the following recommendations set out a means of qualifying welding in a manner equivalent to that used in the fabrication Standards The threaded hole repair configuration recommended by AS/NZS 3800 requires some form of qualification. The use of weld metal as an overlay deposit prior to machining should be addressed in a similar manner. (See AS/NZS 3992, Section 8.)

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3.13.2.4 Welding procedure qualification For most weld repairs it will be necessary to create a job-specific repair procedure that includes procedures to qualify and control welding. Workshops should qualify the proposed procedure by creating a defect equivalent to that being repaired, in similar material, perform the proposed weld repair and test to establish that suitable properties have been achieved. The tests applied should be agreed on by the parties concerned. Examples of suitable tests may include destructive tensile, bend and impact tests, macroscopic examination of the weld deposit, with hardness traverse, or stud pull-out tests, depending upon the nature of the repair. All welders doing the job must repeat this procedure using either the agreed test or a cut specimen demonstrating full fusion to qualify as a welder for the process. Procedures should be documented in a manner equivalent to AS/NZS 3992, Appendix B. 3.13.2.5 Typical considerations in welding activities 3.13.2.5.1 General There are many considerations in establishing a suitable weld procedure and service facilities are advised to consult with persons having appropriate expertise prior to undertaking and welding an item of explosion protected. 3.13.2.5.2 Welding joint preparation Items for repair must be gouged to remove all traces of cracking. This should be checked using a suitable non-destructive testing method, such as magnetic particle testing in accordance with AS 1171, Non-destructive testingMagnetic particle testing of ferromagnetic products, components and structures, or dye-penetrant testing in accordance with AS 2062, Non-destructive testingPenetrant testing of products and components for non-magnetic materials. Particularly when using weld metal deposition to fill holes or gouges, care must be taken to ensure that a suitable bevel is applied to promote fusion of weld metal to parent metal. While commonly used as a means of restoring damaged threaded holes, fill-and-tap techniques present particular problems regarding side-wall fusion and slag inclusions. Slagless techniques (such as GMAW) are recommended. Surfaces must be cleaned immediately prior to commencement of welding. 3.13.2.5.3 Welding position In large enclosures it may be necessary to weld in a position other than the preferred flat orientation. This should be considered when qualifying welding procedures. 3.13.2.5.4 Welding energy input In some instances, thin-walled enclosures may distort under high heat input. Heat input can also change the properties of adjacent parent metal. This is particularly relevant in metal deposition, such as gouge-and-hole filling activities, where heat is more concentrated than normally occurs in fabrication welding. 3.13.2.6 Post-weld testing Each item repaired should be subjected to relevant post-repair testing. Depending on the nature of the repair, this could include a non-destructive test (NDT), possibly radiographic examination in accordance with AS 2177, Non-destructive testingRadiography of welded butt joints in metal or ultrasonic testing in accordance with AS 2207, Non-destructive testingUltrasonic testing of fusion welded joints in carbon and low alloy steel. Acceptance criteria should be as per AS 1554 Part 1 grade SP. Weld-repaired enclosures should be subjected to a suitable and relevant mechanical test, such as a hydrostatic pressure test, or possibly a pull-test on a threaded stud.

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3.13.3 Metal spraying Thermal spray techniques are increasingly used to build up worn or eroded surfaces prior to re-machining to the desired surface finish. Thermal spraying melts a filler or feeder wire to droplets that are deposited onto the target surface. These droplets key onto the surface, with additional bonding provided through diffusion and other chemical/physical processes. The bonding of the sprayed droplets to the target surface, and to previously deposited material, is influenced by (a) (b) (c) (d) (e) target cleanliness; surface finish/profile; temperature of the deposited spray and cooling rates; deposition velocity; and physical and chemical properties and reactions between the target surface, the molten droplet and the entrainment media (typically air or inert gas).

Cleaning and grit blasting are important for substrate preparation. A rough and clean target area provides the surface needed for good bonding. Both chemical and mechanical bonding is relevant. Sprayed material cools rapidly, however the applied temperature remains important in promotion of diffusion bonding. In some cases, bonding can be improved through application of a pre-heat to the target surface, although the formation of oxidation products may impair the bonding. An increase in thermal and kinetic energy increases chances of metallurgical bonding. Poor deposition can result in a number of failure modes including (i) (ii) porosity; stress;

(iii) thermal shock; and (iv) cracking.

3.13.4 Sleeving Should the fitting of a sleeve be considered a form of reclamation, serious consideration must be given to the process and materials to be used because incorrect procedures can lead to development of a second flamepath or distortion of casing through effects of heat from brazing. Once the sleeve has been securely fitted, the surface is to be machined. AS/NZS 60079.1 states that the surfaces of joints should be such that their average roughness Ra does not exceed 6.3 m. This may be readily checked through the use of a surface roughness comparator. 3.13.5 Thread repair 3.13.5.1 General AS/NZS 60079.1 requires that the quality of threads be of medium or fine tolerance according to ISO 965-1 and ISO 965-3 In addition threaded fasteners are required to be in accordance with AS/NZS 60079.0:2008, Clause 9.2. These ISO Standards for thread form are reproduced in AS 1721.

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Thread form measurement is a technically involved activity demanding a deep understanding of the thread phenomena. AS 1721 recommends thread forms be verified by gauging in accordance with AS 1014. However, it is impractical for workshops to hold gauges for all thread forms likely to be encountered. As an alternative verification measure, the workshop should follow these steps: (a) (b) (c) (d) (e) Establish that the threaded fasteners provided with the enclosure are all similar and show appropriate markings. Conduct a visual examination for damage to the thread form. Confirm the depth of penetration and numbers of threads engaged. Perform a physical test to establish that the threads engage without seizing. Establish that the engaged fastener does not allow axial movement.

If any doubt exists to the suitability of threaded fasteners arising from these checks, the final arbiter should be gauging. Where uncertainty over the suitability of a threaded fastener exists, it is recommended that the fastener be replaced. 3.13.5.2 Reclamation of threaded holes Particularly when using weld metal deposition to fill holes or gouges, care must be taken to ensure that the hole is suitably prepared. This should involve the following Steps: (a) (b) (c) Removal of metal in excess of original hole depth. Ensuring a suitable bevel is applied to promote fusion of weld metal to parent metal. Thorough cleaning of the hole immediately prior to welding.

Although commonly used as a means of restoring damaged threaded holes, fill-and-tap techniques present particular problems regarding side-wall fusion and slag inclusions. Instead, GMAW techniques are recommended. Tapped holes must comply with the depth requirements of AS 60079.1 in order to accommodate threaded fasteners. After tapping, threaded holes should have their quality of reclamation verified through nondestructive testing for weld faults (typically inclusions, cracking and lack of side-wall fusion) and undergo a physical test involving the insertion of a stud and application of a tensile pull-out load. The applied load when testing a reclaimed threaded hole should reflect the load that would be placed on that hole during the conduct of the relevant hydrostatic test for the enclosure. 3.13.6 Bolt fitFixing bolts, studs and nuts Broken or missing fasteners should be replaced with the fasteners described in the certification/approval documents, or equivalent new fasteners where fastener information is not detailed in the certification/approval documents. Stud or bolt holes that could pass into the flameproof enclosure should always be blind holes, with a thickness of metal at the bottom of the hole of not less than 3 mm or one-third of the hole diameter, whichever is the greater. If, for reasons of construction, holes have to penetrate such enclosure walls, they should be plugged for not less than 6 mm or the diameter of the hole, whichever is the greater, by a screwed plug complying with thread pitch requirements, which is permanently fixed in place. Permanently attached studs should be screwed in place and securely fixed. No washers (plain or lock) should be placed under bolt heads, screw heads or nuts unless they form part of the original approval.

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For coal mines, bolt heads, nuts and the like used on flameproof equipment and enclosures should be suitably shrouded or designed (e.g. with a button or pyramid head so that they can only be loosened and removed with the aid of a special tool). A pyramid or buttonheaded bolt should only be used if the surface around the hole has been spot machined to ensure that the axis of the bolt is normal to the surface. Where replacement bolts are used, they should be of the same type, diameter, pitch and length, and at least the same tensile strength. Any broken or damaged attachment, which could affect the flameproof properties of an enclosure, should be replaced with a part that does not void the current certification. For Group II equipment, shrouding is no longer a requirement, however for Group 1 enclosures, shrouding is still a requirement. 3.13.7 Distortion repair Bent and distorted enclosures may be restored to their original shape. However, cold forming can change the mechanical properties of the parent metal, particularly in cast structures. Enclosures subjected to cold forming repairs should be subjected to a hydrostatic pressure test after repair.

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HB 239:2011

S E C T I O N 4 G E N E R IC T E ST IN G PROCESSES FOR VER I F I CAT I ON O F E XP L O S I O N - PRO T E CT I O N TECHN I QUE S

4.1 NON-DESTRUCTIVE TEST (NDT) Non-destructive testing techniques may be used by the repair facility to: (a) (b) (c) Identify volume defects (voids or porosity) in metal. Determine wall thickness of metal and bonded dissimilar metal materials (e.g. bearings). Locate and size cracks, both surface breaking and sub-surface.

Techniques available include: (i) (ii) Magnetic particle testing, which uses magnetic fields to identify and size surface and near-surface defects. Dye-penetrant testing, which uses coloured dyes to identify surface breaking defects, usually on non-magnetic materials.

(iii) Ultrasonic testing, which uses non-audible high frequency sound to locate and size cracks and voids in bulk material, and can be used to determine the thickness of materials. (iv) (v) Radiography, which uses gamma or X-rays to identify and size voids and larger cracks in bulk materials. Eddy-current testing, which uses magnetic fields to identify surface-breaking cracks in magnetic materials.

General testing techniques are specified in Australian Standards, but specific details and acceptance criteria will be job dependent. The selection of the most appropriate technique depends onof the following factors: (A) (B) (C) The configuration and materials of construction used in the equipment for overhaul. The presence of surface coating materials (paint) and surface finish used on the equipment for overhaul. The anticipated type and size of the expected defect.

Care should be exercised to ensure that the technique selected is appropriate for the testing task, and to establish that should defects be identified, they are evaluated for significance to the integrity of the item under test and/or to the integrity of the explosion-protection properties of the equipment. Non-destructive testing is a group of highly specialised techniques and overhaul facilities using NDT should be familiar with the relevant Standards, techniques and competence systems, or use an appropriately qualified subcontract supplier. 4.2 DIELECTRIC WITHSTAND (HIGH POTENTIAL OR HI-POT) TESTING 4.2.1 General Dielectric Withstand or high-potential testing is commonly abbreviated as hi-pot testing. Hi-pot is the term given to a class of electrical testing instruments that uses a power frequency test voltage to verify electrical insulation in finished equipment cables or other wired assemblies, printed circuit boards, electric motors and transformers.
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A hi-pot test verifies the insulation of a piece of equipment or component to identify excessive electrical leakage and deterioration in the insulation scheme. Under normal conditions, any electrical device will produce a minimal amount of leakage current due to the voltages and internal capacitance present within the device. Yet due to design flaws or other factors, the insulation in a piece of equipment can break down, resulting in excessive leakage current flow. This failure condition can cause shock or death to anyone who comes in contact with the faulty equipment. A hi-pot test applies a high voltage between a devices current-carrying conductors and its metallic chassis or screen. The resulting current that flows through the insulation, known as leakage current, is monitored by the hi-pot tester (detailed in the next Clause). The theory behind the test is providing a controlled over-stressing of the insulation scheme to verify its Dielectric Withstand performance for future service. In addition to over-stressing the insulation scheme, the test can also be performed to detect material and workmanship defects, most importantly small gap spacing between currentcarrying conductors and earth ground. When a piece of equipment is operated under normal conditions, environmental factors such as humidity, vibration, contaminants, and dirt can close these small gaps and allow current to flow. This condition can create a shock hazard if the defects are not corrected. No other test can uncover this type of defect as well as the Dielectric Withstand (hi-pot) test. 4.2.2 Hi-pot (high voltage, line frequency or Dielectric Withstand) test A hi-pot tester is a test instrument used to stress test the electrical insulation in a device or other wired assembly that could fail and cause someone to receive an electric shock. It generally consists of a (a) (b) (c) variable high (a.c.) voltage source; leakage current indication meter; and switching matrix to connect the high voltage source and leakage current indicator to all of the contact points in a cable or device.

Hi-pot testers may also have a microprocessor and a display to automate the testing process and display the results. A hi-pot tester can be very similar to a cable tester and often the two are combined in a single unit. In a commonly wired assembly, a hi-pot tester connects all circuits in common to ground. Each circuit is then individually disconnected from ground and connected to the high voltage. The current that flows is monitored to ensure that it is low enough. Typical test levels are twice the system phase voltage (U) plus 2500 V for high voltage equipment or twice the system phase voltage (U) plus 1000 V for low voltage equipment. These tests are generally done on each phase in turn, with other phase and auxiliary equipment bonded to ground. Where the testing configuration does not require a lengthy charging period to achieve the test voltage, the test duration may be just a few seconds. A testing configuration with lengthy cables may require substantial amounts of charging time to achieve the required test voltage.
NOTE: The above test voltages are for new equipment only. De-rating factors need to be applied to repaired and overhauled equipment (see AS/NZS 4871.1, Table H3). For further guidance on hi-pot testing, refer to AS/NZS 4871.1, Appendix H.

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WARNING: HI-POT TEST EQUIPMENT UTILIZES HIGH AC VOLTAGES OF 25KV AND GREATER. IT IS CRITICAL THAT SUITABLE SAFE WORK PROCEDURES ARE DOCUMENTED AND UTILIZED FOR THIS TESTING.

The hi-pot tester is intended for use by experienced electrical personnel only and requires the use of established safety procedures and proper personal protective equipment (PPE). The test is performed only on de-energized, out-of-service isolated equipment. The ramp-up voltage is usually about 2 kV/s and the hi-pot tester should be wound fully down at the end of the task to avoid injecting extremely high voltage spikes into the tested equipment. Care should be taken to ensure the equipment under test is completely discharged (noting that some equipment has the tendency to recover charge), at the end of the test prior to disconnecting the hi-pot tester. 4.3 INSULATION RESISTANCE An insulation resistance test is necessary to ensure that the insulation resistance between all live conductors and earth or, as the case may be, all live parts and earth is adequate to ensure the integrity of the insulation. Refer to AS/NZS 4871.1, Appendix H for the insulation resistance test procedure and acceptability of results. 4.4 COMPONENT TESTING 4.4.1 Circuit breakers The testing of circuit breakers for use in explosion-protected equipment can be performed at the service facility. There are a number of different methods of achieving this. The most common method is by current injection where a test unit injects a set current and measures the time taken for the circuit breaker to trip. The results of multiple tests at different currents may be plotted and are compared with specified current and time curves that are usually supplied by the circuit breaker manufacturer. Test units should be accurate to within a few percent. The results of circuit breaker tests are supplied as part of the overhaul report. Together with these tests the report should note the units general physical condition, and include comments on the condition of contact tips, under voltage trip units and no volt trip units, if applicable. The test units details and a calibration date (if relevant) should also be noted. 4.4.2 Overloads Overload testing is similar to testing circuit breakers, using the same test rig and the appropriate manufacturers test curve. The maximum current, the condition of the overload, condition of any heaters, external condition of the unit under test and the results at various stages of the test should be recorded. 4.4.3 Current transformers 4.4.3.1 Primary injection testing This test is used to test the overall operation of a current transformer. In this type of test, a high current is injected in the current transformer (CT) primary winding and the resulting secondary current is measured in each secondary CT. This test is mainly conducted during a major circuit modification or rewire. This is part of the overhaul process. The polarity of the current may also be critical and other equipment, such as a phase angle meter, may be used in conjunction with the high-current test source.
NOTE: Care should be taken to ensure that the current transformer is always connected. Open circuit secondary windings can produce very high voltages.

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4.4.3.2 Secondary injection testing This test is performed on the individual devices, such as relays and meters, to verify the accuracy and proper operation of the equipment. These devices receive their input current from the CT secondary winding so these tests are at a much lower level of current than that used for primary injection. The correct operation of the current-sensing protective equipment can be verified by comparing the device operating characteristics with the manufacturers published time-current characteristic curves. Ensure that the equipment nameplate data complies with drawings and specifications. Every CT test sheet should include the information included in AS 1675. 4.5 TEMPERATURE MEASUREMENT Monitoring of temperature is undertaken during numerous test processes, including the following: (a) (b) Motor and transformer load and no-load testing. Winding removal.

Temperature sensing can take the form of contact, infra-red or embedded devices. Other less frequent forms of temperature measurement may also be employed.

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SECT ION 5 OVERHAU L O F ROTAT I NG MACH I NES

5.1 GENERAL Unlike enclosures, rotating machines generally cannot be routinely inspected in the field application due to the spigot design, mounting arrangements and inaccessibility of the plant. Therefore, when conducting a repair or overhaul, it is imperative that the rotating equipment leaves the workshop in a condition that will retain its explosion-protection characteristics until the next scheduled overhaul. The importance of correct repair and overhaul of rotating machines is critical to ensure the performance of the machine is returned to original manufacturers design, performance and construction. Key issues affecting performance relate to heat generation, the mechanical damage caused by stress, impact and vibration, and the structural strength of the enclosure. Other key factors to consider are the degree of protection, winding data, condition of bearings housing and journals, terminal boxes and termination blocks as well as water jackets (when applicable). This Section endeavours to highlight specific areas that require attention when conducting repairs and overhauls on Ex rotating machines. 5.2 REPAIR/OVERHAUL When conducting the repair or overhaul, the objective of the repair facility is to identify the cause of any failure and submit recommendations to be considered to limit possible reoccurrence and to ensure the piece of equipment is returned to the owner/operator fully complying to the applicable certification/approval documentation. Due to the importance of ensuring compliance to certification/approval, the repair facility should ensure that only competent persons (defined in Section 3) are utilised to work on this equipment during repair and overhaul. In the event that repairs by third parties are involved, the repair facility must ensure that the third party understands the importance of compliance, has the capabilities to carry out the work, and has the ability to test for compliance after completion of the repair.
NOTE: Both the ANZEx and IECEx equipment certification schemes require regular audits of manufacturers to verify continued manufacture of equipment in a certified condition. Unless certification specifically allows the use of non-OEM parts and components, then only OEMsupplied parts and components should be used. The use of non-OEM parts and components may invalidate the certificate of conformity.

Notwithstanding the capabilities of the third party, the repair facility should conduct rechecks on the repair work and include this report documentation with all other job sheets for inclusion with the final report. Following the inspection, the repair facility will be able to identify a detailed scope of work, which identifies the possible cause of failure (if applicable), a possible course of action to ensure re-occurrence is limited, whether it is economical to proceed with repair and overhaul and any other alternative option that could arise, bearing in mind the need to maintain compliance to the hazardous area and type of protection required. Ideally there should be designated hold points where discussion is held with the owner/operator to review the status of the job. This should be conducted with the competent person or a designated person who fully understands the type of protection involved.
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The scope of work should also have re-verification points for reworked/repaired components. Past experience has shown that the use of components or parts supplied by a source other than the manufacturer can be quite dangerous and may also result in the piece of equipment not meeting the certification/approval documents. These issues arise mainly because of a difference in the materials used or in some instances by incorrect dimensions, brought about by copying worn components. It is highly recommended that if components require replacement, these are acquired directly from the original manufacturer. In the event that the manufacture or his representative no longer exists, then the recommendation should be to replace the complete unit with a new fully compliant item. 5.3 OWNER/OPERATOR RESPONSIBILITIES Having acquired a piece of rotating equipment for use in a hazardous area, the owner/operator is responsible to ensure that they are in possession of the following material (a) (b) (c) Certification/approval documentation. Maintenance and installation manuals. Any relevant documentation referring to special instructions or tools applicable for installation and maintenance of the equipment, in accordance with the certification/approval documents and other regulatory requirements.

This documentation is available from the manufacturer and should be filed for future use in each repair and overhaul, then filed in a verification dossier and retained by the owner/operator of the equipment. Prior to powering up the item initially, the owner/operator must ensure that the equipment complies with documentation, documents have been received, the termination of power leads is in accordance with regulations, gaps where applicable have been checked and recorded for compliance and installation is in accordance with regulations. By design and the location, it may be difficult to conduct regular maintenance/inspections for compliance to certified documentation. Therefore, the designated person should establish a routine schedule to ensure the equipment is appropriately removed from service for inspection, repair or overhaul. 5.4 QUALITY-MANAGED ASSESSMENT STRATEGIES Due to the difficulty of routine site inspections and the critical importance to ensure that explosion protection is maintained, it is recommended the service facility introduce a quality programme for rotating machines repair and overhaul, including procedures and where applicable acceptance criteria for (a) (b) winding removal technique; controlled temperature burn out oven temperature and method of measurement with relevance to the inter-laminar core insulation types. These insulation types include organic and oxide insulants; refurbishing of materials to be re-used (with material and dimensional acceptance criteria); re-design of windings if allowed within certification/approval (establishing equivalence of machine-wound and hand-wound coils); test of old core (after stripping, before and after winding);

(c) (d) (e)

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(f) (g) (h)

core loss evaluation (if required as criterion for proceeding with rewinding); Testing of rotating parts (rotor assembly or laminated core, cage winding, pole face dampers, spider cracks, rim bolts, permanent magnets); specifications and installation procedures for new windings, wedges and winding overhang support systems (vacuum-pressure impregnated or resin rich), armature overhang banding); testing of vacuum/pressure impregnation processes, type and frequency of resin quality tests (dielectric tests pre and post-curing); commutator repairs (bar-to-bar tests, over-speed tests, seasoning); banding of armatures (type and composition of bands); brazing of cages (braze alloy to exclude phosphorous if motor used in a hydrocarbon or H 2 S atmosphere); leakage test of cooler and cooling circuits; material acceptance for anti-corona tapes and paints; performance and quality of anti-corona tapes and paints after application; acceptance of run-out and balancing results; acceptance of rotor electrical tests after balancing; acceptance of results of magnetic core proving; dismantling and restacking of magnetic cores and poles;
NOTE: Because these procedures will require the re-stacking to be under pressure, it is recommended that the owner/operator ensures that the repair facility has the capability to carry out these procedures, otherwise the original manufacturer should be consulted or undertake to complete the procedure.

(i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s)

(t)

performance verification reference documents, which include IEC 60034-1, IEC 60034-2, IEC 60034-2A, IEC 60034-3,IEC 60034-4, IEC 60034-9, IEC 6003410, IEC 60034-11, IEC 60034-12, IEC 60034-14, IEC 60034-15 and IEC 60034-16; determination of pass/fail criteria for critical dimensional checks, the water flow test and the water jacket thickness test from certification/approval drawings, and the recording of test results to establish the pass/fail status.
NOTE: Pass/fail determination and status verification should also be verified following repair work carried out by third-party facilities.

(u)

5.5 EVALUATION PROCEDURES FOR ROTATING MACHINES 5.5.1 General It may be necessary to conduct preliminary processes prior to removing a piece of equipment for repair or overhaul. In these circumstances it is recommended that as much operational information as possible prior to shutdown of power is obtained. The following pages provide some scenarios. 5.5.2 Before power shutdown (typically for large machines only, i.e. 1 MW In order to establish the correct operating conditions of a rotating machine that is to be repaired/overhauled it is strongly recommended that before shutdown (on-load or no-load, excited or unexcited, as applicable) the following conditions and parameters are established: (a) Operating voltage, current, power factor, speed and frequency.

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(b)

Operating characteristics needed for re-design if applicable within certification/approval (for example, open-circuit or short-circuit curves for d.c. machines and generators). Voltage unbalance and harmonic distortion (for example, motors for run-up of gas turbines and pumped storage machines). Current unbalance or fluctuation, or spectral analysis. Leakage flux spectral analysis (for example, industrial motors). Ambient temperature, humidity, air pressure or altitude. Ozone emission of machine windings (windings with high electric stresses). Brush sparking inspection (commutator and slip ring machines). Commutation test (IEC 60034-19), d.c. machines. Bearing temperatures (where sensors are fitted). Bearing and shaft vibration (where sensors are fitted). Coolant temperatures, flows, pressures (where sensors are fitted). Winding temperatures (where sensors are fitted). Winding vibration (where sensors are fitted). Lubricant temperatures, flows, pressures (where sensors are fitted). Core vibration (where sensors are fitted). Frame vibration. Shaft voltages and currents. Stator winding insulation partial discharges or dielectric loss analysis (bars or formwound coils with high dielectric stress). Rotor cage integrity. Rotor winding inter-turn insulation (impedance measurement) for cylindrical rotors. Rotor winding ground insulation resistance for wound rotors.

(c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v)

5.5.3 After shutdown In the event that the equipment is to be removed to a service facility it is strongly recommended that footprint positions are clearly recorded to aid in alignment checking when the equipment is to be repositioned. This task is to be completed before any work is undertaken to remove hold-down bolts. It should also be noted that in many instances shims are used to assist in achieving correct height alignment. Where these are found to have been used, correct recording of the quantity, position and thickness of each shim must be undertaken. 5.5.4 Before dismantling Upon receipt of the equipment at the repair facility an assessment should be undertaken to determine the following: (a) (b) (c) (d) Reference to documents from owner/operator. Cause or contributing factors of failure or work to be undertaken, as instructed by owner/operator. Visual external condition (for example, damage noted). Missing items.
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(e) (f) (g) (h) (i) (j) (k) (l)

Full nameplate data including certification references. When applicable, water jacket flow test. Shaft straightnessRun out. Electrical testsInsulation resistance of bearings, couplings, pedestals and shaft seals (where insulated). Stator winding insulation d.c. leakage currents (form-wound coils or bars). Stator winding insulation resistance and polarization index. Dismantle noting condition of bearing caps, bearings, end-shield spigots, stator flamepaths, etc. Dimensional checks of commutators and sliprings, journals, seal faces, shaft run-out couplings and bolts, shaft extensions, keys and keyways, and other parts subject to wear. Dimensional checks to stator housing ovality, spigoted joints, terminal boxes, terminal blocks and terminals including bushes where applicable. Rotor condition. Bearing fits on shaft. Bearing fits in housings. Bearing housing fits on frame. Rotor retaining ring crack testing. Rotor slot wedge crack testing. Rotor cage integrity (crack detection). Shaft forging and end-ring integrity (ultrasonic, dye penetrant, magnetic particle, as appropriate), solid cylindrical rotors. Shaft, spider, rim and through-bolt integrity (hydro machines). Winding condition. Fretting at winding, core, core/frame junction. Loosening of end-winding supports and bracing system. Statorrotor air gaps.

(m) (n) (o) (p) (q) (r) (s) (t) (u) (v) (w) (x) (y) (z)

(aa) Signs of electrical corona and tracking. (bb) Flashover. (cc) Single phasing. (dd) Surge damage. (ee) Cooler gaskets erosion marks on the heat exchangers. (ff) Burn damage between core plate dovetails and dovetail beams.

(gg) Insulation resistances of bearings, couplings, pedestals and shaft seals (where insulated). (hh) Insulation integrity of up-shaft leads, radial connectors and slip rings (solid cylindrical rotors). (ii) Insulation integrity of winding connectors, leads, and terminals.

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(jj)

Dielectric loss angle (DLA) (tan delta) testing of terminal bushings (high voltage machines).

(kk) Gas-tightness of up-shaft leads and radial connectors (hydrogen cooled machines). (ll) Core insulation integrity (power flux test, low flux test), before and after winding removal.

(mm) Diagnosis of the cause of the machine failure. (nn) For water-cooled motors de-scale the water jacket and conduct volumetric, pressure, flow and wall thickness tests to ensure compliance with certification/approval documentation.
NOTE: In the event that a rewind is required for an Ex e motor, the manufacturers original winding data is required or a full locked rotor test is required to ensure compliance to the tE time.

5.5.5 Rewinding Before undertaking a rewind the following information is necessary: (a) (b) (c) (d) (e) (f) (g) Type of winding, e.g. single layer, double layer. Winding diagram. Number of conductors per slot and parallel paths per phase. Interface connections. Conductor size. Insulation system, including varnish specification. Resistance per phase or between terminals.

NOTE: Winding data should be available from the manufacturer or the certified holder. The whole of the winding should be restored to the original condition, except that partial winding replacement may be possible on larger equipment. A partial winding replacement should only be undertaken after reference to the equipment manufacturer or the appropriate certification/approval authority.

5.5.6 Removal of windings The process for softening the impregnating varnish of damaged windings with solvents, before stripping, is acceptable. The application of heat in a controlled manner, via a temperature controlled burn-out oven, is acceptable provided that the operation is carried out with caution so it will not adversely affect the insulation between the laminations of magnetic parts. If in doubt, the advice of the equipment manufacturer should be sought regarding the inter-laminar insulation material used in a rotating machine classified as utilising the increased safety technique. An increase in core loss resulting from degradation of inter-laminar insulation can significantly affect the motor operation or cause the temperature class to be exceeded. As part of the motor rewind process the service facility should conduct a core-loss test following the removal of windings. Burn out ovens should be equipped with accurate temperature control and monitoring systems. They should also be fitted with water spray devices that activate automatically in the event of an over temperature alarm or ignition within the oven. 5.5.7 Before winding (a) (b) Casing and frame weld quality (certification) (welder qualification, if necessary). Frame and mounting integrity (weld integrity, crack detection, distortion).

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(c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o)

Shaft straightness. Shaft forging and end-ring integrity (ultrasonic, dye penetrant, magnetic particle, as appropriate), solid cylindrical rotors. Shaft, spider, rim and through bolt integrity (hydro machines). Core insulation integrity (power flux test, low flux test, acceptance criterion for rewinding. Core loss evaluation (refer to Clause 5.11). Core lamination stack tightness tests (stators, rotors, hydro machine rotor rims), acceptance criterion for rewinding. Winding material quality checks (to winding designers requirements). Winding support components fits and dimensions (in overhangs and slots) to winding designers requirements. Winding connector, lead and terminal insulation integrity. Bearing fits on shaft. Bearing fits in housings. Stator winding dielectric loss angle (DLA) (tan delta) tests on replacement bars and coils (HV windings only). Stator winding partial discharge tests on individual bars and coils (HV windings only). Stator winding dielectric tests with high voltage on each bar or coil (HV windings only).

5.6 ADDITIONAL NOTES FOR COPY WINDING The option for copy winding explosion-protected rotating machines may be considered when insufficient information is in the equipments verification dossier. Before any copy winding on motors is considered, it is expected that a competent person has verified what tests are required to maintain Ex compliance, and has confidence that the existing winding data is original. The first step in this would be a review of the verification dossier and equipment history, supplied by the owner/operator. A visual inspection of the winding, and comparison with the certification/approval data would then be undertaken. For example, during a standard motor winding, varnishing is found to be present, while the verification documents specify formed coils, with higher levels of insulation/varnish. Following the rewind of an Ex e motor, a locked rotor test at full voltage would be a minimum expectation to determine and verify the tE (stall time). 5.7 AFTER WINDING The following tests and inspections should take place after the winding has been installed (a) (b) (c) (d) Winding material quality checks (to manufacturers or winding designers requirements). Winding support components fits and dimensions (in overhangs and slots) to manufacturers requirements Winding connector, lead and terminal insulation integrity. Coil polarity checks.
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(e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u)

Rotor banding check. Rotor cage continuity check. Stator winding insulation tests. d.c. leakage currents (form-wound coils or bars). Insulation resistance and polarization index. Dielectric tests at high voltage (according to IEC 60034-1). Surge comparison test for inter-turn insulation (form-wound coils or bars). Dielectric loss tangent (DLA) and tip up (form-wound coils or bars). Partial discharge tests on form wound coils and bars and on random wound windings used on inverter fed supplies. Discharge location test (ultrasonic or peak pulse probe) form-wound coils or bars. Rotor winding insulation tests. Insulation resistance and polarization index. Dielectric tests at high voltage (according to IEC 60034-1). Inter turn insulation tests. Recurrent surge oscillograph (solid cylindrical rotors). Impedance measurements (hydro and solid-cylindrical rotors). Winding resistances (stator, wound rotors).

NOTE: Dielectric and inter-turn tests before vacuum/pressure impregnation are by agreement between the owner/operator and the service facility.

5.8 REPAIR OF ROTORS Rotors with faulty diecast aluminium cages should be completely replaced with new rotors obtained from the equipment manufacturer. Bar-wound cage rotors should be rewound using materials of equivalent specification. Particular care is necessary to ensure a tight fit if replacing conductors in a cage rotor. The same method used by the manufacturer to achieve the degree of slot tightness and end-ring connection should be used. 5.9 TEMPERATURE SENSORS In cases where additional auxiliary equipment is requested (e.g. anti-condensation heaters or temperature sensors) the manufacturer should be consulted to establish the feasibility of and the procedure for the proposed modification. Replacement or the retrofitting of temperature sensors or anti-condensation heaters should only be attached to existing windings after the correct procedure to undertake this task has been obtained from the manufacturer. 5.10 ENCLOSURES If minor damage to enclosures, terminal boxes and covers is to be repaired by welding or metal stitching, care should be taken to ensure that the integrity of the equipment is not impaired and, in particular, that it remains capable of maintaining the degree of protection.

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5.11 SPECIFIC TESTS APPLICABLE TO ROTATING MACHINES 5.11.1 General Depending on the scope of work to be undertaken, the repair facility should reach agreement with the owner/operator on the type of test that the repair facility undertakes as standard and what, if any, additional tests are required. It should also be noted that specific tests may be shown in the certification and therefore are a mandatory requirement to be undertaken. Typical tests are as follows: (a) (b) (c) (d) (e) (f) (g) (h) Insulation resistance. Continuity. Degree of protectionIP rating. Core loss testing. Full load test. Temperature rise test. Lock rotor test. Vibrationbase reading.

DLA, Partial Discharge testing, locked rotor and surge testing are destructive tests, to insulation and should only be conducted under strict supervision. 5.11.2 Core loss testing Stator core testing, often referred to a loop test, has proven effective in detecting shorted laminations in stator core iron. The test involves establishing a specific magnetising level in the core by energising loops of cable wound through the stator bore and around the outside of the frame. The circulating currents induced in the laminations will simulate core loss and heat up the stator iron. The approximate design core loss can be calculated from the core dimensions. The loop turns, required current and saturation point can then be calculated. The condition of the core can then be determined from the core temperature, input power and saturation point. The point-of-core saturation can be verified by use of a voltmeter connected to a separate loop of insulated wire passed through the core. The voltmeter reading can be plotted against the input current to the energising loop circuit to confirm saturation point. It is essential to monitor the core temperature at all points to detect any hot spots. Infra-red probes and thermographic devices are recommended for this.
NOTES: 1 2 Hot spots in the back iron may need 2030 min. of testing before they become evident on the surface of the core. The core is going to become hot during this process.

Further information on core testing can be found in EASA publications. Core loss should always be verified prior to and after winding removal to ensure that (a) (b) (c) the inter-laminar insulation has not been damaged; physical damage has not occurred to the core; and acceptance criterion for rewinding is achieved.

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5.12 SPECIFIC REQUIREMENTS FOR REPORTING ON ROTATING MACHINES It is important to monitor the life cycle maintenance of machines operating in hazardous areas. This is to ensure that the machine maintains its hazardous protection technique at all times during operation. The information detailed in reports by repair facilities should be comprehensive and up-todate, since the information can and would be used to review possible reasons for any consistent non-warranty failures. 5.13 SPECIFIC REQUIREMENTS FOR PACKAGING AND DESPATCH OF ROTATING MACHINES One might think that once a machine has been overhauled and tested the job is complete, but not so. The correct packaging of rotating machines is also a very important factor that must be addressed to ensure that the equipment is received at the site in a usable condition. Typical steps to take during packaging include: (a) (b) (c) Bearings should be locked to prevent brinelling, which will cause premature failure. Terminal box gland entries are to be closed off to prevent the ingress of moisture in the event of inclement weather. It is recommended that shaft locks be fitted as a mandatory requirement and that the machine should be packed in a manner that will minimise potential damage to any external component.

5.14 REINSTALLATION RECOMMENDATIONS FOR ROTATING MACHINES Factors to be considered during an installation include: (a) (b) (c) (d) (e) (f) (g) Correct alignment. Correct fitting of couplings. Correct fittings of cables and appropriate glands. Any additional advice given by the service facility. Maintenance of IP and EX rating, i.e. unused gland entries are appropriately blanked. Correct installation of monitoring equipment, i.e. vibration and RTDs. Correct setting of protection equipment, i.e. overloads.

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SECT ION
6.1 INTRODUCTION 6.1.1 General

EX d F L AMEPROOF EQU IPME NT

Flameproofing is an explosive-protection technique where the parts which can ignite an explosive atmosphere are placed within enclosures that can withstand the pressure developed during an internal ignition of an explosive mixture, and prevent the transmission of the explosion to the explosive atmosphere surrounding the enclosure. AS/NZS 60079.1 details the construction requirements for this equipment. The important aspects of the flameproof design guard against the following: (a) (b) Without suffering damage. Without causing ignition.

6.1.2 Without suffering damage Substantial pressures can be generated due to an explosion within a flameproof enclosure. Typical pressures are in the range of 2001000 kPA. It is most important that an enclosure can withstand the particular pressures that it may encounter in service. The pressure created by the explosion within the enclosure is released to the atmosphere so that the enclosure is not permanently deformed in a way that can impair the integrity of the enclosure. 6.1.3 Without causing ignition As the explosive pressure within an enclosure forces its way through the gaps in the enclosure, the explosion flame is carried with it. If the energy of the explosion is not reduced as it forces its way through the gaps, the explosion pressure front could have sufficient energy to ignite a surrounding explosive atmosphere. The gaps and joints in the enclosure are designed to act as energy sinks and reduce the level of energy in the accompanying explosion flame to below the level needed to ignite the surrounding explosive atmosphere. The specially designed gaps and joints in the enclosure are referred to as flamepaths. The first source of these flamepath dimensions is the certification/approval drawings. If not specified here then AS/NZS 60079.1 specifies the minimum requirements for the length of the flamepath and the allowable gaps or diametrical clearances. 6.1.4 Overhaul pre-requisites The overhaul of electrical equipment for use in hazardous areas is extremely important and should only be carried out under the guidance of a competent person. It is further recommended that any person working on equipment for use in hazardous areas has an understanding of the purpose and implications of the type of protection involved. Persons should have a minimum trade qualification and be proficient in the use of measuring tools, drawing evaluation and report writing with respect to flameproof equipment.

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6.1.5 Initial inspection The initial examination should ensure that: (a) All protective access covers are removed and flameproof enclosures and/or covers are inspected as follows: (i) (ii) Check that all marking plates/labels associated with certification/approval are securely in place and are complete and legible. Check for external and internal damage to the enclosure/case, including indications of heating, burning and spatter.

(iii) Check for indications of environmental penetration (dust, fluids) of the enclosure/case. (iv) (v) (vi) Where fitted (e.g. in Ex e and i equipment), check seals and O-rings for integrity. Examine flamepaths for signs of pitting, damage and deviation from true plane surfaces. Examine flamepath lengths for compliance with minimum length, as specified by the certification/approval drawings. This includes L and l.

(vii) Check all door and enclosure flanges thickness for compliance with the minimum allowable on the certification/approval drawings. If no minimum is specified on the certification/approval drawings, then refer to the guidelines in AS/NZS 3800. (viii) Examine all boltholes for hole depth, thread depth, thread form and condition, along with the correct amount of material behind blind holes, as specified by the certification/approval drawings. Where shrouds are fitted, check condition. (ix) Examine all fasteners for correct length, thread form, tensile strength and head type, as specified by the certification/approval drawings. Note: It is accepted industry practice to replace all fasteners as part of standard overhaul scope of work. Inspect all windows to ensure that the fixing medium is sound and serviceable, and that the lens is not damaged (look for cracking, scouring, impacts and other deterioration). If guards are fitted, also check their condition. Assess all push button/switch operators and measure the worst case. They should also be checked to ensure correct securing method.

(x)

(xi)

(xii) Remove and inspect spigot glands associated with electric motor junction boxes to assist in future motor change-out. (xiii) Check all hand-hole and inspection covers and their corresponding threaded holes for thread pitch, thread engagement, thread wear and locking devices. (xiv) Check all interlocking mechanisms for signs of wear. Cover interlocks and all mechanically actuated electrical interlocks forming part of the enclosure interlocking system should be checked individually and collectively for freedom from action and correct sequence of operation. (b) All electrical equipment associated with flameproof equipment should be tested and inspected, as follows: (i) (ii) Check all electrical equipment for correct mounting. Carry out insulation testing on all electrical circuits, low voltage and above.

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(iii) Check all cables for damage, including all machine cables and their associated cable protection hoses, etc. (iv) (v) Check all connections for signs of corrosion or heating. Check all protection devices (whether operated thermally, electrically or by pressure) for correct settings, and where test facilities are incorporated within the machine, correct operation should also be verified. Consideration should be given to the calibration, testing and verification of all primary protective devices, tripping values and operating times.
NOTE: This may require removal of protective devices and off-site verification.

(vi)

Check all earth connection resistance, including ensuring that any resistance is less than 1 between the earth connection and the machine frame.

(vii) Insulation resistance of transformers, operating at low voltage and above, should be checked between primary and secondary windings and windings to frame and core. (viii) Check all contactor mechanical interlocks for correct operation. (ix) (x) (c) Check all insulation to ensure it is clean and sound and no signs of overheating or cracking are evident. Check all insulation for appropriateness, ensuring no polycarbonates are within the vicinity of potential points of arcing.

Rotating machinery should be subjected to basic checks to establish continued operability as follows: (i) (ii) Insulation test. Voltage drop.

(iii) Free rotation. (iv) (v) (d) Functional. Overload tests.

Where the equipment incorporates a number of explosive-protection techniques, check that the installation complies with the relevant certification/approval documents or appropriate Standard, or both. These components should be checked for damage and should be within the recommended intervals for overhaul. On completion of the inspection, the competent person should produce a comprehensive report and record, taking into account the results of the pre-overhaul audit or review including: (i) (ii) The serial number and condition of each item examined. A list of parts and components supplied but not examined, and the reason for their omission.

(e)

(iii) All items that require overhaul. (iv) Details of any components that do not comply with the relevant requirements of AS/NZS 3800 or the certification/approval drawings. Rectification work required to ensure safety should be highlighted and brought to the attention of the owner/operator.

NOTES: 1 2 The certification/approval documents are the primary inspection criteria. Design standards should not be used where certification/approval documents are available. A typical report form is included in Appendix C.
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6.2 OVERHAUL It is essential to establish a scope of work for the repair and overhaul that is to be accepted by the owner/operator before commencing any work. Equipment should be received into the repair facility, externally inspected, photographs taken and electrical tests conducted, if applicable, prior to commencing to dismantle. Once the equipment has been fully dismantled and cleaned a full inspection of all components, measurements for compliance and repair procedures established are carried out and documented for issue to the owner/operator. The repair facility must insist that the owner/operator provide a copy of the certification/approval documentation for the equipment, together with history of previous overhauls, repairs or failures. Repair facilities cannot rely on drawings or documents they may have from some other overhaul of similar equipment, because some small changes may have been applied under a supplementary certificate. 6.3 REPAIR Where the work includes machining to flameproof surfaces, certification and approval will not be considered invalidated provided that the cumulative effect of such machining does not (a) (b) reduce the flanges below the minimums where the minimum dimension of the thickness of flanges is detailed in the certification/approval drawings; reduce the flange thickness more than 12.5% for internal flanges and 7.5% for external flanges, if nominal-only dimensions are detailed in the certification/approval drawings for the thickness of flanges; alter the volume of the enclosure (without internal parts) by more than 0.5%; reduce the length of any flamepath whether plain or threaded; or result in any deviation to the requirements of the relevant Standards.

(c) (d) (e)

Where any flamepath was originally grooved to relieve internal pressure, the grooving should be machined out and eliminated. This will not be regarded as a modification provided that the conditions required in Items (a), (b), (c) and (e) are satisfied and where explosion pressure tests are carried out in order to determine the new explosion pressure test figure and to verify flamepaths. After repair, the procedures in Clause 6.1.4 should be followed. 6.4 RECLAMATION Refer generally to Clause 3.13 covering mechanical repair processes. Metal spraying on flamepath flanges and spigots in considered an inappropriate practice. 6.5 CATEGORIES OF REPAIR The level of reclamation work completed on flameproof equipment needs to be categorised into major or minor repairs. It is the competent persons role to categorize the repairs. Major repairs include any repair involving thread replacement, rebuilding flamepaths, structural welding or any action that brings the enclosure integrity into doubt. These must be classified as a major repair and be verified by pressure test. Minor repairs are simple in nature, such as hinge replacements (where minimal heat is applied to the body of the enclosure) or a window lens replacement, etc.

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6.6 CHECKS AND REPORTING 6.6.1 General The safe use of electrical equipment in hazardous areas may depend on other factors besides use of flameproof enclosures, such as the following: (a) Because the flameproof technique depends on operation of the equipment within its rating, means should be provided to prevent overloading of the equipment and for power-interrupting devices, to ensure that the rated breaking capacity or temperature level is not exceeded. The consequences of a destructive short-circuit within the equipment should be guarded against by providing the means to achieve automatic interruption of the short circuit elsewhere before the risk of destroying the enclosure supervenes. (b) Because the flameproof technique depends on maintenance of the structure in its designed condition, it is essential that due attention is paid to this condition at all times, and that corrosion, deformation or wear of parts be remedied before any design openings or gaps in the enclosure have enlarged beyond the limits shown in Figure 6.2.

6.6.2 Flameproof motors Electric motors, generators and machinery with rotating shafts require separate consideration for flameproof classification. Clearances and tolerances normally provided for ball, roller or sleeve bearings in motors do not provide safe flameproof gap dimensions. To overcome this difficulty, special glands or labyrinths have been designed to provide a flameproof path along the shaft; at times, this applies to the drive shaft bearing only, if the rear-end bearing carrier and end cover have flameproof dimensions. In all cases, however, the flamepath bush or labyrinth should always be checked for damage or excess tolerances. 6.6.3 Maximum surface temperature The maximum operating external surface temperature for flameproof equipment should not exceed 150C for Group I equipment and an appropriate value from AS/NZS 60079.0 for Group II and Group III equipment. The maximum permissible surface temperature for equipment or parts of equipment external to the enclosure should be determined by (a) (b) (c) danger of ignition of the explosive gas/air mixture and its ignition temperature; danger of ignition of combustible dust deposited on a heated surface; and the thermal stability of the materials used.

The glow temperature of certain types of combustible dust is known to be within the range 150C to 170C. Also the temperature of a surface in contact with combustible dust can be raised significantly owing to the effect of reduced heat dissipation. This temperature increase can lead to exothermic reaction due to oxidation of the combustible dust. Therefore, combustible dust should not be allowed to build up on any equipment surface. Equipment design makes provision for heat radiation, e.g. cooling fins and water jackets, therefore any obstruction to the heat transfer medium should be removed to keep the surface temperature as low as possible. 6.6.4 Fixing bolts, studs and nuts To ensure the safety of equipment, broken or missing fasteners should be replaced with identical fasteners and not with just any bolt selected at random.

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Stud or bolt holes that could pass into the flameproof enclosure should always be blind holes, with a thickness of metal at the bottom of the hole of not less than 3 mm or one-third of the hole diameter, whichever is the greater. If, for reasons of construction, holes have to penetrate the enclosures walls, they should be plugged for not less than 6 mm or the diameter of the hole, whichever is the greater, by a screwed plug complying with thread pitch requirements, which is permanently fixed in place. Permanently attached studs should be screwed in place and securely fixed. No washers (plain or lock) should be placed under bolt heads, screw heads or nuts unless they form part of the original approval. For coal mines, bolt heads, nuts and the like used on flameproof equipment and enclosures should be suitably shrouded or designed (e.g. button or pyramid head bolts), so that they can only be loosened and removed with the aid of a special tool. A pyramid or buttonheaded bolt should only be used if the surface around the hole has been spot machined to ensure that the axis of the bolt is normal to the surface. Where replacement bolts are used, they should be of the same type, diameter, pitch and length, and at least the same tensile strength. Any broken or damaged attachment, which could affect the flameproof properties of an enclosure, should be replaced with a part that does not void the current certification. For Group II equipment, shrouding is no longer a requirement however for Group 1 enclosures, shrouding is still a requirement. 6.6.5 Breathing devices Where used, breathing devices should be regarded as component parts of the enclosure and should maintain the explosion-protection properties of the enclosure and comply with the requirements specified for the approval of such devices. The testing of breathing devices should be at the direction of the relevant regulatory authority. 6.6.6 Flamepaths 6.6.6.1 Surface finish When running a fingernail across the flamepath a tactile indication of surface finish is revealed. The level of finish is critical and must be maintained should remachining of the flamepath be required at any time. A more scientific analysis can be achieved using a RUGO gauge. 6.6.6.2 Flamepath straightness/deviation Tests of joint surfaces using straightedges are illustrated in the Figure 6.1 below.

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Straightedge /position A

300 mm

300 mm

Straightedge /position B

Straightedge/position A - No deviation Straightedge/position B - No deviation 150 mm 150 mm 150 mm 150 mm

Flamepath flange

300 mm Straightedge /position C

Straightedge/position C - Deviation

Straightedge across flamepath Deviation

NOTE: Use of straightedges to determine flange deviation: (a) (b) (c) (d) All measuring devices are to be calibrated as per the quality management system. Straightedges should be 300 mm long. The straightedge is to be used over the full length of the flange in approximate 150 mm increments. The straightedge should be used in such a way that the worst case deviation of the flange can be detected. If a flange is longer than 300 mm and a 300 mm straightedge is used, care should be taken not to use discrete steps of 300 mm for measurement, or else excessive deviations may not be detected as demonstrated in straightedge position C.

The deviation over any 300 mm length of flange should not exceed one half of the flamepath gap as specified in AS/NZS 60079.1. The intent of this practice is to detect imperfections in flanges that can result in a flamepath gap greater than that specified in AS/NZS 60079.1 when the flamepath flanges are bolted together. A longer straightedge should be used over openings or un-machined surfaces to ensure that opposite flanges are on the same plane. Although this Figure shows a method of carrying out this test, there is no one specific method of determining the deviation; methods will vary from enclosure to enclosure and length of straightedge. Whatever method is used the main aim is to detect the possibility of excessive flamepath gaps and all measurements should be made with this in mind.

FIGURE 6.1 TESTS OF JOINT SURFACES

6.6.6.3 Flamepath length and gap dimension Flamepath lengths and gaps dimension positions are shown in Figure 6.2

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C D1 D2

Flange

L = length of flamepath C = clearance between flameproof faces when flanges have been tightened D 1 and D 2 = depth of corrosion or surface indentation in each face

FIGURE 6.2 FLAMEPATH AND GAP DIMENSION

6.6.6.4 Corrosion or surface indentation tolerances Maximum allowable depth of corrosion or surface indentation is shown in Figure 6.3

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NOTE: Example is for Group I only. DIMENSIONS IN MILLIMETRES

FIGURE 6.3 MAXIMUM ALLOWABLE DEPTH OF CORROSION OR SURFACE INDENTATION ON THE FLAMEPROOF FACES OF AN ENCLOSURE

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6.6.6.5 Checks on circular flanges, spigots and holes This Section indicates the checks to be performed on circular flanges, spigots and holes using inside and outside micrometers and dial gauges. These checks should be carried out in accordance with Figures 6.4, 6.5 and 6.6.

FIGURE 6.4 DIAMETRAL CHECK

FIGURE 6.5 FLANGE FLATNESS AND SPIGOT DEPTH CHECK

FIGURE 6.6 END COVER FLATNESS, DIAMETRAL AND SPIGOT DEPTH CHECK

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6.6.6.6 Guidance for repaired/overhauled

measurement

tolerances

in

flameproof

equipment

when

The values shown in Tables 6.1 and 6.2 are an indication only of what the gaps would become for a reduction to 80% of the maximum allowable diametral gap, and to 40% of the maximum allowable gap for a flange. If achievable, these reduced gaps may enable prolonging the use of equipment in injurious environments. However, regular inspection should be carried out to determine the condition of the gaps in flamepaths, in all flameproof enclosures. The values shown for diametral clearances do not take into account any bore tolerances or eccentricities for bearings, bearing housing and the like. 6.6.6.7 Shafts with rolling-element bearingsLimits for radial clearance The limits stated in AS 2380.2 are as follows: Minimum radial clearance, k (a) (b) for Groups I, IIA and IIB ...................................................................... 0.075 mm; or for Group IIC ............................................................................................. 0.05 mm.

Maximum radial clearance m not greater than two thirds of the maximum allowed diametral gap.
NOTE: For rods, spindles and shafts the maximum diametral gap is the maximum diametral clearance.

6.6.6.8 Values corresponding to 80% of the maximum allowable diametral gap These values are given in Table 6.1.

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TABLE 6.1 GUIDANCE FOR TOLERANCES FOR SHAFTS WITH ROLLING-ELEMENT BEARINGS
Parameters Group Value for Groups I, IIA and IIB, using minimum flamepath, in accordance with AS/NZS 60079.1 V 1000 m (not > than 2/3 gap) I IIA IIB IIC m+k
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Values for Group IIC, using minimum flamepath, in accordance with AS/NZS 60079.1 V 100 0.10 0.15 0.15 0.12 100 < V 500 0.10 0.15 0.15 0.12 500 <V 1500 0.16 0.21 0.25 0.2 1500 < V 2000 0.16 0.21 0.25 0.2 2000 <V 6000 0.16
62

1000 < V 2000 0.40 0.30 0.20 0.475 0.375 0.275 0.60 0.45 0.30 0.48 0.36 0.24

V > 2000 0.40 0.20 0.13 0.475 0.275 0.205 0.60 0.30 0.20 0.48 0.24 0.16

0.30 0.30 0.20 0.375 0.375 0.275 0.45 0.45 0.30 0.36 0.36 0.24

I IIA IIB IIC

0.21 0.25 0.2

Maximum allowable diametral gaps

I IIA IIB IIC

Diametral gaps at 80% of maximum allowance

I IIA IIB IIC

6.6.6.9 Flanged joints The values corresponding to 40% of the maximum allowable gaps are given in Table 6.2. TABLE 6.2 GUIDANCE FOR TOLERANCES FOR FLANGED JOINTS
Parameters Group Value for Groups I, IIA and IIB, using minimum flamepath, in accordance with AS/NZS 60079.1 V 1000 Maximum allowable flange gaps
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Values for Group IIC, using minimum flamepath, in accordance with AS/NZS 60079.1 V 100 0.1 0.04 100 <V 500 0.1 0.04 500 < V 1500 0.04 0.016 1500 < V 2000 0.04 0.016 2000 < V 6000 0.04 0.016
63

1000 < V 2000 0.4 0.3 0.2 0.16 0.12 0.08

V > 2000 0.4 0.2 0.15 0.16 0.08 0.06

I IIA IIB IIC

0.3 0.3 0.2 0.12 0.12 0.08

Flange gaps at 40% of maximum allowable

I IIA IIB IIC

NOTES: 1 2 All dimensions are in mm except V in cm 3. The gaps should not exceed those specified in the certification/approval documents

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6.7 IN-SITU TEMPORARY REPAIR FOR HOLE OR THREAD A typical method for carrying out a temporary repair to a damaged hole or thread is depicted in Figure 6.7. Care must be taken not to weaken the original enclosure. It is recommended that the method be practised in a workshop before on-site repairs become necessary and are undertaken. It will be necessary to record all details so that permanent repair can be made during next overhaul.

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FIGURE 6.7 TEMPORARY REPAIRS STAGES

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6.8 HYDROSTATIC PRESSURE TESTS 6.8.1 General Over pressure testing (static testing) of flameproof enclosures or flameproof rotating machines is required in the following instances: (a) (b) (c) Where repairs or modifications are of a structural nature. When the structural integrity of the enclosure is in doubt. All grey cast iron enclosures (refer to Clause 3.11.3 on cast iron) and enclosures with screwed covers, irrespective of the category of repair.

It is only necessary to test individual compartments that have been repaired, including after thread repair/replacements, modifications or if the structural integrity is in doubt. If the modification or integrity affects multiple chambers, then each of the chambers must be individually tested. Where over-pressure tests are carried out on motors (rotating electrical machines) or enclosures that are water-cooled, the tests should be conducted with the water jacket dry and open to the atmosphere. Repairs of a minor nature to an enclosure, such as re-welding hinges, support brackets, extra cable entries and the like, may not require over-pressure testing after repairs, provided that the explosive-protection properties of the enclosure are verified and documented by a competent person. There are two methods suitable for the over-pressure test. These are (i) (ii) dial gauge measurement; and straightedge and feeler gauge measurement.

Typical test rigs for both of these methods are shown in Figure 6.8. The method used should ensure that the assembly, sub-assembly or component parts are subjected to representative stress patterns. Actual fastening facilities as well as additional clamping are used to reduce leakage that may affect the mechanical properties of the enclosure which would invalidate the test.

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FIGURE 6.8 EXAMPLES OF OVER-PRESSURE TEST RIGS

6.8.2 Testing personnel All personnel associated with over-pressure testing should be familiar with this procedure and have demonstrated competency in the set up and completion of over-pressure testing using the relevant facilities and processes. A competent person should verify and evaluate the results of over-pressure tests, and issue and authorise the relevant documentation. 6.8.3 Test procedure The over-pressure test procedure should be as follows: (a) Check the test piece against the original drawings (that is, a dimensional check). The following faces should be checked with a straightedge and feeler gauge: (i) (ii) Flamepaths on enclosure or covers. Flat surfaces, which will show up on the drawings as the weakest sections of the enclosure.

(iii) Flanges on pressurized enclosures. (b) (c) For dial gauge measurement (see Figure 6.6) install dial gauges to surfaces on top, back, front and sides of test piece. For straightedge and feeler gauge measurement (see Figure 6.5) draw a line where the straightedge is placed and mark along this line (+) or (-) deformations around the test piece.

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(d)

Seal the test piece and fill with the testing fluid, taking care that trapped air is minimized. A pressure gauge should be fitted to the test piece to check the pressure at the test piece, and also to crosscheck the gauge fitted in the vicinity of the regulator.
NOTE: Air or gas testing fluid is recommended only for pressurized enclosures where relatively low pressures are involved.

(e)

Apply pressure gradually until the test pressure figure is reached. Suitable personnel protection equipment should be worn while a visual inspection is made to check for cracks or flaws in the test piece. The pressure for the over-pressure test should be held for 1 min for flameproof enclosures and 5 min for pressurized enclosures.
NOTES: 1 2 The pressure to be used for the over-pressure test should be either the value nominated in the certification/approval documents for such purpose or 1.5 times the reference pressure. If neither the over-pressure test value or the reference pressure test value are known, the values for the pressure test should be: (a) (b) For Group I, Group II A and B1050 kPA. For Group II C1500 kPA.

(f)

(g) (h) (i)

Remove the pressure source and the testing fluid and open up the test piece for inspection. For dial gauge measurement (see Figure 6.8a), record the difference in dial gauge readings. For straightedge and feeler gauge measurement (see Figure 6.8b), place the straightedge on the marked areas and compare results to determine the deformation (if any) due to the over-pressure test. For flameproof enclosures, give particular attention to the flamepaths, because these are the most important sections. Flat sections manufactured from steel or metals with a high elongation factor may show minor deformation, but this may not take away from the structural strength of the enclosure. Threaded entries and fasteners should be checked for deformation.

(j)

6.8.4 Reporting of results The test should be considered satisfactory if the enclosure has not suffered structural damage or permanent deformation that may affect its explosion-protection properties. 6.8.5 Interpretation of results Permanent deformation is the difference between measurements taken before and after the application of the required pressure test. Measurements should be taken at atmospheric pressure. Where the enclosure area being measured is rectangular, the measurement to be used should be that across the shortest side. Where this side is greater than 300 mm, the measurement should be taken across the total length of the side, and the total amount of deformation should be calculated from the above requirement. Following the over-pressure test, a test of joint surfaces in accordance with Figure 6.5 and Figure 6.6 should be conducted.
NOTE: It is permissible to apply pressure to an enclosure prior to the over-pressure test to release stresses and elasticity in the Ex d enclosure.

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6.9 FINAL VERIFICATION Following reclamation of components, all measurements pertaining to certification must be re-verified against the certification/approval drawings and original overhaul dimensions. All information should then be recorded and included in the final report. 6.10 PACKAGING AND DESPATCH Prior to despatch, the repair facility should ensure that the equipment is securely packed for the mode of transport to be used.
NOTE: Transport by rail is not recommended due to possible deterioration of surfaces, etc., through vibration.

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SECT I O N

E X

I N CRE A SE D

SA FE T Y

7.1 INTRODUCTION 7.1.1 General Increased safety is an explosive-protection technique that may only be applied to electrical equipment which does not normally contain arcing or sparking devices, or hot surfaces that may cause ignition. In order to reduce the possibility of arcing, sparking or hot surfaces being present to an acceptably low order of probability, AS 2380.6 and AS/NZS 60079.7 specify the following rigorous requirements: (a) (b) (c) (d) (e) (f) (g) (h) Superior insulation requirements. Minimum creepage and clearance distances to avoid arcing or tracking between live parts. Special requirements for internal connections and terminal arrangements for external connections to prevent them working loose and causing sparks and arcs. Protection against the ingress of foreign bodies or moisture. Stringent temperature limits for both internal as well as external surfaces of equipment. Additional requirements for specific equipment, such as motors and luminaires. Control requirements for specific equipment to avoid excessive temperatures, e.g. in motors. Specific testing to determine a safe stall-time ratio.

7.1.2 Arcing or sparking parts If arcing or sparking parts or components are essential to the operation of equipment, safety can only be assured by the use of suitable types of protection, such as flameproof enclosures. Such arcing or sparking parts should comply with the requirements of the appropriate Australian Standards, e.g. AS 2380.1 or AS/NZS 60079.0 and AS 2380.2 or AS/NZS 60079.1 for flameproof enclosures. 7.1.3 Insulation Increased safety equipment should be designed so that the likelihood of arcs or sparks occurring in normal operation as a consequence of insulation failure is minimal. As a result, AS 2380.6 and AS/NZS 60079.7 specify strict creepage and clearance distances. The high level of protection against the occurrence or arcs and sparks in service is the basis of the increased safety protection technique, because no additional form of explosion protection is used to ensure safety. 7.1.4 Temperature Unlike flameproof enclosures, the temperature rating T assigned to increased safety equipment relates to the internal surface temperature of equipment, rather than the external surface temperature. For certification purposes, the limiting temperature of increased safety equipment should be determined by taking into account the condition of maximum ratings, other factors according to the type of equipment and those conditions considered by the certification authorities to produce the highest values of internal temperatures (see AS 2380.6).
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There are some types of electrical equipment, such as rotating machines, that may require special techniques to ensure safety in respect to dangerous temperatures under conditions of duty that may be variable and onerous. Such special techniques include the use of thermal protection devices, which may be used directly or indirectly to disconnect equipment from the electrical supply in the event of a predetermined temperature being attained. This predetermined value for temperature should take into account the properties of the protected equipment (e.g. the winding insulation) in addition to limitations that may be imposed by the intended application (see AS 2380.6 and AS/NZS 60079.7 for further guidance). 7.1.5 Terminals and terminations Increased safety equipment is largely installation dependent, in that the safety of such equipment, appropriately certified, can be compromised if due care is not taken during installation. Therefore, creepage and clearance distances should be maintained and it should be ensured that terminals cannot work loose and create an arcing situation. AS 2381.6 addresses these issues by placing strict requirements on the number of conductors for each termination and various torque values appropriate to each terminal clamping screw. Reference should also be made to certification/approval documents for any special conditions that may apply. 7.2 OWNER/OPERATOR Unlike Group I flameproof equipment, there is no advisory schedule for the periodic overhaul of increased safety equipment. In particular, mobile and transportable equipment in a harsh underground coal mines is subjected to considerable stresses. Historically, the increased safety explosion-protection technique was limited to connection or motor terminals boxes, but recently a broader range of increase safety equipment is being utilised in the environment. Many operators appear not to have a clear strategy for periodic, detailed inspections or overhauls of increased safety equipment that does not have a flameproof part. Therefore, the owner/operator of increased safety equipment is recommended to seek the advice of the manufacturer for a timetable on overhauls. The owner / operator may schedule overhauls to coincide with process industry major shutdowns or coal mining long wall moves. 7.3 INSPECTION/OVERHAUL Inspection should be carried out to ensure the following criteria is met: 7.3.1 Insulation material The insulation materials used appear to be original and in good condition. If not original, the service facility needs to carry out assessment/testing to determine whether the insulation materials meet the requirements of AS/NZS 60079.7. There is no evidence of deterioration due to heating, physical damage or chemical degradation.
NOTE: Chemical degradation can be a major issue in some installations, e.g. at petrochemical plants.

7.3.2 Insulation clearances Clearances are still within the constraints specified in the certification/approval drawings or manufacturers data.
NOTE: If the above data is not available, refer to the requirements in AS/NZS 60079.7.

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7.3.3 Insulation creepage Creepage distances are still within the constraints specified in the certification/approval drawings or manufacturers data.
NOTE: If the above data is not available, refer to the requirements in AS/NZS 60079.7.

7.3.4 Physical damage The equipment needs to be fully inspected for any signs of physical damage and compared against the certification/approval drawings or manufacturers data. If any type of physical damage is uncovered, its IP rating should be tested to ensure it has not been adversely affected in addition to correcting the physical damage.
NOTE: Physical damage includes degradation due to chemical reactions.

7.3.5 Temperature sensing devices Temperature-sensing devices are to be tested for correct operation, including the operating temperature. RTD devices should be tested using a compatible test device to ensure correct operation over its operating range. One method of achieving this is to place the equipment inside a temperature-controlled oven and raise the temperature at a controlled rate while observing the output of the temperature-sensing device. These tests need to be carried out on all temperature-sensing devices, including bearing temperature sensors, which may not be nominated on the certification/approval documents. 7.3.6 Terminals and terminations All terminals require examination to determine the following: (a) (b) (c) (d) (e) (f) (g) (h) They comply with the certificate of conformity. All creepage barriers are in place and not damaged. The surface finish of barriers is as original and not scratched, which may cause creepage. They are the correct size, complying with the enclosures specified heat loading. Retaining devices are present, in good order and comply with the certificate of conformity. Terminal lugs and lead wires are sized correctly and crimped in an approved manner. No corrosion or degradation has occurred, due to chemical or other means. They have not been subjected to undue mechanical stress.

7.3.7 Glands If cable glands are supplied with the equipment, ensure that the glands are suitable for use with an increased safety enclosure. The packing in the gland should be checked to ensure that it is in good condition and retains its flexibility. It is recommended that gland packing be replaced at the time of overhaul. If the gland is of the compound-filled type and appears to be in good condition, there is no requirement to dismantle and perform further testing other than to ensure that its attachment to the enclosure is in good condition and does not compromise the IP rating and the certification/approval documents.

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7.3.8 Seals and IP rating 7.3.8.1 General It is essential that all seals are inspected to ensure that the IP rating of the equipment is not compromised. Inspection should look for signs of physical damage, including nicks and cuts within the seal. Seals and their material should be examined to ensure compliance with the certification/approval documents, including mounting to the enclosure. 7.3.8.2 Rubber/Neoprene-type seals These types of seals should be examined to ensure they are pliable and without a memory. The attachment to the enclosure should also be verified. Any concern in this regard should prompt a full replacement of the seals. 7.3.8.3 Shaft seals Shaft seals should be examined to ensure compliance to the certification/approval documents (including sizing and fixing to the enclosure). 7.3.8.4 Equipotential Bonding Equipment comprising multi-section enclosures require examination and testing to ensure that all parts of the enclosures are earth bonded. This is a particular issue when sealing gaskets are used between equipment compartments. Refer to AS 60079.7 for rotating machine requirements. 7.4 SPECIFIC ISSUES FOR ROTATING MACHINES

7.4.1 Rotor Rotors should be inspected for the following: (a) (b) (c) (d) (e) They comply with the certificate of conformity. The stator rotor gap complies with the certificate of conformity. Integrity of windings/rotor bars. If faulty, cast rotors must be replaced in their entirety. Spigot gland is manufactured from the correct material.
NOTE: This is critical to ensure that no sparking will occur if the rotor bearing collapses.

For common tests relating to all rotating machines refer to Section 5. 7.4.2 Stator Stator winding must comply with the original manufacturers design unless the repairer can demonstrate that an alternative design will comply with the certification/approval documents. Windings and their insulation systems in Increased Safety machines have some specific requirements that are detailed in AS 60079.7, such as: (a) (b) (c) (d) (e) That windings have, as a minimum, two layers of insulation. Impregnation methods and materials include requirements for double dipping when solvent-based varnishes are used. Minimum winding wire dimensions. Specific requirements for lead connections. Requirements for embedded temperature detection devices.
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7.4.3 Fans Fans used on Increased Safety machines should comply with the requirements listed in AS 60079.0. These include the following: (a) (b) (c) Have a surface resistance of not less than 1 G. Thermal stability. Clearances as detailed in the certification/approval documents.

7.4.4 Overloads It is recommended that the associated overload detection equipment be assessed, curves verified as compliant with the Ex e motors certification/approval documents when an Ex e motor is overhauled. 7.5 REPAIR 7.5.1 Enclosure repair If an Increased Safety enclosure is structurally damaged to the point where its IP rating is compromised, it is recommended to replace the enclosure. If repairs are undertaken, the IP rating must be verified. 7.5.2 Winding replacement The electrical construction of increased safety equipment decisively influences the explosion safety, and the overhaul service facility needs to be in full possession of the necessary information and equipment to enable equipments restoration to the original or certified condition. Unless the overhaul service facility is able to meet all the requirements of AS/NZS 60079.7 and AS/NZS 3800, the rewind should be referred to the equipment manufacturer. Information needed to carry out a rewind includes the following: (a) (b) (c) (d) (e) (f) (g)
1 2

Type of winding, e.g. single layer, double layer. Winding diagram. Number of conductors per slot, parallel paths per phase. Interface connections. Conductor size. Insulation system, including varnish specification. Resistance per phase or between terminals.
Copy winding is not acceptable unless a locked rotor test is conducted to verify the tE stall time complies with the certification/approval documents. Winding data should be available from the manufacturer or the certified holder. Partial rewinding is not recommended.

NOTES:

7.5.3 Removal of windings Refer to Section 5 for specific requirements on removing windings, including core loss testing. 7.5.4 Repair of rotors Refer to Section 5 for specific requirements.

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7.6 FINAL VERIFICATION Tests as detailed in AS 3800 should be carried out and recorded to ensure that the equipment meets the certification/approval documentation and is fit for purpose. 7.7 PACKAGING AND DESPATCH When packaging Increased Safety equipment for transport, additional care must be taken to ensure that no damage could occur during transport or storage, which could have an adverse effect on the physical construction or IP rating. 7.8 REPORTING Reporting is to be carried out as detailed in the following documents: (a) (b) Appendix A. AS/NZS 3800.

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SEC T I O N
8.1 GENERAL

E X

I N T R I N S I C

SA FE T Y

The essential elements or characteristics of intrinsic safety as an explosion-protection technique are detailed in the equipment compliance standards. However, the following provides a brief introduction to the protection technique: (a) Intrinsically safe circuit A circuit in which any spark or thermal effect produced in the prescribed test conditions (which include normal operation and specified fault conditions) is incapable of causing ignition of a given explosive atmosphere. (b) Intrinsically safe electrical equipment Electrical equipment in which all circuits are intrinsically safe. The equipment may be self-contained or it may form part of an intrinsically safe electrical system. The most important aspects of these definitions are as follows: (i) Spark or thermal effect As a general rule, gases are not excluded from the inside of intrinsically safe equipment. The equipment design concept is based first on the fact that the energy available in the circuit can be maintained below the minimum ignition energy of the gas, and hence a spark cannot ignite the gas. Second, a temperature classification is assigned, based on the maximum thermal ignition temperature of any part of the circuit. (ii) Specified fault conditions To ensure an adequate safety margin, faults are applied to the circuits when they are tested. This is done to ensure that the equipment will remain safe under any normal service condition. Close attention is also given to design requirements that limit the possibility of a fault condition occurring. For the purposes of intrinsically safe electrical equipment, gases and vapours are classified according to the ratio of their minimum igniting currents (MIC) with that of laboratory methane. AS/NZS 60079.12 gives the following subdivisions for Group II: (A) (B) (C) Group IIAMIC ratio above 0.8. Group IIBMIC ratio between 0.45 and 0.8. Group IICMIC ratio below 0.45.

It is important to note the correlation between the MIC and the MESG values in AS/NZS 60079.12. This justifies having the same groupings for flameproof and intrinsically safe equipment. There are three categories of intrinsically safe electrical equipment: ia, ib and ic. Essentially, ia involves the application of more arduous testing conditions and provides a higher confidence of safety, which allows its use in zones of higher risk. Intrinsically safe electrical equipment may be self-contained or it may be connected to associated electrical equipment, generally located in a safe (non-hazardous) area. This second case is called an intrinsically safe electrical system. Even though the electrical equipment is located in the safe area or protected by some other means (e.g. a flameproof enclosure), it will still affect the safety of the equipment to which it is connected. Figure 8.1 illustrates the various possibilities.
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FIGURE 8.1 INTRINSICALLY SAFE ELECTRICAL EQUIPMENT AND SYSTEMS

A safety barrier is a safe area device, which may be used as an interface for connecting safe area non-explosion protected equipment (or associated electrical equipment with inappropriate entity parameters) to hazardous area intrinsically safe electrical equipment. The situation is similar to that illustrated in Figure 8.1 except that, instead of the associated equipment containing the necessary protective circuitry, the protective circuitry is contained in the safety barrier. Since the early 1960s, the most common application of this technique has been the shunt diode safety barrier, the requirements for which are specified in AS 2380.7 and AS/NZS 60079.11. The shunt diode safety barrier restricts the current by means of a resistor and the voltage by means of a zener diode(s) referenced to earth. In the event of a major failure placing mains voltage on the circuit, the fuse will rupture. The system relies on maintaining a low resistance to earth. A more recent arrangement involves modules that incorporate a transformer, conforming to intrinsic safety infallibility requirements and relays (or opto-couplers) to achieve the safety barrier. For this arrangement, earthing is generally not as critical as the shunt diode safety barrier, where earth reference is used to prevent over-voltage occurrences in the hazardous area. After reviewing the design aspects of intrinsically safe equipment, it is also important to consider the unique aspects of electronic circuit manufacture and understand likely flaws that may be detrimental to the intrinsically safe characteristic of the equipment. Unlike many other explosion-protection techniques, intrinsically safe circuits are built up from a considerable number of small solid-state components. The solid-state safety components, circuit board laminates and solder materials are mass manufactured and statistically or batch-sampled for operating specifications. The production of printed circuit boards (PCBs) are almost exclusively automated (steps include etching, drilled and plating, with varying levels of staged inspections.

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Currently, however, manufacturers still use a mix of automatic and manual processes to populate intrinsically safe circuit boards (1) (2) (3) fully automatedpick and place components onto pre-solder masked PCBs and thermal oven soldering; partial automatedpick and place, as above, with the remaining component hand mounted and soldered; and hand mountedfully hand mounted through hole components, then hand or wave soldered.

Production quantities and component selection are important factors in determining the method of assembly. Additionally, fully automated manufacture may also be complimented by automated conformal coating to be applied to the finished PCB. However, when components are hand mounted, conformal coating would typically be completed by hand. Intrinsically safe circuit boards that are assembled with fully automated process may be individually or sample inspected. Inspection methods include one or a mixture of visual, automated optical recognition or pin-cushion test bed checks, while hand assembled boards are typically individually inspected manually. Some observed flaws in modern PCB manufacture that could influence the integrity of intrinsic safety equipment include (a) (b) (c) (d) (e) electrostatic component damage; hardware (component) clearances, tomb-stoning and omissions; solder splatter, bridging, non-wetting, tin-fingers or growths; corrosive flux residues; and pads lifting for heat and/or pressure from soldering.

Whichever method of manufacturer and inspection occurs, all methods are subject to errorWhether through missing or incorrect component selection, poor component alignment, incomplete board etching, incomplete or damaged tracks and solder pads, or simply because of incorrect PCB version or software control. Similarly, mass manufactured PCBs may only be subjected to sample inspection or testing, and hand manufactured PCBs are subject to the likelihood of human error during the production process. Add to this mix is the current deviation from leaded solders, with some experimentation in new alternate solder compositions that do not have the tried-and-proven history of leaded solders. The competent person must be cognizant of the possible manufacturing errors during Ex i equipment inspections and must not assume that in-service equipment presented for overhaul are exact replicas of the certified equipment. 8.2 OWNER/OPERATOR RESPONSIBILITIES The safe use of electrical equipment in hazardous areas may depend on factors other than correct selection of intrinsically safe equipment. The following factors must also be considered: (a) (b) (c) (d) The installation of intrinsic safety equipment and its location, including its interconnecting cables, in relation to other power devices and cable. The environment in which the equipment is installed, such as dusty, moist, acidic or alkaline conditions. Heat from mechanical or electrical external sources. The external circuit parameters, which must be controlled to prevent them exceeding the limits of safe operation.
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Apart from impact, vibration and environmental damage, there should be no great need to overhaul fully encapsulated, intrinsically safe barriers, because the parts selected are inherently overrated for the purpose intended. However, industry experience shows that the intrinsically safe and functional characteristics of equipment with uninsulated parts, such as pin and edge connectors, can be jeopardized by ingress of moisture and dust contaminants. When the intrinsically safe equipment is associated with other assemblies and housed in common enclosures, it is advisable to overhaul the intrinsic safety equipment and clean, test and check the circuits and parts specifically related to intrinsic safety at the same time as the other equipment is undergoing overhaul. Manufacturers manuals should lay down recommended checks, tests and overhaul procedures for their particular products and these should be followed closely by any other overhaul procedures that may be developed by each location, as experience is gained in service. The equipment owner/operator should have a high degree of confidence that service personnel and facilities will not invalidate the explosion-protected properties. Parts specifically associated with the intrinsic safety of the assembly or circuit should be checked and replaced if necessary. If there is any doubt, the intrinsically safe assemblies should be replaced and on no account should any attempt be made to replace parts with those of different ratings and for which no compliance/approval has been granted. All encapsulated parts must be replaced in their entirety and no attempt should be made to repair the faulty assembly in hard encapsulant. A single exception may be items specifically designated as explosion-protected by encapsulation (Ex m), where the equipment has been certified with a soft encapsulant (see Section 10). Operators need to have a strategy for periodic inspections and/or overhauls for all intrinsically safe equipment at the installation. However, it is essential to verify that the manufacturers manual correctly defines the same replacement parts as specified in equipments certification/approval documentation. Should a difference in parts specification be identified, it should be referred to the manufacturer for resolution.
NOTE: The requirements of the certificate should always prevail.

The replacement of components and sub-assemblies by the equipment owner/operator must not deviate from the specified parts and manufacturers instruction as this could invalidate the certification/approval and explosion-protection characteristics of the equipment. It is essential that the following items are satisfied prior to attempting adjustments and/or part replacements: (i) The owner/operator has sufficient understanding of intrinsic safety equipment requirements and preferably a competency associated with this explosion-protection technique.
NOTE: In some jurisdictions there are legislative requirements for third-party assessment and licensing of service facilities who undertake activities that may alter the explosion protected characteristics of equipment, irrespective of the facilitys status as a manufacturer and/or certification/approval.

(ii)

The operation is specifically described in the manufacturers documentation (e.g. owner/operators handbook) supplied as an integral part of the original equipment.

(iii) The replacement item is the manufacturers component or sub-assembly, as described and clearly identified in the certification/approval documentation. (iv) The operation does not require the use of special tools, soldering, cutting of components/PCB tracks, removal of conformal coatings or the use of excessive force that may cause damage.

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(v) (vi)

Due diligence is exercised in the reassembly, including replacement of insulating barriers and seals as appropriate. The equipment is inspected, tested and verified in accordance with the manufacturers documentation.

Examples where these activities may apply to the owner/operator include the following: (A) Replacement of plug-in sensors in gas detectors.
NOTE: It may be necessary to verify that replacement gas sensor part numbers not only align with the explosion-protection certification/approval bill of materials, but also align with any design registration that verifies the performance of the instrument, because these may not always align.

(B) (C)

Replacement of chargeable battery packs. Component replacement of sub-assemblies such as pumps or other plug-in assemblies.

An alternative is to return the equipment to the certificate holder or a certified third-party service facility for overhaul, adjustment, parts replacement, repair and/or calibration. The equipment owner/operator is cautioned not to use non-certified service personnel and/or facilities because of the numerous pitfalls that could occur. Incorrect repair will invalidate the equipment compliance and possibly render the equipment to be non-explosion protected. Uninformed repairers have been found to use equivalent parts (semiconductor, batteries, etc.), cut and bridge components, test and charge equipment with (non-entity compactable) equipment. Agents and distributors of intrinsically safe equipment, including national distributors for overseas manufacturers, may not be equipped or competent to conduct overhaul or repair activities. Recognized service facilities are typically recognised to overhaul and repair a specified list of intrinsically safe products depending on the availability of certification/approval documentation, service equipment and competencies. Unlike Group I flameproof equipment, there is no advisory schedule for the periodic overhaul of increased safety equipment. In particular, mobile and transportable equipment in a harsh underground coal is subjected to considerable stress. There is considerable intrinsic safe equipment items that have remained in service for many years without detailed inspection or overhaul. Many operators appear not to have a clear strategy for periodic detailed inspections or overhauls of intrinsically safe equipment that is not associated with flameproof equipment. Therefore, the owner/operator of intrinsically safe equipment is recommended to seek the advice of the manufacturer for a timetable on overhauls. The operator may schedule overhauls to coincide with process industry major shut downs or coal mining long wall moves. Alternately, an assessment study may be considered appropriate to determine an appropriate SIL for the installation; this will in turn reveal the approximate failure rates and inspection frequencies to maintain the required availability on demand of the safety features of the equipment. Most intrinsically safe items of equipment are fairly robust, but no engineered product can operate indefinitely. Component or connection failures are generally caused by mechanical and thermal stresses. Moisture and dust ingress typically cause corrosion and reduction of critical creepage and clearance requirements. Period overhaul of all Ex equipment is highly recommended. This becomes more significant with Zone 0 intrinsically safe equipment because it is expected to perform safely within the explosive limits of its designated gas, mist, vapour and/or dust type.

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Similar to other explosion-protection techniques, some failure of Ex i safety criteria may not be self-revealing. Therefore, similar to other explosion-protection techniques, overhaul of Ex i equipment must include periodic detailed inspections to verify that the explosionprotected characteristic are maintained. Best practice may be to have laminated copies of the PCB layouts and parts lists, with criteria safety features highlighted, at the competent persons workbench, so that overhaul inspections can verify that: (1) (2) (3) (4) (5) (6) no ingress of dust and/or moisture is occurring; screwed and soldered lead corrections are secure, undamaged and without corrosion; correct PCB board(s) are being used; all safety components (highlighted on laminated PCB layouts) are in place and correctly mounted; PCB tracks are complete, undamaged and show no sign of thermal discolouring; and if relevant correct fuse(s) and gas sensor(s) are installed.

The explosion-protected characteristics of gas detection equipment can be compromised by: (a) (b) (c) (d) (e) incorrect selection of component parts, whether an incorrect board, switch, sensor, display or battery; incorrect assembly that may cause component or board damage; repair, adjustments and/or soldering that could comprising the creepage and clearance distances; charging from a power supply that is not within the rating of the device; and failure to comply with the manufacturers requirements and the conditions within the Ex certificate of conformity.

Component or module (circuit board, display, switches, batteries*, sensors**) replacement is a repair and not a maintenance activity. A maintenance activity for this type of equipment would be to clean and verify calibration, but not jeopardize the explosion-protection characteristics of the equipment. Repairs to explosion-protected equipment must only be undertaken by a recognised service facility specifically accredited for the item of equipment.
NOTES: 1 2 Some certified Ex i equipment have a specific range of batteries and use of batteries outside this range. Only sensors that are listed in the certification / approval documentation must be used, so as to maintain compliance.

8.3 INITIAL ASSESSMENT The objective is to repair/overhaul intrinsically safe equipment to a condition as described in the certification/approval documentation. Typical documents required to undertake intrinsically safe equipment service and repairs includes the (a) (b) (c) (d) (e) (f) manufacturers checklist(s); manufacturers test specifications; manufacturers overhaul procedures; equipment parts specification; certification/approval documents; preferably including the test report(s); and manufacturing drawings.
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The competent person will be aware that features used to achieve intrinsic safety usually include a number of critical factors that are not obvious, even on reading certificates and test reports. Apart from circuitry, critical factors include segregation, insulation and its thermal properties, connectors, wire sizes and earthing. Generally, only spare parts obtained from the manufacturer or certification/approval holder should be used. Where it is impossible to obtain the replacement parts as specified in the certification/approval documentation, the problem should be referred to the manufacturer and/or the certificate holder. The use of parts that deviate from those listed in certification/approval documents will require further assessment and verification that the equipment retains its explosion-protection characteristics. A modification and additional certification/approval may be required. Certification schemes such as IECEx and ANZEx require initial type testing and periodic audit of the manufacturer. Therefore, certification can generally only be sought by the manufacturer or the certificate holder and additional certification, such as a Restricted Type Test Certificate may be possible, but this would only likely occur with the support from the manufacturer or certificate holder. The service facility, owner/operator and manufacturer should retain an awareness of safety alerts and bulletins that relate to products they repair and overhaul. There have been numerous incidents on intrinsically safe equipment relating to stuck switches on radio remote controls and control units for longwall roof support. Moisture ingress and stuck pilot solenoids are also frequent occurrences. The service facility, owner/operator and manufacturer should embed this knowledge and any recommendations from safety alerts and bulletins into their operation and inspection procedures. 8.4 OVERHAUL 8.4.1 General For intrinsically safe equipment, the certification/approval drawings, conditions and any manufacturers overhaul recommendations should form the basis of the overhaul procedure. The intrinsically safe overhaul procedure set out in this Section and any additional functional reviews should be carried out and the extent of the work and test results recorded on the overhaul and examination report. The construction of Ex i equipment may require that any overhaul must be carried out by the manufacturer if no other suitable service facility is available or the extent of repair and overhaul is beyond the capabilities of a service facility.
NOTE: A typical overhaul inspection and test report for intrinsically safe equipment is shown in Section 19.

8.4.2 Overhaul of intrinsically safe equipment The competent person should also consider the age and work history of the equipment during the inspection process and not assume that the equipment was fully compliant while in-service. A typical inspection of Ex i equipment would include at least the following checks (additional functional checks may also need to be completed): (a) (b) (c) Check that all certification labels associated with the certification/approval are securely in place and are complete and legible. Clean loose dust or corrosion from the equipment to ensure an inspection can take place. Check, where relevant, that ingress protection has not been reduced by mechanical damage to the enclosure or gaskets, or by corrosion or heat. Replace the enclosure or the whole assembly when either the damage sustained or continuing corrosion would reduce the degree of protection before the next overhaul.

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(d)

Check that all parts are exactly as set out in the certification/approval documents and that they are in good condition. In particular, checks on the following parts, where fitted and accessible, should be performed: (i) (ii) Infallible transformersFor damage to windings, earth connections, thermal protection devices (where visible) and mounting arrangements. FusesFor correctness of type and rating (current and time) and to ensure that the fuse holders are in good condition.

(iii) Infallible resistorsFor correctness of type, rating (resistance, construction, wattage) and any damage, and to ensure that their capacity to dissipate heat is not impaired. (iv) SemiconductorsFor correctness of rating of diodes, zener diodes, transistors or heat-sinks and to ensure that they are correctly mounted. Where such parts are encapsulated, no inspection is possible and any faulty equipment would require total replacement of the encapsulated part. BatteriesFor correctness of type, proper retention in the assembly and any associated current-limiting devices.
NOTE: In modern compact apparatus containing encapsulated assemblies (such as battery packs) the construction may prevent checks at the level of detail implied by the above.

(v)

(vi)

Protective coatingsFor damage to varnish or encapsulant, and freedom from cracks, also repairs which could alter the thermal properties of underlying components as these may all affect the intrinsic safety of the assembly.

(vii) Printed circuit boardsFor signs of potential failure such as charring or scorching that may reduce the insulation properties. Check for component-level repairs that may have affected creepage and clearances. Replace the printed circuit board unless the affected area is not relevant to the intrinsic safety of the assembly.
NOTE: In modern high-density printed circuit boards, many components will be of a size or connection that prevent checks at the level of detail implied.

(viii) Plugs and socketsfor cleanliness, signs of corrosion and to ensure that they are in good condition.
NOTE: In cases covered by Notes 1 and 2 above, a careful examination under magnification should be performed. This should check for damage to coatings and connectors; and possible damage caused by corrosion, excessive temperature, chemical attack or mechanical operations.

(e) (f)

Check that earth connections have correct terminations, conductors have the correct cross-Section area and that all screens and terminals are in good condition. Check all relevant insulation, insulating barriers, wiring looms and that terminations have their correct creepage distances and clearances from each other (from power conductors and from other non-IS conductors). Carry out any other specific test recommended by the manufacturer.

(g)

8.4.3 Overhaul of intrinsic safety associated equipment Associated equipment forming part of the intrinsically safe equipment certification/approval should be inspected and overhauled as necessary in accordance with the relevant parts of this Standard for the type of explosion protection under which it is classified. The extent of the work should be recorded on the overhaul and examination report for either intrinsically safe equipment or the relevant type of explosion protection.

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8.5 PASS/FAIL CRITERIA FOR OVERHAULED EQUIPMENT Tests and inspections should have pre-designated pass/fail criteria. This may include the extent of enclosure ingress, observed circuit board flaws, discolouring at components or sections of the PCB. The length of service may indicate the likely need for replacement of batteries, lamps, electrolytic capacitors or switches. If a service facility inspects the same piece of equipment on a regular basis, it may be able to add notes to the report detailing future likely failures and the effect on the equipments condition. 8.6 COMPONENTS FORMING PART OF INTRINSICALLY SAFE EQUIPMENT 8.6.1 Enclosures Enclosures of intrinsically safe equipment and associated apparatus are only required where intrinsic safety is dependent upon them. They are, however, often required for other reasons. Therefore, if the equipment has an enclosure, repair and overhaul activities should not reduce the protection offered by the enclosure (i.e., its IP rating). 8.6.2 Cable entries Where special entries are used to maintain the degree of ingress protection of the enclosure, care should be taken to ensure any repairs do not result in a reduction in the degree of ingress protection. 8.6.3 Terminations Corrosion and lack of cleanliness can invalidate intrinsic safety. When refurbishing terminal compartments, any terminals replaced should normally be of the same type that they replace. Where the same type is not available, any alternative type used should satisfy the creepage (according to the comparative tracking index CTI) and clearance requirements specified in the Standard for the maximum voltage of the equipment and the separation required by the Standard to avoid inadvertent cross-connection. Earthing is a very important consideration for intrinsic safety, and a duplicated or triplicated earth connection may be a requirement of the intrinsic safety certificate. Primary and redundant earth connections/earth bonds, internal and external to the intrinsically safe equipment, should be fully restored at the conclusion of repairs. 8.6.4 Soldered connections When it is desired to carry out repairs that require soldering techniques to be used, care should be taken to ensure that the requirements of the certificate are not invalidated. The following matters are to be considered to determine whether it is possible to undertake the repairs: (a) (b) Creepage and clearance distances are maintained. Solder material is compatible.
NOTE: Long-term stability of some lead-free solders and the growth of tin fingers that could erode creepage and clearance distance are emerging issues that need to be monitored.

(c) (d) (e) (f)

Components and printed circuit boards are not subjected to excess heat or force so that the PCB burns or is physical damaged. Flux residues and solder splatter can be adequately removed. Conformal coatings can be fully restored. Refer to AS/NZS 60079.11 for conformal coating and application requirements.

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8.6.5 Fuses Fuse replacement within intrinsically safe equipment should be with an identical component or an acceptable alternative as identified in certification/approval documents. Replacement of fuses should only be attempted when the fuse is readily accessible. In the supply-side of associated apparatus, if replacement with an identical fuse is not possible an alternative may be used, provided that it has (a) (b) (c) (d) (e) the same current rating or less; the same time characteristics; the same prospective current rating or more at the same or greater voltage; the same type of construction; and the same physical size.

NOTE: Prospective current rating is also known as break current rupture capacity.

Fuse replacement in barriers or in encapsulated battery packs (or similar) is inappropriate. 8.6.6 Relays If a relay is faulty, it should be replaced by one that is identical or identifed as an acceptable replacement in certificate documents. 8.6.7 Shunt diode safety barriers These devices are totally encapsulated and no repair should be attempted. Where a barrier device is replaced, the replacement should be verified as having the same safety description (including all entity parameters) and equal to or greater Um value of the original barrier. Care should also be taken that differing physical construction does not erode the 50 mm separation required between the intrinsically safe circuits and non-intrinsically safe circuits. In intrinsically safe systems, replacing a barrier with an alternate type not listed in the system certificate should not occur without additional verification of the full system parameters. 8.6.8 Printed circuit boards These parts of the equipment often have critical distances between conducting tracks (creepage distances), which should not be reduced. Therefore, when components are replaced, care should be taken in positioning them on the board. Where conformal coating is damaged during repair, insulating coating of the type prescribed by the manufacturer should be applied in the approved manner (for example, one coat if using dipping, two coats using other methods). 8.6.9 Optocouplers and piezoelectric components Only components of the same type or nominated in the certificate should be used as replacements. Minor changes in part numbers can dramatically alter the segregation, performance under impact and other essential properties. 8.6.10 Electrical components Components such as resistors, transistors and zener diodes may normally be replaced with items purchased from any source, but when components are not procured from the manufacturer or certificate holder, the replacement components should be verified as identical in type and package. For instance, a change of package can invalidate the thermal properties.

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In exceptional circumstances, however, some manufacturers use a select on test procedure for some replacement components. Where this is done, the documentation supplied with the equipment should indicate that either replacements be obtained from the equipment manufacturer or selected by the method they recommend. Replacing components with alternate types not listed in the certificate should not occur without additional assessment and test. 8.6.11 Batteries Only those types specified in the equipment manufacturers instructions and certificate documents should be used as replacements. Where batteries are encapsulated, the whole assembly should be replaced. The use of different battery packs or cell types (such as equivalent generic types from the same or other manufacturers) may invalidate the type of protection, therefore additional assessment and testing will be required prior to use. The certificates of modern intrinsically safe designs will usually specify the manufacturer and type number of replaceable cells that have been tested and are acceptable. Different cells of the same generic type and even different types from the same manufacturer may have different short circuit currents, and under short circuit conditions may be prone to electrolyte leakage or bursting, or produce excessive temperatures. 8.6.12 Internal wiring Certain distances between conductors and their segregation are critical. Therefore, if disturbed, internal wiring should be re-located in its original position. If insulation, screens, outer sheaths, and/or double insulation of wiring or the method of fixing are damaged, they should be replaced with equivalent material and re-fixed in the same configuration. 8.6.13 Transformers If a transformer is found to be faulty, the replacement should be obtained from the equipment manufacturer. No attempt should be made to repair or replace any embedded (encapsulated) thermal trip device. 8.6.14 Encapsulated components Encapsulated components (for example, batteries with internal current-limiting resistors or fuse-zener diode assemblies) are non-repairable and should be replaced only with assemblies of the original design from the equipment manufacturer. 8.6.15 Non-electrical parts Where the equipment has non-electrical parts (for example, fittings or a window) that do not affect the electrical circuit or creepage and clearance distances and hence the intrinsic safety of equipment, the parts may be replaced by new parts of equivalent type. Equivalent non-electrical parts should not invalidate the impact, anti-static or IP rating of the original equipment. 8.7 TESTING/ASSESSMENT The relevance and extent of any testing and calibration varies widely for the many types of intrinsically safe equipment that may be used. The manufacturers recommendations and manuals should be followed, together with any certification/approval conditions that apply. In every case, a test and calibration certificate should be supplied with all or part of the overhaul and examination report, which accurately describes what was done and the results obtained. The service facility must be responsible for the final assembly of the equipment and should carry out the tests that are typified by the following: (a) Test that the equipment complies with the functional and intrinsic safety requirements, as set out in the certification/approval documents and in accordance with the manufacturers recommended test procedures.
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(b)

Calibrate, as applicable, using the techniques and instruments set out in the certification/approval documents, and the manufacturers recommendations.

8.8 REPAIR 8.8.1 General No attempt should be made to repair printed circuit board laminate or tracks. Encapsulated parts should be replaced, not repaired. Repairs to intrinsically safety circuits, typically by desoldering components, leads or connectors should be carefully assessed to ensure that a suitable component replacement is available and the activity can be completed without damage or degradation to the intrinsic safety characteristics of the equipment. 8.8.2 Repairs using soldering 8.8.2.1 General When it is necessary to carry out repairs that require soldering techniques to be used, care should be taken to ensure that the basis of certification/approval is not invalidated. The basic criteria for this is shown in Clause 8.6.4, and soldering should not be contemplated if these conditions cannot be met. Experienced electronics personnel will understand the significant of flux applications prior to soldering and excess removal after soldering. Soldered joint inspection is also an acquired skill where insufficient fillet lacks electrical and mechanical integrity, and excess solder leads to splatter and bridging. Understanding the required flux application, solder eutectic point and the appropriate manual dexterity are the requirements for correct and reliable solder work. Finally, at the completion of the soldered repair and removal of all traces of flux, a minimum of two layers of conformal coating will be required to restore the original conformal coating. Additional clarification of these points is offered in Clause 8.8.1.1; 8.8.2.2 Compatibility of soldering materials with certification/approval Confirm that the type of solder proposed is the same as used in the original work: (a) Lead-free solders are used in modern equipment. There is more than one type of leadfree solder and they are not necessarily compatible and may not have the same wetting properties. Solder paste typically used with surface mounted components generally has a much lower melting point on initial application because prior to use it still retains volatiles in solution. The volatiles evaporate during the first solder application and once set, a much higher temperature is required to achieve a liquid state in subsequent operations.

(b)

8.8.2.3 Compatibility of soldering method Once the solder characteristics are known, an appropriate de-solder/re-solder method must be considered to achieve the required repair without board damage. Temperature controlled de-solder stations and hot air guns vary considerably in capability, particularly regarding temperature and alignment control. The manufacturers of solder/desolder stations offer advice and training. There are a number of international associations that advise manufacturers on highly reliable soldering material, equipment and training. Two examples are IPC (www.ipc.org) and the Surface Mount and Circuit Board Association (www.smcba.asn.au).
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8.8.2.4 Maintenance and verification of creepage and clearance Points for consideration include the following: (a) (b) (c) (d) Creepage and clearance values are not usually marked on certification/approval documents. Requirements for creepage distances may vary, dependent on whether the soldered joint is sweated and coated or not. Soldering should not be conducted where insufficient space is available to readily verify creepage and clearance values before and after soldering. Modern circuit boards that depend on pick-and-place assembly are complemented by the surface tension of the solder at the eutectic point to correctly align components onto the PCB pad. However, occasionally the component does not align or may tombstone (stand on one solder pad only). Solder spatter and flux residues can affect both creepage clearances and coatings.

(e)

Where these points make it impractical to use soldering, the only recourse possible is to resort to replacing the whole board. 8.9 RECLAMATION Reclamation of intrinsically safe equipment should be limited to restoration of conformal coating, per the original equipment specification, as a repair or after-component replacement, and possibly after the replacement of soft sealing encapsulant. No attempt should be made to reclaim components or PCB tracks on which intrinsic safety depends. 8.10 TESTING Tests nominated by the manufacturer and described in the certification documents should be undertaken at the completion of repair and overhaul. Testing of galvanic isolating components is recommended, especially upon replacement of transformers and optocouplers. Before equipment containing intrinsically safe circuits is re-installed in the hazardous area, the dielectric strength of the insulation between the intrinsically safe circuit and the metallic enclosure should be checked after completion of the repair or overhaul. The method is to apply a 500 V a.c. to 50 Hz to 60 Hz voltage between the terminals and the enclosure for 1 min. This test can be omitted if the enclosure is of insulating material or if one side of the circuit is galvanically connected to the enclosure for safety reasons. 8.11 ALTERATIONS AND MODIFICATIONS Alterations defined in the certificate should be verified by a competent person. Any change to the equipment, including to component parts not described in the certification documents is considered a modification. Modification of intrinsic safety equipment should not be carried out without verification by the manufacturer and/or the certification/approval authority. 8.12 REPORTING Reporting is to be carried out as detailed in the following documents: (a) (b) Appendix A. AS/NZS 3800.

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8.13 PACKAGING AND DESPATCH Intrinsically safe equipment should be packed appropriately to ensure that it can be handled and transported without suffering detrimental effects.

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S E C T I O N
9.1 INTRODUCTION

E X

E N CA PSU L AT I O N

The protection technique encapsulation (Ex m) derives its explosion-protection properties from the fact that the encapsulation excludes the explosive atmosphere from the electrical equipment, thus isolating the explosive atmosphere from any arcing, sparking or hot surfaces. The protection technique Ex m may be used in conjunction with other protection techniques, for example Ex e to allow the connection of a power source or loads. In this situation the encapsulant forms part of the equipment insulation and therefore is subject to all the same requirements of insulation, namely for its voltage rating and comparative tracking index (CTI). The encapsulation also protects the electrical equipment from the ingress of moisture. Traditionally, Ex m explosion-protected electrical equipment has not been subject to the activities of repair and overhaul. In fact, overhaul has been restricted to cleaning and inspection of the outer-exposed surfaces of the encapsulant. However, with the introduction of softer adherent silicone-based encapsulating compounds that maintain their insulation properties to the same degree as the harder epoxy-based compounds, it has become possible to design Ex m explosion-protected electrical equipment that may be repaired by cutting or picking away the encapsulant to expose repairable components within. The replacement of a fuse is a typical example of the type of component that may be replaced in Ex m protected equipment. The equipment must be designed so that it is repairable and the repair activity must be restricted to the part(s) that have been designated as repairable by the manufacturer and recorded as such in the equipments certification/approval documentation. 9.2 REPAIR/OVERHAUL PROCEDURES 9.2.1 Removal of encapsulation material The exact location, surface boundaries and depth of any excavation of encapsulation material should be determined from the manufacturers certification/approval documentation and the repair or overhaul procedure. Under no circumstances is exploratory removal of encapsulation material to be undertaken. The method of removal of encapsulating material should be in accordance with the manufacturers certification/approval documentation and repair/overhaul procedure. Once the component to be replaced and its termination(s) have been exposed, the component can be removed. The opening made in the original encapsulation material to gain access to the faulty component(s) should be made in such a way that it has (a) (b) a greater cross-sectional area at the bottom of the excavation than the cross-sectional area at the opening in the original surface of the encapsulation; or an undercut around the opening in the original surface of the encapsulation not less than 10% of the greater axis of the opening.

9.2.2 Replacement of components Only those components listed in the original manufacturers certification/approval documentation should be replaced. The faulty component should be replaced by an identical one.
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Fuses should normally be replaced in any circumstance either with a replacement of identical type or, if this is not possible, with an alternative that has (a) (b) (c) (d) the same rating or less; the same prospective current rating or more at the same or greater voltage; the same type of construction; and the same physical size.

Printed circuit boards may be replaced by exchange units that have been obtained from the manufacturer. The printed circuit board should be terminated in the same manner as the original. 9.2.3 Preparation for replacing encapsulation The inner surface of the excavation into the encapsulation material should be free of the following: (a) (b) Loose or partially attached encapsulation material that may remain after the excavation process. Oil, moisture or any other material that may interfere with the adherence of the replacement encapsulating material to the original encapsulation material.

If required by the encapsulation procedure, the surfaces of the excavation should be treated with a primer. 9.2.4 Encapsulating material The replacement encapsulation material should be identical to the original encapsulation material. The use of any other type of encapsulation material other than that stated in the certification/approval documentation is considered a modification. The replacement encapsulant should be mixed and prepared in accordance with the manufacturers instructions. It is important that the mixing process does not introduce air bubbles into the mixture. The chemistry of encapsulant materials may vary between batches and it is good practice for service facilities using encapsulant materials to confirm the mixture and curing properties of each batch prior to use. Records of batch numbers for all components of each mixture of encapsulant should be retained. 9.2.5 Pouring encapsulation material The replacement encapsulant should be poured into the excavation so that (a) (b) (c) the surface of the replacement encapsulant is parallel to the surface of the original encapsulant in all planes; it does not entrap air or leave voids; and it fills the entire excavation to a level the same as, or higher than, that of the surrounding original surface.

9.2.6 Visual inspection Each piece of Ex m explosion-protected equipment should be subjected to a visual check. No visible damage should be evident, such as cracks in the compound, crazing, exposure of encapsulated parts, flaking, shrinkage, swelling, decomposition, discolouration, failure in adhesion or change in hardness.

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9.2.7 Reclamation Because of the removal and addition of material to gain access to faulty components, reclamation is considered the same activity as repair for the Ex m explosion-protection technique.

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SECT ION
10.1 INTRODUCTION 10.1.1 General

10

EX

NO N-SPARK IN G

Non-sparking (Ex n) is an explosion-protection technique that may only be applied to electrical equipment which does not normally contain arcing or sparking devices, or hot surfaces that may cause ignition. In order to reduce the possibility of arcing, sparking or hot surfaces being present to an acceptably low order of probability, AS 2380.9 and AS/NZS 60079.15 specify the following rigorous requirements: (a) (b) (c) (d) (e) (f) (g) Superior insulation requirements. Minimum creepage and clearance distances to avoid arcing or tracking between live parts. Special requirements for internal connections and terminal arrangements for external connections to prevent them working loose and causing sparks and arcs. Protection against the ingress of foreign bodies or moisture. Stringent temperature limits for both internal as well as external surfaces of equipment. Additional requirements for specific equipment, such as motors and luminaires. Control requirements for specific equipment to avoid excessive temperatures, e.g. in motors.

10.1.2 Arcing or sparking parts If arcing or sparking parts or components are essential to the operation of equipment, safety can only be assured by the use of suitable types of protection, as in that of a flameproof enclosure (Ex d). Such arcing or sparking parts should comply with the requirements of the appropriate Australian Standards, for example AS 2380.1 or AS/NZS 60079.0 and AS 2380.2 or AS/NZS 60079.1 for flameproof enclosures. 10.1.3 Insulation Increased safety equipment should be designed so that the likelihood of arcs or sparks occurring in normal operation as a consequence of insulation failure is minimal. As a result, AS 2380.9 and AS/NZS 60079.15 specify strict creepage and clearance distances. The high level of protection against the occurrence or arcs and sparks in service is the basis of the increased safety protection technique, because no additional form of explosion protection is used to ensure safety. 10.1.4 Temperature Unlike flameproof enclosures, the temperature rating T assigned to non-sparking equipment relates to the internal surface temperature of equipment, rather than the external surface temperature. For approval purposes, the limiting temperature of non-sparking equipment should be determined by taking into account the condition of maximum ratings, other factors according to the type of equipment and those conditions considered by the certification authorities to produce the highest values of internal temperatures (see AS 2380.9).

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There are some types of electrical equipment, such as rotating machines, which may require special techniques to ensure safety in respect to dangerous temperatures under conditions of duty that may be variable and onerous. Such special techniques include the use of thermal protection devices that may be used directly or indirectly to disconnect equipment from the electrical supply in the event of a predetermined temperature being attained. This predetermined value for temperature should take into account the properties of the protected equipment (for example, the winding insulation), in addition to limitations that may be imposed by the intended application (see AS 2380.9 and AS/NZS 60079.15 for further guidance). 10.1.5 Terminals and terminations Non-sparking equipment is largely installation dependent in that the safety of such equipment, appropriately certified, can be compromised if due care is not taken during installation. Therefore, creepage and clearance distances should be maintained and it should be ensured that terminals cannot work loose and create an arcing situation. AS 2381.9 addresses these issues by placing strict requirements on the number of conductors for each termination and various torque values appropriate to each terminal clamping screw. Reference should also be made to certification/approval documents for any special conditions that may apply. 10.2 INSPECTION AND OVERHAUL 10.2.1 General Inspection of non-sparking equipment is required to check and verify the insulation material, insulation clearances, insulation creepage, the temperature-sensing devices, terminals and terminations, glands, seals and to check the IP rating and for physical damage. The following Sections detail the criteria to be met during inspection. 10.2.2 Insulation material The insulation materials used appear to be original and in good condition. If not original, the service facility needs to carry out assessment or testing to determine whether the insulation materials meet the requirements of AS 60079.7. No evidence of deterioration exists, due to heating, physical damage or chemical degradation.
NOTE: Chemical degradation can be a major issue in some installations, e.g. in petrochemical plants.

10.2.3 Insulation clearances Clearances are still within the constraints specified in the certification/approval documentation, the manufacturers drawings or data, or refer to the requirements in AS/NZS 60079.15. 10.2.4 Insulation creepage Creepage distances are still within the constraints specified in the certification/approval documentation or the manufacturers drawings or data. See also the requirements in AS/NZS 60079.15.

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10.2.5 Physical damage The equipment needs to be fully inspected for any signs of physical damage and compared against the certification/approval documentation and manufacturers drawings or data. If any type of physical damage exists, it must be remembered that the IP rating will probably have been adversely affected too.
NOTE: Physical damage includes degradation due to chemical reactions.

10.2.6 Temperature-sensing devices Temperature-sensing devices are to be tested for correct operation, including the correct sensing of temperature. Resistance temperature devices (RTD) should be tested using a compatible test device to ensure correct operation over their operating range. One method of confirming correct sensing of temperature is to place the equipment inside a temperature-controlled oven and raise the temperature at a controlled rate while observing the output of the temperature-sensing device. These tests need to be carried out on all temperature-sensing devices, including bearing temperature sensors, which may not be nominated in the certification/approval documents. 10.2.7 Terminals and terminations All terminals require examination to determine: (a) (b) (c) (d) (e) (f) (g) (h) That the terminals and terminations comply with the certificate of conformity. That all creepage barriers are in place and not damaged. That the surface finish is as original and not scratched, which may cause creepage. The terminals are of the correct size and quantity to comply with the enclosures specified heat loading. Retaining devices are present, in good order and comply with the certificate of conformity. Terminal lugs and lead wires are sized correctly and crimped in an approved manner. Corrosion or degradation due to chemical or other factors. Terminals and terminations are not subject to undue mechanical stress.

10.2.8 Glands If cable glands are supplied with the equipment, ensure that the glands are suitable for use with a non-sparking enclosure. The packing in the gland should be checked to ensure that it is in good condition and retains its flexibility. It is recommended that gland packing be replaced at the time of overhaul. If the gland is a compound-filled type and appears to be in good condition, there is no requirement to dismantle and perform further testing on the gland other than to ensure its attachment to the enclosure is in good condition and does not compromise the IP rating and certification/approval documentation. 10.2.9 Seals and IP rating It is essential that all seals are inspected to ensure that the IP rating of the equipment is not compromised. Inspection should look for signs of physical damage, including nicks and cuts in the seal. Seals and their materials should be examined to ensure compliance with the certification/approval documentation, including the mounting to the enclosure.

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10.2.10 Rubber/Neoprene type seals These types of seals should be examined to ensure they are pliable and without a memory. The attachment to the enclosure should also be verified. Any concern in this regard should prompt for full replacement of the seals. 10.2.11 Shaft seals Shaft seals should be examined to ensure compliance to the certification/approval documentation, including the sizing and its fixing to the enclosure. 10.2.12 Equi-potential (earth) bonding Equipment comprising multi-section enclosures require examination and testing to ensure that all parts of the enclosures are earth bonded. This is a particular issue when sealing gaskets are used between equipment compartments. Refer to 60079.7 for rotating machine requirements. 10.3 ROTATING MACHINE SPECIFIC ISSUES 10.3.1 Rotor Rotors should be inspected for the following: (a) (b) (c) That they comply with the certificate of conformity. The stator rotor gap complies with the certificate of conformity. Integrity of windings and rotor bars.
NOTE: If faulty, cast rotors must be replaced in their entirety.

For common tests relating to all rotating machines, refer to Section 5. 10.3.2 Fans Fans used on non-sparking machines should comply with the requirements listed in AS 60079.0 These include meeting the following requirements: (a) (b) (c) A surface resistance of not less than 1 Gigohm. Thermal stability. Clearances as detailed in the certification/approval documents.

10.4 REPAIR 10.4.1 Enclosure repair If a non-sparking enclosure is structurally damaged to the point where its IP rating is compromised, it is recommended to replace the enclosure. If repairs are undertaken, the IP rating must be verified. 10.4.2 Winding replacement The electrical construction of non-sparking equipment decisively influences its explosion protection, and the overhaul service facility needs to be in full possession of the necessary information and equipment to enable restoration to the original or certified condition. Information needed to carry out a rewind includes the following: (a) (b) (c) Type of winding, e.g. single layer, double layer. Winding diagram. Number of conductors per slot, parallel paths per phase.
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(d) (e) (f) (g)

Interface connections. Conductor size. Insulation system, including varnish specification. Resistance per phase or between terminals.
NOTE: Winding data should be available from the manufacturer or the certificate holder. Partial rewinding is not recommended.

As part of the motor rewind process the service facility should conduct a core loss test in the following instances: (i) (ii) Prior to winding removal. After removal of windings.

(iii) After replacement of windings. There should be no increase in core loss. Refer to Section 5 on rotating machines for core loss testing methods. 10.4.3 Repair of rotors Refer to Section 5 for details on this process. 10.5 FINAL VERIFICATION Tests as detailed in AS/NZS 3800 should be carried out and recorded to ensure that the equipment is fit for purpose. 10.6 PACKAGING AND DESPATCH When packaging non-sparking equipment for transport, additional care must be taken to ensure that no damage could occur during transport or storage that could have an adverse effect on the IP rating. 10.7 REPORTING Reporting is to be carried out as detailed in the following documents: (a) (b) Appendix A. AS/NZS 3800.

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11.1 INTRODUCTION

11

E X

t D

( D IP)

The requirements for dust ignition protection (DIP) enclosures are specified in AS/NZS 61241.1.1. A DIP enclosure is sealed against dust and the surface temperature must be maintained below the cloud or layer ignition temperatures of the dust. About 70% of dusts produced by industrial processes are flammable. Dusts differ from gases in that energy levels required to cause ignition are higher, typically millijoules rather than microjoules, and the ignition temperature is generally lower. DIP design limits the build up of dust on the exterior surfaces of the enclosure by avoiding flat horizontal surfaces. Dusts do not disperse with time and ventilation can convert dust layers into dust clouds AS/NZS 61241.3 follows the IEC convention and classifies dust hazardous areas into Zone 20 (continuous release), Zone 21 (primary release) and Zone 22 (secondary release). A suitably certified DIP enclosure may be used in Zone 20, 21 and 22 areas. For further details refer to AS/NZS 2381.1 and AS/NZS 61241.1.2. All light fittings, with the exception of fluorescent fittings, must be clearly marked to indicate the maximum wattage of the lamp that may be used in the fitting without exceeding the maximum surface temperature of the enclosure. AS/NZS 61241.1.2 sets out the requirements for the selection, installation and maintenance of electrical apparatus in combustible dust areas. 11.2 INSPECTION AND OVERHAUL 11.2.1 General Inspection of DIP enclosures should be undertaken as follows: 11.2.2 Gaskets Where gaskets are incorporated into the joints, replacements should be of the same materials and dimensions as the original. Any proposed change of material should be referred to the equipment manufacturer or certification/approval documentation. All gaskets must be of one-piece continuous construction, i.e. with an uninterrupted periphery. Where the original was cemented or moulded to one face the new gasket must be likewise. Any boots or similar flexible protection should be replaced only with new parts from the manufacturer. 11.2.3 Motors Before a rewound or repaired rotating machine is put back into service, it should be ensured that the fan cover ventilation holes are not blocked or damaged to so impair the passage of cooling air over the machine, and that any fan clearances comply with the Standard or certification/approval documentation, as appropriate. When a fan or fan cover is damaged to the extent that it requires renewal, the replacement parts should be of the same dimensions and at least the same quality and material as the original parts, and should, where appropriate, take account of the requirements of AS 2236 to avoid frictional sparking and electrostatic charging.

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11.2.4 Temperature-sensing devices Temperature-sensing devices are to be tested for correct operation including the operating temperature. RTD devices should be tested using a compatible test device to ensure correct operation over its operating range. One method of testing the operating temperature of the RTD is to place the equipment inside a temperature-controlled oven and raise the temperature at a controlled rate while observing the output of the temperature sensing device. These tests need to be carried out on all temperature-sensing devices, including bearing temperature sensors, which may not be nominated on the certification/approval documents. 11.2.5 Cables and conduit entries Entries into DIP enclosures should conform, after repair or overhaul, to the requirements of the applicable manufacturing Standard or certification/approval documents, and should preserve the appropriate degree of ingress protection, according to the certification/approval documentation. 11.2.6 Seals and IP rating 11.2.6.1 General It is essential that all seals are inspected to ensure that the IP rating of the equipment is not compromised. Inspection should look for signs of physical damage, including nicks and cuts within the seal. Seals and their material (including the mounting to the enclosure) should be examined to ensure compliance with the certification/approval documents. 11.2.6.2 Rubber/Neoprene type seals These seals should be examined to ensure they are pliable and without a memory. The attachment to the enclosure should also be verified. Any concern in this regard should prompt a full replacement of the seals. 11.2.6.3 Shaft seals Shaft seals should be examined to ensure compliance to the certification/approval documents, including their sizing and fixing to the enclosure. It is normal practise to replace these seals when overhaul is undertaken 11.2.7 Repair 11.2.7.1 Damage to components Damage to components that are not an integral part of the dust-excluding enclosure (e.g. fixing lugs), may be repaired by welding or metal stitching, but care is required to ensure that the integrity and stability of the equipment is not impaired. It is particularly important to check that any cracks being repaired do not extend into the enclosure. 11.2.7.2 Joints Corroded joint faces may be machined provided the mechanical strength and operation of the component is not significantly impaired, and the type and degree of protection are not adversely affected. 11.2.7.3 Fans Fans used on DIP AS/NZS 60079.0. machines should comply with the requirements listed in

These include the following requirements: (a) Have a surface resistance of not less than 1 Gigohm.
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(b) (c)

Thermal stability. Clearances as detailed in the certification/approval documents.

11.2.7.4 Spigoted joints Spigoted joints are normally provided to achieve close tolerance. Thus, machining the male part will require adding metal to, and machining of, the female part (or vice versa) to retain the location properties of the joint. If only one part is damaged, that part may be restored to its original dimensions by the addition of metal and re-machining. The addition of metal may be by electroplating, sleeving or welding, but metal spraying is not recommended. It is particularly important that, where applicable, the quality of surface finishes is not reduced below that specified in the Standard. 11.2.7.5 Shafts and housings Shafts and bearing housings may be reclaimed, preferably by use of metal spraying or sleeving techniques. Welding may be appropriate with due regard to the limitations of this technique. Care should be taken to preserve any special provisions for dust exclusion, such as a labyrinth joint or O rings. 11.2.7.6 Boots No attempt should be made to reclaim boots or similar flexible protection. 11.2.7.7 Journals Journals may be built up by electroplating. 11.2.7.8 Damaged stator cores Damaged stator cores should be subject to a core test to ensure that there are no remaining hot spots that could compromise the temperature classification or cause subsequent damage to the windings. 11.3 OVERHAUL As well as the following requirements for overhaul of motor windings and repair of rotors, refer to the specific requirements outlined in AS/NZS 3800. 11.3.1 Motor windings Unless the service facility can meet all the requirements outlined in AS/NZS 3800 it should be recognized that any rewinding should be carried out by the original manufacturer in accordance with AS 2236 and the certification/approval documents. Rewinding of equipment for a different speed is not permissible without reference to the manufacturer, since the electrical and thermal characteristics of the machine could be significantly altered to the point of being outside the limits of the certification/approval documentation. The original winding data should be obtained from the manufacturer. 11.3.2 Repair of rotors Refer to Section 5 for guidance on this process. 11.4 FINAL VERIFICATION AND TESTS Tests as detailed in AS/NZS 3800 should be carried out and recorded to ensure that the equipment is fit for purpose.

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11.5 PACKAGING AND DESPATCH When packaging non-sparking equipment for transport, additional care must be taken to ensure that no damage could occur during transport or storage, which could adversely effect the IP rating. 11.6 REPORTING Reporting is to be carried out as detailed in the following documents: (a) (b) Appendix A. AS/NZS 3800.

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SECT ION
12.1 INTRODUCTION 12.1.1 General

12

EX

PRESSUR ISED

Pressurised (Ex p) is an explosion-protection technique that relies upon the enclosure being subjected to a continuous pressure as per AS/NZS 60079.2 or AS/NZS 4871.3, as applicable, from a supply of uncontaminated air or other non-flammable gas while electricity is connected to the enclosure. While uncontaminated air is the most common source of enclosure pressurisation, inert gases can also be used. These inert gases can present an environmental risk, and care with handling/releasing these gases need to be implemented. The specific equipment used within an Ex p enclosure is generally not identified in certification documents, but will be limited by some performance characteristics. Variations can therefore be made to change equipment in an Ex p enclosure without invalidating the certification/approval. However, there are general restrictions such as electrical performance and temperature rating that are relevant when changes to internal equipment are made. 12.1.2 Removal from service Care should be taken to ensure that the interior of the enclosure is purged for sufficient time after shutdown or maintenance to ensure that there is no accumulation of flammable gas in the enclosure. Any ancillary equipment installed to ensure that this purging process is always carried out should be inspected for correct operation. When charged to the required pressure, an enclosure may incorporate a sealing method that permits it to operate within its specific limits without the need for it to be permanently connected to a continuous air or non-flammable gas supply. To comply with the minimum and maximum pressure requirements of AS/NZS 60079.2 some enclosures should be fitted with pressure-activated devices for the operation of alarm or electrical trip circuits. Where these devices are used they should be checked for correct and fail-safe operation. Where test facilities for under pressure, over pressure or under flow are incorporated, these should be overhauled, and their correct operation verified, as part of the overhaul procedure. It will be quite common for Ex p protected equipment to be delivered to a service facility for overhaul without the system monitoring/purging equipment (e.g. pressure switches, pressure transducers, etc). 12.2 INITIAL INSPECTION The examination should ensure the following: (a) (b) (c) Equipment incorporated within an enclosure is examined in accordance with checks appropriate to the relevant protection techniques. All protective access covers are removed and both explosion-protected enclosures and/or covers have the following inspections. All marking plates/labels associated with certification/approval are securely in place and are complete and legible.
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(d) (e) (f) (g)

Check for external and internal damage to the enclosure or casing, including indications of heating, burning and spatter. Check for indications of environmental penetration (dust, fluids) of the enclosure or casing. Check seals and O-rings for integrity. Where monitoring or purging equipment that is part of the certification/approval requirements for the equipment, is delivered to the workshop, check for marking and setting.

12.3 ENCLOSURES 12.3.1 Materials As any suitable material may be used for enclosures, care should be exercised in the overhaul of enclosures to ensure that they have not deteriorated in service. 12.3.1.1 Joints in the enclosure Where applicable, all joints should comply with certification/approval or approval drawings and may include seals. Where hinges are used, they should be clear of the joint and should not be used as part of a seal. 12.3.2 Gaskets and seals 12.3.2.1 Joints The correct fitting of a gasket should be able to be determined without opening the enclosure. No gasket should show appreciable ageing or plastic flow. A check should be made that gaskets are cemented to one face of the enclosure where this is required in the certification/approval documentation . 12.3.2.2 Shafts and spindles A check should be made to ensure that seals for shafts and spindles are in place and in serviceable condition, and that seals are not being provided by grease or a compound. 12.3.3 Fasteners A check should be made to ensure that any screws or bolts used for attaching covers have a head that requires the use of a special tool to deter unauthorized interference and that the fasteners are of the required strength and are all in place. 12.3.3.1 Cable entries A check should be made to ensure that all cable entries comply with AS 2380.4 and that they are installed in a manner that maintains the degree of ingress protection required. 12.4 TEMPERATURE RATING 12.4.1 Lighting fittings A check should be made to ensure that there is a marking on the fitting to indicate the maximum wattage of the lamp that may be fitted, and that the included lamp complies with this requirement. 12.4.2 Heat-generating equipment A check should be made to ensure that any enclosure that houses heat-generating equipment in normal or specified abnormal conditions is able to operate within the temperature limits specified in any certification/approval documents.

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12.5 OVERHAUL EQUIPMENT 12.5.1 General

AND

REPAIR

PROCEDURES

FOR

PRESSURISED

The inspections and tests set out in this Section should be undertaken as part of the overhaul of the equipment. Where inspections and tests identify non-compliance with certification/approval requirements or uncover faults prejudicial to the pressurized enclosure properties of the equipment, then the equipment should not be returned to service without re-certification or repair. When equipment consists of a number of individually certified components, then each component should be overhauled in accordance with this Section. The inspections and tests specified relate only to the pressurized enclosure properties of the equipment. Additional requirements relating to other properties of the equipment enclosed should be specified by the owner/operator. The extent of work, inspection and test results should be recorded and issued to the owner/operator on an overhaul and examination report. A single report may be issued for equipment consisting of a number of individually certified components. A typical overhaul and examination report for pressurized enclosures is shown in Appendix C. Where applicable, the procedure should be inclusive of. but not limited to, the following: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Check that all marking plates associated with the certification/approval are securely in place and are complete and legible. Following appropriate cleaning, visually inspect the equipment for corrosion, distortion or damage. Check the relevant dimensions of the equipment to ensure compliance and completeness to the certification/approval documents. Check the material properties certification/approval documents. of the equipment for compliance to the

Check that enclosures or other physical protection provided are in good order and in accordance with certification/approval documents. Examine all accessible welds to ensure that no cracks exist that may affect the design strength of the equipment. Check if interlocking mechanisms or locking devices where fitted are operating in accordance with design. Check that ancillary components are correctly installed and comply with certification/approval documents. Check that all labels are fitted, in good order and in compliance to the certification/approval documents. Check that all bolt holes, threaded holes, studs, screws, shrouds, bolts and nuts are in good order and are the correct dimension, thread pitch, tensile strength and head type. Where a water-cooling system is incorporated into the equipment, descale the water jacket and test the volumetric capacity and flow rate of the cooling system. Check that there are no leaks in the water-cooling system by applying an appropriate overpressure test. Where specific values for these tests are not given in certification/approval documents, the values used should be in accordance with the original manufacturers recommendations.

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(l) (m) (n)

Test the operation and settings of the protection devices for compliance with the certification/approval documents. Check the condition of all electrical terminations and connections for security and ensure that there are no signs of overheating. Carry out suitable tests to determine that the equipment operates in accordance with design. This testing should include any routine test specified in the approval documents and those recommended by the original manufacturer. Following any repairs, additional tests and checks should be carried out to confirm that the equipment remains in compliance with the certification/approval documents. Carry out any other specific test recommended by the manufacturer.

(o) (p)

12.5.2 Routine tests Routine tests include the following: (a) (b) (c) (d) (e) Functional test. Leakage test. Tests for an infallible containment system. Test for a containment system with a limited release. Over and under pressure tests.

12.5.3 Marking Before Ex p equipment is returned to service the equipment should be checked to verify that markings reflect the current status regarding: (a) (b) (c) (d) (e) (f) (g) (h) (i) Identifying as pressurized. Warnings. Supplementary marking. Internal source of release. Static pressurization. Pressurization systems. Warnings required in other clauses. Overpressure limited by owner/operator. Inert gas.

12.6 GROUP I EXPLOSION PROTECTED TRANSFORMERS From the beginning of the use of transportable substation within the hazardous areas of mines, hermetically sealed, pressurized transformer have been used within Australian Group I installations. While transformers use pressurisation as their explosion-protection technique, they are normally certified as Ex s special protection or Ex p pressurised. The above overhaul technique can be utilised for the overhaul of the pressurised portion of the transformer protection. High and low-tension flanges of the transformer tank are normally flameproof flanges, and should be separately inspection and overhauled in accordance with Ex d requirements. These transformers are typically pressurized with nitrogen gas to 5 kPa at 25C. In operation the enclosure pressure can be expected to reach 55 to 60 kPa.
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The repair and overhaul of these transformers should be in accordance with the Ex p (Pressurized) explosive protection principles. Over pressure test should apply the typical 1.5 times safety factor. i.e. 60 1.5 = 90 kPa It is normal to pressurize the enclosure to the 90 kPa, and leave it for 24 hours, to ensure there are no leaks. Under pressure tests should also be carried out, normally at a vacuum pressure of 90 kPa. For older equipment, the original NSW Mines Department approval documents nominated the test pressure. To ensure that the transformer is always subjected to an inert gas atmosphere, filling of the transformer enclosure should be undertaken from the vacuum pressure of 90 kPa. Under and over pressure monitoring and tripping mechanisms are always fitted to these transformers, along with test facilities to prove their operation. These pressure monitoring and trip mechanisms must be also overhauled and their correct setting and operation confirmed, because in the past, monitoring or test equipment has been the most likely source of any leaks. Thus care in overhaul and leak testing of this equipment is essential. The bushed flanges of these transformers are normally an Ex d (flameproof) flange, and these should be overhauled in accordance with Section 6 of this Handbook. Where an internal circulation fan has been fitted, it is recommended that this be replaced if the repair or overhaul involves de-tanking the core and coils.

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13.1 INTRODUCTION

1 3

E X

O I L

F I L L E D

The oil-filled explosion-protection technique, Ex o, primarily applies to power equipment with windings where the oil provides an improvement in the insulation qualities and is used for cooling. The basis for the protection technique is in providing equipment with Ex n protection and then by adding the oil make it Ex o and suitable for Zone 1 applications. The repair and or overhaul of such equipment falls into two areas nonsparking protection and oil conditioning. 13.2 NON-SPARKING PROTECTION The equipment can be repaired or overhauled according to the requirements for Ex n. Refer to Section 10. 13.3 OIL CONDITIONING This would generally come under maintenance and deals with the condition of the oil. This process ensures that any contaminants are removed on a regular basis to ensure the insulating properties are not compromised. This work should be undertaken by specialists in this field and observing the specific instructions from the manufacturer. Obviously, any faults in the container or tank giving rise to leakage must be rectified immediately. 13.4 TESTING Periodic test of the oil quality is essential. The tests that are generally applied to transformer oils are as follows: (a) (b) (c) Dielectric test. Water absorption test. Dissolved gases test.

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SECT ION

14

EX

VE NT I L ATED

The ventilation explosion-protection technique, Ex v, deals with dilution of the explosive atmosphere rather than the ignition source, and for this reason does not rely on the traditional equipment protection, nor does certification normally apply. Generally considered a system, any repair or overhaul would only deal with normal industrial aspects. If explosion-protected equipment needs to be used to deal with specific situations, they will use techniques already covered elsewhere in this Handbook. Any repair or overhaul should include the functional testing and setting of air pressure and airflow monitoring or tripping equipment.

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SECT ION

15

EX

SPEC IA L

PROT ECT IO N

Special protection is a concept that has been adopted to permit the certification/approval of specific types of electrical equipment that, by their nature, do not comply with the constructional or other requirements specified for equipment with established types of protection, but which nevertheless can be shown, where necessary by test, to be suitable for use in prescribed zones or hazardous areas. This concept permits the flexibility on the part of certifying and assessment authorities in their approach to applications for certification/approval or assessment of equipment, the use of which would otherwise not be permitted in hazardous areas on account of noncompliance with the requirements of Standards for recognized or established types of protection. This applies not only to current types of equipment, but also allows flexibility of approach to new design and innovatory ideas, the development of which might otherwise be hindered. Because of the very nature of special protection, it is impossible to put down generic guidelines for the repair and overhaul of this equipment. Consequently, it is imperative that guidance be sought from the manufacturer before any repair or overhaul process is undertaken.

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SECT ION 16 R E E L I N G
16.1 SCOPE

GROUP I HA ZARDOUS AREA A N D T RA I L I NG CA B L E S

This Section includes guidance notes for cable repair facilities to assist in compliance to AS/NZS 1747. It aims to embrace not only cable repairs but also the several types of explosion-protection techniques currently associated with plugs, receptacles and couplers that cable repair facilities are likely to encounter. Maintenance and repair of cables, and for that matter any asset plant or equipment, is an essential part of the life cycle of that equipment. Failure to properly maintain cables will lead to unexpected failures and premature aging, which in turn will lead to ever-increasing production down time and safety risks. 16.2 CABLE COMPONENTS 16.2.1 General To appreciate the complexity of cable repair, it is necessary to look at the individual components in cables and the role they perform. 16.2.2 Conductors and conductor constructions The important flexibility, strength and the electrical properties of mining cables are mainly derived from the particular conductor design used and armouring or reinforcement. Conductors used in Australian and New Zealand flexible mining cables are based on AS/NZS 1125 and IEC Standards and usually employ tinned annealed copper wires stranded to provide flexibility and flex life suited to the end use, as well as for ease of cable repair and extended service life suited to the end use. Reeling cables use rope lay-stranded conductors. Factors affecting flexibility include the number of individual wires for a given size, the lay length of bunches and strands, and the geometric arrangement of the strands. A simple count of wires and their size is not a reliable guide to flexibility or endurance, since special designs are often developed to suit particular applications. These would include cables for heavy-duty reeling or flexing applications in mining. The cores of each underground coal mining cable design specified in AS/NZS Standards are electrically symmetrical for added safety. An earth check pilot may be found in the interstices of cables used for aboveground applications (e.g. Type 450). Such asymmetrical uses require special considerations due to capacitive induction created from the asymmetrical design. The conductors nominated by the Standards are designed to maintain a circular profile. The wires are of a larger cross-section and the assembly of the wires is in a very regular formation. Rubber-tyred vehicles may frequently squash the cable and the conductor is designed to avoid changing shape (to oval). Thus, these stronger conductors provide greater support for the insulation and other cable components and, overall, the cable is more robust. The negative effects of such a conductor design are that the cable has a larger natural bending radius (the conductors are more able to resist bending) and the wires are subject to greater abrasion as they rub against each other. In applications requiring frequent reeling, especially in conjunction with tight bending radii, eventual failure is likely in the form of broken wires within the conductor. This is particularly true for the smaller conductors and the interstitial earth conductors.

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Recent machine developments for long wall methods have needed a cable for the shearer machine that can tolerate the extremely tight bend of the Bretby cable chain in conjunction with frequent movement. The better conductor for this application is one that is easily bent even if it may change shape. Thus, the design of the conductor has been migrating to the type that has very fine wires. For example, a 95 mm2 normal conductor has 259 wires of 0.67 mm each, while the conductor for a shearer cable will have over 1200 wires of 0.30 mm size. The unfortunate effects of using these soft conductors are that the cable can easily change shape. Thus, in a situation where the cable is squashed, much more mechanical force is applied to the insulation, causing splits in the insulation and electrical failure. In conclusion, it is important to select a conductor to suit the application. 16.2.3 Insulation The insulation material commonly used in cables is EPDM and is generically known as EPR or R-EP-90 in Australian and New Zealand Standards. Although it has poor oil and hydrocarbon resistance, the EPDM compound is used as an insulation material for flexible and trailing cables as per AS/NZS 1802, AS/NZS 2802 and AS/NZS 5000.1, etc., because it possesses the following desirable properties: (a) (b) (c) (d) (e) Excellent electrical properties. Flexibility, even to 6 0C. Outstanding heat ageing resistance. Excellent thermal properties. Outstanding moisture resistance.

16.2.4 Earthing and earthing conductors The earth conductors in the Australian and New Zealand designs are particularly special. In almost all cable types, the cable includes three earth conductors disposed in the outer interstices of the active cores, and the earths are covered with semi-conductive rubber. This rubber provides an electrical conductive connection between all the earth conductors and allows the three earths to combine to give a low resistance path to earth. The Standards dictate the maximum resistance for the earths. With some exceptions, the rules are that the combined earths represent half the conductivity of the active core. In some cables, notably the Shuttle Car cable, the earth conductors are increased to represent 75% of the conductivity of the active cores, mainly to provide greater mechanical strength and reduce the very frequent occurrence of broken earth wires. For the underground coal cables of 1.0/1.1 kV rating and with active cores above 70 mm 2 , the earths are allowed to be smaller and represent one third of the active core. This is possibly to avoid oversized and more expensive earths in an electrical system that reduces earth faults to a few hundred amps. However, such smaller earths are not allowed for the higher voltage cables. When voltage is applied between an electrical conductor and earth, or between conductors, the insulation is electrically stressed in a non-uniform fashion. If the voltage is sufficiently high, such stresses can cause the insulation to break down. This stress on the insulation may be controlled by use of a screening system around the insulation. The screen causes the stress distribution to become uniform. 16.2.5 Screens on the active cores Screening is used in the high voltage cables (3.3 kV and above) and may consist of either semi-conductive rubber or metallic braided wires over each core. Cables used in continuously flexing applications achieve a longer life when screened with semi-conductive
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rubber that can stretch and bend almost an infinite number of times. The braided wire screens limit cable life when the flexing and stretching of the cable induces wear or tensile wire breaks in the screens. In underground coal mines, even 1 kV cables are screened with semi-conductive rubber in direct contact with the earth conductors. Screens provide an immediate electrical path to earth for any phase voltage before that phase voltage can contact another phase. Thus, the fault level can be limited to the phaseto-earth current rather than getting the much higher current (and explosion) that is available on phase-to-phase faults. When the phase-to-earth fault current is high, then the extra conductivity of the copper screens ensures that the fault damage is limited to the immediate location of the fault and that the low impedance trips the circuit breakers quickly. Thus, many mines engineers prefer the security of copper screens, but more are accepting the continuing long-term performance of the semi-conductive screens. Core screening in trailing and reeling cables to AS/NZ Standards cab be achieved by (a) (b) (c) a helically applied layer of wires over individual cores; a composite textile and tinned copper wire braid over individual cores; and braids or pliable steel wire armour with copper wires to achieve the desired conductivity as collective screens (mainly for fixed cables).

16.2.6 Semi-conductive elastomer Besides being part of the earth-fault detection circuit, screens relieve non-uniform electrical stresses and provide a uniform capacitance to earth. Metallic screens over the power cores, and/or the semi-conductive components of the cable ensure that a direct fault path to earth is provided. Bending of conductors under tension accelerates the breakage of metallic screen wires. Partial failure of conductors can lead to wire ends penetrating through the insulation. Low voltage reeling or trailing cables usually have individual core composite braids, or semi-conductive rubber screens to provide for minimal fatigue failure. Australian and New Zealand underground mining cables have fire propagation-resistant semi-conductive screens as an additional safety factor. Semi-conductive rubber screens such as those used in Type 275, Type 241 and Type 441 cables are designed to be connected to systems that are able to limit earth faults to around 5 amperes and fitted with earth leakage detection that trips at 500 mA rms, within about 200 milliseconds. This is tested in AS/NZS 1802 and AS/NZS 2802 by the needle penetration test. Fault tests conducted with higher currents show that semi-conductive rubber and metallic-braid screens will burn away from the fault location. 16.2.7 Central pilot Provision of a central pilot is a unique cable feature found only in AS/NZS mining cables. Many cable types have a small, insulated extensible pilot core that is located in the middle of the cable and is therefore straight rather than being twisted as are the active cores. Any longitudinal tension on the cable becomes effective immediately on this pilot and excessive cable stretching results in the pilot breaking and giving an open circuit. This pilot is designed and manufactured to permit at least 15% extensibility in service. This pilot protection scheme consists of an earth continuity relay that uses the pilot and the earth conductors as part of an electrical loop. Once the pilot is broken, the loop is broken and the relay trips the cable circuit breaker. This system is primarily used to ensure there is an effective connection to earth of a mobile machine. However, the nature of its design and operation provides for detection and tripping before an imminent breakage of the whole cable, and thus removing power before the cable is stretched to the point of breaking
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A key aspect of safety in design is the overall electrical screening provided by a layer of semi-conductive rubber applied over the core assembly, fully enclosing all the insulated cores, and electrically connecting all the three earth conductors that are placed in the cable interstices. This feature provides a sure connection to earth whenever any object pierces the insulating outer sheath, prior to that object being able to make a connection to the power conductors. 16.2.8 Sheath reinforcement This feature is specified in Standards for some of the cable types. Additionally, manufacturers have chosen to reinforce the sheath on a number of the other cable types. The reinforcement may be in the form of a binder comprising a high tenacity open-weave tape or an open-weave braid of high tensile yarns. Kevlar yarns are often used, as are polyester threads. This feature provides additional strength to the sheath to resist impact and deformation and makes the whole cable stronger and tougher. The reinforcement also improves tear propagation resistance of the cable sheath after the sheath is cut by sharp surfaces. such as rocks. 16.2.9 Sheath The primary role of the sheath is sacrificial protection of the underlying cable components from chemical and mechanical damage. The longer the sheath lasts, the longer you can expect the cable to last. A properly formulated sheathing compound is essential for a high performance trailing cable. Typically, PCP, CSP and CPE-jacketed and EPDM-insulated cables are designed for use from 0C to up to 90C continuous conductor operating temperatures. 16.2.10 Materials 16.2.10.1 General The insulation for most cables is a rubber compound of high dielectric properties designated R-EP-90. This compound is based on ethylene propylene (hence the EP) and is suitable for continuous operation at 90C, even though very few mining cables are operated to such a high temperature. In the case of the Class 1 cables cited in AS/NZS 2802, an even higher grade of EP, called XR EP 90, is used that allows thinner insulation for the same voltage level. Such cables are used in applications where the cable can be protected from mechanical damage or where damage is not likely. These applications include the flexible cable feeding stackers and reclaimers in coal yards or cranes at wharfs and ports. Obviously, the thinner insulation would be more easily breached if the cable were subject to impact or crushing. Thus, for applications where damage is more likely, the thicker layers of R-EP-90 are preferred by cable designers and mine engineers. The sheathing material of choice in almost all cases is a toughened compound called HD 85 PCP. This compound is based on polychloroprene (hence the PCP), is designed to be suitable for heavy-duty applications (hence the HD), and can operate at continuous temperatures up to 85C. Even though few mining cables are operated to such a high temperature due to internal conductor heating, the black outer sheath could get close to such temperatures when exposed to the sun in Australias warmer regions. When people talk about a rubber cable they usually mean a cable with cross-linked elastomeric compounds that is resistant to thermal overload without the deformation of thermoplastic rubber-like materials. Trailing cables in mining and materials handling applications commonly have a neoprene (XHD-85-PCP) or Hypalon (XHD-90-CSP) sheath and ethylene propylene copolymer-based EPDM (XR-EP-90) or (R-EP-90) insulation.
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More than just the base rubber makes up a rubber compound. A rubber compound is actually a mixture of many ingredients. The exact combination of these determines the performance of the rubber material. Commonly the recipe contains at least six groupings of the following ingredients: (a) (b) (c) (d) (e) (f) Base polymer (actual rubber part)A range of polymers are available for any type of base rubber. Reinforcing fillersThese may be carbon blacks or whites such as silica, or coated calcined clays for insulation. Plasticising oilsDifferent oils are used dependent upon compatibility and desired properties. Anti-ageing ingredientsCombat against oxygen, ozone, UV or degradation components. Cross-linking agentsAre involved in the curing of the rubber. Colouring pigmentsCarbon black, for example, also functions as an effective reinforcement and UV stabiliser, as required.

Every cable manufacturer has its own rubber formulations. Each recipe is unique in design and composition. Some rubber recipes may contain only one of each of the above constituents. Others may contain 20 to 30 ingredients. Generally, the more demanding the application the rubber must endure, the more complex the rubber recipe will be. It becomes very difficult to compare one rubber with another let alone different rubber types. 16.2.10.2 What is neoprene (PCP) Neoprene is now a generic name for polychloroprene rubber. The abbreviated name for neoprene is PCP rubber. Neoprene was discovered in the early 1930s and is the oldest oilresistant man-made rubber polymer, and is made from 2 chloro 1, 3 butadiene. Manufacture of neoprene begins with either acetylene or butadiene gas. Over 20 different modified types of PCP are produced. Each grade is slightly modified to enhance some particular physical characteristic or trait. 16.2.10.3 What is Hypalon (CSP) Hypalon is a trade name of E. I. DuPont de Nemours and Company. The chemical name for Hypalon is chlorosulphonated polyethylene rubber, and is abbreviated in Australia to CSP. CSP is a man-made polymer produced by the random chlorosulphonation of high-density polyethylene. The rubber was developed in 1952 by DuPont, and was introduced as an alternative to neoprene. Today, there are about five main types of CSP available. Global supply has been reduced with the recent closure of one of the main production units. 16.2.10.4 What is chlorinated polyethylene rubber (CPE) Chlorinated polyethylene rubber is rubber material very similar to Hypalon. The abbreviated name for this rubber is CPE. CPE is a man-made polymer produced by the random chlorination of polyethylene. CPE was invented by DuPont in the early 1950s before Hypalon. The early development work on CPE was abandoned because of the nonexistence in the 1950s and 1960s of suitable curing or vulcanising chemicals. It was not until the early 1970s that Dow Chemical commercially introduced CPE rubber. 16.2.10.5 What is ethylene propylene diene monomer (EPDM) Vulcanised ethylene copolymers (EPR) and terpolymers (EPDM) are derived from the petrochemical industry and have been used widely for insulation over the last 25 years. There are a variety of types from various manufacturers that differ in ethylene content, average molecular weight, and type and quantity of the third monomer.

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The use of EPDM rubber has replaced the use of natural, SBR and butyl rubber insulation materials. The former insulation materials were rated for lower voltages and temperatures (typically 60C). EPDM provides higher temperature (90C) and voltage ratings for equivalent insulation wall thicknesses. Both CPE and CSP rubbers have been used for many years as insulation for low voltage cables where good oil and fluid resistance is required. 16.3 GUIDANCE ON ASSESSING CABLE CONDITION 16.3.1 General Four processes need to be examined during the testing and repairing of trailing cables. 16.3.2 Initial test During the initial test, insulation and resistance values are noted. The condition of the power core insulation, the general construction and age of the cable are assessed. Symmetrical load test results are recorded. 16.3.3 Sheath test Testing to prove the integrity of outer sheathing should include: (a) (b) (c) (d) (e) Check of general condition (assessment of number and type of repairs on cable). Check of mechanical damage (corkscrewing, abrasions and cuts). Evidence of breakdown (corrosion or attack from oils or petrochemicals). Test for pin holes. Shore A hardness rating (any changes to be noted).

16.3.4 Cable repairer The cable repairer should check the condition of the following: (a) (b) (c) (d) Conductor insulation (chemical corrosion or breakdown due to age or prolonged use at incorrect operating temperatures). Conductor wires (mechanical damage, i.e. knuckling or splintering from continuous reeling and physical stress-stretching). Outer sheath (second opinion). Screens, armouring and other cable components.

16.3.5 Final testing This is normally carried out by a competent person who will gather information from the preceding three procedures to assess its cable condition rating as shown in AS 1747. 16.4 EVALUATION BEFORE REPAIR AND HISTORY RECORD 16.4.1 History record The cable repair facility collects all the documentation and testing results for the owners cable history reports. These records should contain the minimum information provided in the sample test and Repair Record form as shown in Appendix C. Every repair facility should keep its own records of cable history and these should be examined before any testing or repair is carried out. (a) (b) Minimum computer database cable history information. Cable history documentation should include but not limited to Personnel.

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(c)

All personnel recording data or testing cables will be identified on the history documents with reference to their individual competency certificate numbers (if applicable by state regulation). The test facilitys ID number, recorded in all history documentation (if applicable by state regulation).

(d)

16.4.2 Cable construction When identifying cable construction the following information should be recorded: (a) (b) (c) (d) (e) (f) (g) (h) (i) Owner/Location Mine owner or the specific location of the cable (e.g. Standards Colliery) Manufacturer The manufacturer of the cable or registered mark. (e.g. Standards Cable Company) Serial No As it appears on the cable sheath. Manufactured Date The date that is part of the external marking of the cable. Cable Type/Standards reference e.g. 241.1 to 1802 Voltage Rating CSA mm 2 Part of the external marking of the cable. Sheath compound Part of the external marking of the cable (e.g. HD90CPE) Shore hardness (original Sheath) Measurement is taken using a Shore A Hardness tester at 10 points around the circumference of the cable. Rating is the average of all readings. (j) (k) Cable Number (owner-location/designation/no.) e.g. SC. M .23 (Standards Colliery, Miner, No23) Date in service The date the cable was commissioned or final tested for service. 16.4.3 Terminations The minimum information required is recorded for both ends of the cable. e.g. End A End B. Plug type and details. (a) (b) (c) (d) (e) (f) (g) (h) Tails. Bolted coupler. Restrained plug. Plug type A or B. Plug serial numbers. Current rating. Voltage. Plug brand.
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16.4.4 Insulation Resistance test records The following tests are required for cable history with results recorded in M ohms (M): (a) Pilot to earthThis should comprise of 3 readings if separate pilot circuits are employed, as is typical of type 245 cable or a type A or B plug as per AS/NZS 1299 or AS/NZS 1300 is fitted and additional control/pilot circuits are present, readings should be recorded for each conductor or connection point. Pilot to phaseThis should comprise of 3 readings. Pilot to phase a, b, and c. If separate pilot circuits are employed, as is typical of type 245 cable or a type A or B plug as per AS/NZS 1299 or AS/NZS 1300 is fitted and additional control/pilot circuits are present in the cable, readings should be recorded for each conductor of connection point. Phase to earthThis should comprise of 3 readings, a, b and c to earth. Phase to phaseThis should comprise of 3 readings, a-b, a-c, b-c.

(b)

(c) (d)

16.4.5 Symmetrical load test The Continuity Resistance () test should be recorded with the applied current measured in amps (A) and the induced earth current in milli-amps (mA). The continuities should be measured from the contact point on coupler A to the contact point of coupler B, as follows: (a) (b) (c) (d) PilotThis may comprise of multiple readings if multiple pilot or control conductors are present. Each reading should be uniquely identified. Phase/Power conductorIndividual readings are recorded for each phase. EarthA combined earth reading is recorded from termination device/plug to termination device/plug. ArmourA combined earth reading is recorded from termination device/plug to termination device/plug.
NOTE: It is recommended that the details as listed above be recorded or checked in the cable history documentation prior to any pre-repair testing or termination of cables.

A typical history, test and repair record is shown in Appendix C. 16.4.6 Visual examination Visual examination of the cable to be repaired should be made, checking for any obvious damage (e.g. cuts, severe abrasions, previous repair deterioration, extent of corkscrewing) and then the general condition of the cable should be noted and reported to the cable owner (if considered excessive or in accordance with applicable mine regulations). 16.4.7 Pre-repair tests Before any repairs are carried out, a complete pre-repair schedule should be performed. The Typical Cable Repair Form as shown in Appendix C indicates the recommended testing. Details and results should be recorded on the cable history and cable test reports. All test equipment should have the instruments ID number recorded and the currency of calibration verified prior to commencement of testing. Calibration schedules vary with each instrument. Schedules referenced in AS/NZS 1747 can be consulted for frequency.
NOTE: High voltage proof test, surge generators/thumpers, sheath test equipment and insulation resistance test instruments should only be operated by trained competent staff.

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16.4.8 Practicability of repair If, at any stage during the visual examination and pre-repair tests, it is the opinion of the cable repairer that the cable is unfit for repair and further use, they should notify in writing the owner or user of the cable of this assessment and record the decision on the history record of the cable (refer to Clause 2.2). 16.5 PROCEDURE FOR HARD SOLDERING REELING AND TRAILING CABLES 16.5.1 General soldering information Before cutting any of the bunches, it is recommended that: (a) (b) (c) Care is taken when laying in the bunches before they are cut. They should be laid in and tied into place to ensure no other bunches are cut by mistake. Once laid in, the bunches should be pulled tight and cut to leave a gap equivalent to the diameter of a bunch between the two bunches to be joined. Before soldering, twist the end of each bunch tightly. Impregnate each end of the bunch to be joined with pre-fluxed silver solder, being careful not to let the solder migrate up the wire more than 3 mm from the end of the bunch. This process is called pre-soldering. Once each end of the bunch has been pre-soldered, lay the ends together and apply heat to both ends of the soldered bunches so that the solder welds the ends together. When joined, clean the joint and remove any sharp edges. Care is taken to not allow the solder to migrate into adjacent bunches.

(d)

(e)

16.5.2 Procedure A procedure for hard soldering a 19-bunch conductor is described as follows: (a) (b) (c) (d) (e) Position the two cables to be joined, so the cable ends are facing each other. In this procedure, it is assumed one end is at your left, the other at your right. Strip the insulation from both conductors to be joined to a length of 230 mm from the conductor ends. Unwind the outer layer of bunches splitting them into groups of six, on each conductor. Divide the inner layer of bunches into groups of three. This should leave the centre bunch only. Cut the centre bunch approximately 20 mm from the end of the insulation taper on the conductor to your left. The centre bunch of the other conductor is laid in place and cut so that the total length of the joined bunch will be 230 mm. Starting from the lefthand side of the splice, lay in the first group of three bunches following the original lay of the bunches, cut one bunch approximately 50 mm from the end of the insulation taper on the conductor to your left. Cut each other bunch 25 mm longer than the previous bunch and pre-solder each end. Then lay in the matching righthand group, cut the bunches and pre-solder these three ends. It may be necessary to twist one cable end, so the lay of the bunches will coincide. Butt up each bunch to where it will lay in, then solder the two corresponding bunches together. Solder the other bunches together. Wind in the next group of three bunches from the left and cut each bunch 25 mm longer, pre-solder, and wind in the corresponding righthand bunches. When satisfied, cut and pre-solder, then solder as in the previous steps. This will complete the first layer of bunches.
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When laying in the two groups of six, the righthand side is laid in with the lefthand groups laid in over the top. Starting on the lefthand side, tie the first bunch to be soldered, and then every second bunch is to be marked and tied in place, ready to be cut. Stagger the position of the cut so there are no adjacent joints. When up to the second group of six, miss two bunches and repeat the process of marking every second bunch. When all bunches are laid in, marked and in their correct position, cut and solder them. Once completed, remove any sharp edges, file any deformities from the joints and clean away any flux residue.

(i)

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SECT ION

17 PRE-OVERHAU L I NSPE CT IO N (CODE C1) F OR GROUP I

17.1 PRE-OVERHAUL REQUIREMENTS AS 2290.1 specifies Code C1 pre-overhaul audits. The pre-overhaul audit is a thorough examination of the equipment to aid in determining when the next overhaul is required, with the proviso that extending overhaul periods indefinitely is not a suitable strategy. This is due to the fact that only accessible components can be checked during a pre-overhaul inspection. A full overhaul process is necessary to check all component parts. Responsibilities are as follows: (a) (b) It is the role of the owner or operator to set up the correct pre-overhaul schedule in their equipments maintenance scheme. A complete and correct statement of compliance is to be issued to the owner/operator by the OEM for new equipment or the service facility following an overhaul of the equipment.

17.2 FLAMEPROOF The requirement for pre-overhaul starts with the initial inspection of the new equipment or the accurate and concise results of the full overhaul. All the information pertaining to each item of equipment must be recorded on the report (as required in Appendix A). The actual measured values need to be entered on the report. The first pre-overhaul audit should be conducted at minimum of 1 year before the specified full overhaul due date of the equipment. The pre-overhaul requirements are laid out in AS/NZS 2290.1 as are all the items that are required to be checked. This is not just a measurement to ascertain that the nominated equipment is still in compliance. It is also a verification to check the rate of deterioration of the equipment where results are compared against those obtained in the previous test certificate for either new or overhauled equipment. This is also a good opportunity to look at equipment that should be removed and replaced or compliance verified at the nominated overhaul period. The verification dossier should contain this relevant information. At the nominated overhaul period, any electric motors on the machine that have run for the full period must be overhauled to the requirements of AS/NZS 3800, or the owner/operator must perform a risk assessment to ensure that the equipment is safe to continue past the overhaul date. Items such as protection devices and control equipment contained within the flameproof equipment are required to be tested and calibrated, or repaired and documented in the report. At the completion of the audit, the competent person should produce a comprehensive report with all the details and recommendations as specified in AS/NZS 2290.1. The verification dossier should also be updated. The longest time period that a pre-overhaul audit can be valid is 1 year, then the process is required to be repeated. 17.3 INCREASED SAFETY EQUIPMENT The requirements for increased safety equipment are similar to those for flameproofing.

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17.4 PRESSURISED EQUIPMENT The requirements for pressurised equipment are similar to those for flameproofing.
NOTES: 1 2 If any information that is a requirement of Clause 12.2. of this document is not available, then the pre-overhaul audit cannot extend the overhaul period. It is a requirement of AS/NZS 2290.1 that the maximum overhaul period of the equipment does not exceed the original overhaul period by more than two years unless the requirements in AS/NZS 2290.1 Clause 2.9 can be satisfied.

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S E C T I ON 1 8 CO M P L I A NCE L E G AC Y P L A NT
18.1 GENERAL

O F

With the changes that have occurred in Standards, legislation and regulations in recent years, it is becoming increasingly difficult to determine compliance of older installations and of plant commissioned before the mid 90s. When equipment from older installations is sent for repair and overhaul to service facilities, the overhaul repair facility can assist with the gathering of some of the objective evidence about the equipment at the plant, and thus assist with the compliance verification process for the installation. The process of verifying compliance is by obtaining objective evidence. This evidence should be retained in a verification dossier for the equipment. Where no dossier exists, a dossier should be created. 18.2 HISTORY For further information relating to equipment approval schemes, refer to Appendix D. 18.3 USING THE FACTS While legislation, standards and codes are not applied retrospectively, there is an obligation that the installation and equipment are maintained in a state of ongoing compliance with the legislation, standards and codes relevant at the time of commissioning of the installation and equipment. Some post-commissioning modifications to the plant may lead the installation to be deemed new, and this may change the relevant compliance requirements. In addition, older equipment will have a history of installation, operation, maintenance and overhaul, and may have been subjected to alteration, upgrade and improvement. Extensive records for the equipment and the wider installation are needed to demonstrate compliance. Where full compliance with the relevant legislation, standards and codes cannot be established, the equipment and installation will need to be brought into compliance with the current requirements. This may involve significant cost and effort. 18.4 ASSUMPTIONS The assumption is made here that an installation prior to mid-1990s, when this transition started, was compliant at the time. The reality is that in the majority of hazardous sites in Australia did not strictly comply, but were approved and permitted to operate. 18.5 VERIFICATION DOSSIER Documentation is required to resolve compliance issues. In this sense it can be recognised that the verification dossier is a source for this documentation. 18.6 FACT GATHERING 18.6.1 General At the outset, some key facts need to be obtained in order that the plant in question can be considered as Legacy Plant. These facts can then be used in the decision-making process to determine how to proceed. A list to help when fact gathering follows:

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(a)

What was the date of the original installation? (i) (ii) What evidence exists to establish a date? Have any modifications been undertaken that would deem this a new installation?

(b)

What Standards was it built to? (i) (ii) Can the actual Standard used for installation be determined? Is the installation to Australian requirements or has some other requirements been used?

(iii) What was the legislation in force at the time? (c) Was the installed equipment compliant at the time of installation? (i) (ii) (d) Is there any evidence that suggests that the equipment installed was compliant? Can the wiring system be identified?

Was it signed off by the regulator? (i) (ii) Who was or was likely to be the regulator having jurisdiction? Does the operator have any report or record?

(iii) Does the regulator have any record of the approval? (e) Have inspection and maintenance routines been followed? (i) (ii) Have hazardous area inspections been carried out? Are there any records from these inspections?

(iii) Has the equipment been maintained? (iv) (v) (f) What manufacturers documentation is available for the equipment? Are there records from any maintenance?

Have any changes been made since the original installation? (i) (ii) Can changes be identified? Are there any records of these changes

(iii) What Standards applied at the time of the change? (iv) (g) Was the change determined to be compliant at the time?

Has any of the equipment been repaired? (i) (ii) Was the repair done in-house or by contract? Did the repairer need or have accreditation?

(iii) Is there a report of the repair available? (iv) (h) Was the repair to certification/approval documentation or to a Standard?

Is documentary evidence available to support any or all of the above? (i) (ii) Is there a verification dossier? Are all product certificates available?

(iii) Do the products have any installation or operation instructions? (iv) (v) Are drawings of the wiring system available? Are inspection reports available?
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(vi)

Maintenance reports?

(vii) Repair reports? 18.6.2 Auditing With all the information gathered, an audit can then be carried out to identify any gaps in compliance. The verification dossier requirements can be implemented regardless of whether or not it was a requirement at the time of commissioning of the equipment. All the missing information can be re-created based on the best information available. 18.6.3 Missing information If the date of the installation is not recorded, it can be estimated from records held somewhere else. Even government records of building approvals can be useful. Any change in ownership should be noted and persons involved with the initial installation can be a reliable source. When determined, this information is added to the verification dossier or is used to start the dossier. Where the Standards that applied are not known, then it is reasonable to assume that the Standard that applied at the time of installation was used.. In determining the Standards that applied at the time of installation it is important to work from legislation and regulations to the Standards and not the reverse. Most likely, an Electricity Act will lead to the wiring rules, which in turn will give the applicable hazardous area Standards. It is important to note that legislation, regulations and Standards related to hazardous areas do not apply retrospectively. Any change to the installation must be assessed to ensure its impact is correctly dealt with in relation to the Standards that are applied to the change. For this reason it is critical to know the history of the installation and equipment, so that the correct requirements for compliance are identified. 18.6.4 Status With the date of installation and Standards applied known, the verification dossier can be progressively updated with the remaining information regarding products and the wiring system. Equipment documentation should be obtained or established in order to allow inspection and maintenance, and this will allow competent persons to apply the Standards of the day to any maintenance or repair. 18.6.5 Summary Compliance is about objective evidence and the verification dossier is the source. Establishing a verification dossier regardless of the era of the installation provides the basis for operation in a compliant world.

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APPENDIX A

QUALITY MANAGEMENT SYSTEM COMPONENT

A1 GENERAL A service facility should have a quality management system (QMS) that complies with ISO 9001. Ideally, the system should be certified by a JAS-ANZ accredited body or a a body accredited by a signatory to the IAF MLA* for quality management systems. The quality management system should incorporate the pre-overhaul audit, overhaul, and the repair and modification of Ex equipment as appropriate. Specific matters to be addressed in the quality management system are outlined throughout this Appendix. In particular, prior to the implementation of any changes to workshop practices, processes or materials, the service facility should assess such changes for ongoing compliance with their Certificate of Recognition and advise the assessment body where such changes may impact on the Certificate of Recognition. The following records should be retained by the service facility: (a) (b) (c) All calibration certificates. Relevant examination, overhaul, test, compliance and verification certificates. Records to support the above.

A2 ROLES AND RESPONSIBILITIES OF SERVICE FACILITY The service facility should have a nominated management representative to liaise with and ensure the service facility complies with the requirements of the assessment body. At least one person should be appointed as a competent person by the service facility, following an appropriate assessment of the persons competencies by the assessment body. The competent persons roles and responsibilities should be clearly documented and at least one competent person should be directly associated with and responsible for the assessment of the relevant explosion-protected electrical equipment. Each service facility that is involved in design of modifications should employ at least one person whose competency in the design of explosion-protected electrical equipment has been verified. The competent person assumes the responsibility for the technical validity and accuracy of all information contained in inspection, report and statement of compliance documents. The role of competent persons is limited to the competencies achieved by them in conformity to AS/NZS 4761 and the type of equipment being serviced. Examples of tasks that are usually allocated to competent persons are (a) (b) the identification of equipment submitted for repair or overhaul; the identification of correct certification and/or approval documents (where applicable) for equipment under repair or overhaul;

* To achieve mutual recognition of systems certification, the peak global body for systems certification (the International Accreditation Forum) has established a Multilateral Agreement (MLA) amongst the accreditation bodies that recognize the certification bodies. See www.iaf.nu for more information.
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(c)

the verification/evaluation of the results of repairs and overhauls of explosionprotected electrical equipment belonging to the explosion-protection techniques in which they have been verified as competent by the assessment body; the issuing and authorization of documentation indicating compliance with the relevant procedures, certification documentation and Standards for repair and overhaul work; and the determination of when a repair requires additional or specific types of testing to be undertaken to verify the repair.

(d)

(e)

A3 QUALITY MANAGEMENT SYSTEMRESOURCE MANAGEMENT A3.1 General The premises, tools and equipment of a service facility should be suitable for the type of equipment likely to be overhauled, repaired or modified.
NOTES: 1

Example of machines and equipment that may typically be found in a service facility dealing with flameproof equipment (Ex d):
(a) (b) (c) (d) (e) (f) Turning and/or grinding facilities for flat surfaces and spigots. Fixed facilities for drilling, tapping or reaming holes. Milling machines. Welding facilities. Metal spray application facilities. Static pressure testing.

Access to the necessary tools and equipment may be provided through sub-contracting arrangements.

Where a modification is part of the scope of work, a service facility should possess a drawing board and good quality drawing instruments or a CAD system and provide a suitably qualified or trained person. A3.2 Technical library A technical library should be established and maintained. Particular attention needs to be paid to maintaining current Standards. Typical technical library facilities should include (a) (b) (c) (d) (e) the relevant Standards from the AS/NZS ISO 9000 series; relevant Australian and international Standards and Handbooks relating to electrical explosion-protected equipment; relevant Australian Standards relating to the type of electrical equipment; this document; and relevant legislation and codes of practice.

A3.3 Training and competency A training and competence program should be established by the service facility for all persons involved in the inspection, repair, overhaul and modification or any other matter that may impact on the explosion-protected properties of Ex equipment while at the facilitys premises. The program should (a) (b) (c) (d) comply with the requirements of the assessment body; maintain currency of training; provide for the maintenance of skills and knowledge; comply with AS/NZS 4761; and
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(e)

incorporate safety, quality management, technical skills, legislation, Standards requirements, and this document.

A4 QUALITY MANAGEMENT SYSTEMREPORTS Workshop reports produced by the service facility should include, as a minimum, all of the following information: (a) (b) A title, e.g. an inspection report. Identification of the issuing body by both (i) (ii) (c) (d) (e) (f) (g) (h) (i) (j) (k) the name in which the registration is held; and the registration identifier, street address or other unique organization identification;

Unique identification of the report on each page. Indication of the total number of pages, each page being numbered for multi-page reports. Client identification. Identification of the work ordered by the client. Date(s) the work was conducted. Location of where the work was conducted, where appropriate. Procedure or method used or a statement of the work performed, including mention of deviations, additions or exclusions from agreed methods and procedures. Reference to the use of sub-contractors, where appropriate, including identification of the sub-contracted work performed. Identification of the item(s) or material inspected and, where applicable, identification of specific components inspected and/or subjected to more rigorous inspection (for example, NDT). Type and serial numbers of measuring devices used. Details of sampling, including methods used and where, when, how and by whom sampling was performed. Environmental conditions during the inspection, where appropriate. Overhaul results including reference to specifications, defects or other noncompliances identified. A declaration of conformity, if appropriate. Clear information on what has been omitted if the work was not carried out in full as detailed in the original contract/work order. Caveats and assumptions made by the service facility and the basis for these, where applicable. Reference to sub-contractors attached reports, where appropriate. The name and signature (or electronic equivalent) of the competent person in charge of the inspection. The date of issue of the report. Any other information specified by the client.

(l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v)

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A5 QUALITY MANAGEMENT SYSTEMDIMENSIONAL CHECKS A5.1 Dimensional measurements When conducting dimensional measurements, the service facility should record as found and as left values on their service facility check sheets or examination reports for future reference. A simple tick to indicate pass or fail is insufficient without supporting material. When taking repeated measurements, it is acceptable practice to record the number and location of measurements and the worst-case figures. Where a process can affect the integrity of a type of protection, and where the resulting integrity cannot be verified after completing the process (e.g. the environmental conditions required for curing an encapsulant) then that specific process should be measured or monitored and documentary evidence should be maintained to demonstrate compliance with required parameters. A5.2 Measuring equipment The service facility should undertake all of the following: (a) Identify all measuring equipment that is used to validate explosion-protected properties, and this equipment should be applicable to the scope of work undertaken and the types of equipment worked on.
NOTE: Product Standards may require additional measuring equipment other than that used for Ex matters.

(b) (c) (d)

Keep in calibration all measuring equipment that is used to establish explosionprotected properties. Ensure that calibrations are traceable to the National Measuring Institute or equivalent. Have measuring equipment calibrated periodically by a NATA accredited laboratory.
NOTE: It is strongly recommended that the service facility establishes master sets of measuring equipment. Both master and working measuring equipment should satisfy Item (d). Working measuring equipment used in the workshop should be regularly checked for accuracy against the master set. This checking should be done by a person trained and competent in this procedure. Records of such checks should be maintained. This does not preclude the requirement for periodic calibration of working measuring equipment by a NATA accredited laboratory, except that the period between NATA calibrations may be extended if the workshop has a documented calibration checking system in place.

(e) (f) (g) (h)

Have a documented procedure for calibration of measuring equipment, including calibration checks on working measuring equipment. Review calibration certificates to establish fitness for purpose. Apply correction requirements to the working measuring equipment used in the workshop, where such corrections are indicated in the calibration certificates. Regard as sub-contractors the calibration laboratories that supply a service and, therefore, include them in the review of sub-contractors, with the review including confirmation that any accreditation remains current and valid.
NOTE: It is important to ensure that calibration laboratories are accredited for the particular type of equipment being calibrated.

Examples of typical measuring equipment for a Recognized Service Facility in relation to flameproof (Ex d) equipment include the following: (i) (ii) Straight edges. Feeler gauges.

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(iii) Thread gauges. (iv) (v) (vi) Inside and outside micrometers. Dial gauges (optional). Depth gauges.

(vii) Callipers, inside and outside. (viii) Suitably scaled voltmeter. (ix) (x) (xi) Suitably scaled ammeter. Resistance measuring instrument. Variable voltage source, continuously variable to 4 kV.

(xii) Insulation tester to 10 kV. (xiii) Hi-pot tester to 30 kV. (xiv) Pressure gauges, over pressure test equipment and suitable dial gauges. Measuring equipment should be held to allow the service facility to measure all dimensions necessary to determine Ex compliance. Measuring equipment should have a measurement capability sufficient to discriminate between compliant and non-compliant dimensions. A6 QUALITY MANAGEMENT SYSTEMWORK PROCEDURES The service facility should establish appropriate procedures or work instructions for preoverhaul audits, overhauls, repairs and modifications for Ex Equipment. These procedures or work instructions should incorporate each process covered under the scope of the service facility certificate of recognition in accordance with the following: (a) (b) (c) (d) (e) (f) (g) (h) (i) Type of service offered modification/replacement). (overhaul, repair, reclamation and/or

Type of equipment serviced, e.g. rotating machines. Type of explosion-protection equipment serviced, e.g. Ex d, Ex e, etc. Identification of incoming products. Inspection of incoming Ex components and equipment. Where certified components or parts are identified as non-compliant, the certification body that issued the certificate of conformity should be notified. Identification and acquisition of necessary documentation (approvals, certificates of conformity, relevant Standards). Inspection, assessment, measurement, testing, disassembly, reassembly, final inspection and reporting. Defining when a repair requires additional testing or specified testing to be undertaken to verify the repair (e.g. to what extent a flameproof enclosure can be repaired and when a static pressure test is required). Provision of flowcharts or necessary information to identify processes used and human, material, equipment and test/inspection resources required. Recall of product after despatch should the service facility become aware of any critical or major defect after the repaired product has been released, and notification to the assessment body of the problem and to national authorities (e.g. Mining Regulators for Group I, if this is the case). Details and evidence of competency for persons nominated as competent persons.
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(m)

Sub-contractor activities including the method of control the service facility maintains over any sub-contractor used to perform part of the repair and overhaul process, testing and calibration activities. Any work carried out by the sub-contractor should be supervised to an appropriate degree.

Regarding Item (l), if the subcontractor is not quality accredited, the work may require continuous supervision by a competent person. The level of supervision will depend on the Ex criticality, type of work, accreditations held by the contractor and the ability to do a thorough inspection of the completed work. A7 QUALITY RELEASE A7.1 General Repaired or overhauled equipment should be released from the service facilitys premises only when a competent person is satisfied that all of the required activities have been undertaken and the examination report indicates authorization of results of inspection and tests. On release of equipment, the service facility should supply a service facility report to cover each item of equipment released from the service facility. A7.2 Welding and brazing Where welding and brazing repairs are carried out, the minimum requirements should be as follows: (a) (b) A welding QMS.
NOTE: AS/NZS ISO 3834 provides guidance in this area.

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FOR

EQUIPMENT

Welds should only be made in accordance with a qualified welding procedure specification.
NOTE: Suitable forms for recording the details of welding procedure specifications and procedure qualification records can be found in welding Standards.

(c) (d) (e)

Only welders qualified to use the qualified welding procedure should make the welds. Those engaging in down-hole welding should possess specific qualification to do so. Technical work instructions should be developed that provide details of the method of preparation for welding, drilling out of damaged threads, cleaning out the hole before welding, specific details of the set-up of the welding equipment and any other details necessary for the correct application of the qualified welding procedure. Qualification testing should be carried out to prove the process and procedure.

(f)

Where welding work is carried out by a sub-contractor, the above requirements should also apply. A7.3 Non-conforming product The service facility should take action, appropriate to the degree of risk to the customer, where non-conforming product has been supplied. For all non-conforming products that have been released, the service facility should maintain records of (a) (b) (c) (d) serial numbers or identification of product supplied; the customer who received the product; the action taken to inform customers and the relevant assessment body; and the action taken to implement corrective and/or preventative action.
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APPENDIX B

MEASUREMENT AND CALIBRATION IN Ex WORKSHOPS

B1 SUMMARYESSENTIAL WORKSHOP INFORMATION For Ex equipment, measurement is critical. The selection of measurement technique, traceability of calibration of measuring equipment, the measurement environment, performance of measurements and detail of the records kept are essential parts of determining the conformity of Ex equipment. This Appendix (a) (b) (c) (d) (e) provides information measurement; on the technical infrastructure available to support

offers an overview of how this infrastructure can interface with a companys measurement management system; provides guidance on the analysis of the measurement task; provides guidance on the implications for a determination of conformity of varying measurement techniques; and offers guidelines for the calibration of measurement equipment commonly used in a service facility.

B2 WORKSHOP MEASUREMENT MANAGEMENT A service facility (workshop) should adhere to the following: (a) Have appropriate equipment for the measurement taskWhere any measurement is approaching the limits of capability of the instrument (i.e. a pass/fail depends on the last significant figure), then change the measuring technique. Protect that equipment from accidental damageCases and secure storage are important, as are stable environmental conditions. Ensure that personnel performing measurements are competent in the measurement and use of the equipmentCare is needed when tradespeople are operating in unfamiliar disciplines (e.g. electrical fitters undertaking mechanical measurements). Periodically confirm that measurements remain traceable to the international system of units (SI) by having equipment calibratedEither calibrate reference equipment or, even better, the measurement equipment itself at defined intervals.

(b) (c)

(d)

B3 CALIBRATION INTERVALS Guidelines on calibration intervals are as follows: (a) (b) (c) Start with the manufacturers recommended re-calibration interval. If no interval is provided, a nominal 1 year for mechanical devices or 2 years for electrical devices may be acceptable starting points, or use Table B1. Noting that displayed digits is no indication of accuracy or stability, where any measurement is approaching the limits of capability of the instrument (i.e. a pass/fail depends on the last significant figure), then change measuring technique. If this is not possible, reduced calibration intervals should be applied.

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(d)

Similarly, where any measurement is well inside the limits of capability of the instrument (i.e. a pass/fail depends up the second or third significant figure), then an increased calibration interval may be applied. Apply reduced intervals between calibrations and checks when the equipment operates under less than ideal conditions. If any suspicion of damage arises, the equipment must be re-calibrated immediately and thereafter at reduced intervals until it is shown that stability has not been impaired. Reduced intervals between calibrations and checks may also be required in particular applications or with particular equipment configurations. Any extension of calibration intervals should be based on factors such as history of stability, frequency of use, accuracy required, ability of staff to perform in-house checks and successful participation in relevant proficiency testing programs.

(e) (f)

(g) (h)

The following pages in this Appendix provide more in-depth information on measurement and calibration. B4 CONTEXT Measurement is fundamental to the determination of conformity in an engineering context. The quality of measurement information has a direct bearing upon the validity of the determination of conformity. In the technical domain, a measurement is a test returning quantised data, and the reliability of a measurement is dependent upon a range of features examined in this Appendix. In the context of explosion-protected equipment, an extensive body of knowledge underpins the determination of the physical limits within which equipment is considered explosionprotected. A suite of Standards has been developed to systematically address the physical constraints relating to explosion-protected equipment, and conformity systems utilising a Type 5 product certification system* provide assurance of the ongoing conformity of individual products manufactured in a serial fashion. Equipment usage leads to degradation of the equipment, and periodic overhaul is necessary to ensure that equipment remains explosion-protected throughout its design life. In many items of equipment, the explosion-protection properties are highly dependent upon precise determination of characteristics during overhaul. Service facilities should be familiar with the conduct of a range of measurements, covering dimensional, thermal, electrical and electronic quantities. The following paragraphs offer some guidance on the key features of the systems supporting the calibration of a range of commonly used measuring equipment. Measurement presents a significant challenge. Calibration and high performance measuring equipment is expensive, while product failures arising from inadequate measurement may also be expensive. This paper provides background information regarding issues in measurement, covering a range of commonly measured quantities.

* This system involves design freeze, testing a type of the design, certification of the design and regular assessment of the serial production of items by the certification body or its delegate. In Australia, the ANZEx scheme exists for explosion-protected electrical equipment, with the scheme rules provided in Standards Australia publication MP 87.1.
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B5 DEFINITIONS B5.1 Calibration A series of actions to determine the deviation of the indication of a measuring instrument (or the stated value of a material measure) from a reference or true value. B5.2 Traceability The formal definition of metrological traceability is given in the International Vocabulary of Basic and General Terms in Metrology (VIM-2008) as the property of a measurement result whereby it can be related to a reference through an unbroken chain of calibrations, each contributing to the measurement uncertainty. B5.3 Verification Activities to establish the continued performance of measuring equipment. Verification or check activities might include one or a combination of the following: (a) (b) (c) (d) In-house checks at a reduced number of points. Inclusion of reference checks (blanks, spikes. etc). Confirmation of zero and full-scale readings. Single-point checks prior to and following use of the equipment.

B6 SPECIFYING MEASUREMENTS B6.1 General Meaningful measurement outcomes are depending upon establishing clear communication of data. Measurement data is coded by (a) (b) (c) the quantity or characteristic being measured; the value arising from the measurement*; and an associated uncertainty indicating the range within which the measurement may be expected to vary.

In specifying any measurement, the service facility needs to determine the acceptable level of measurement performancein metrological terms, the acceptable uncertainty associated with the measurement. Factors affecting measurement performance include the contribution to that performance from the equipment proposed, the measurement technique, the environment, the measurement officer and even the item being measured. One factor among these is the calibration of the measuring equipment. Measurement performance information then informs decisions regarding the measurement technique, as well as selection, calibration, verification, use of equipment and reporting of measurement data. Overarching the specification of any individual measurement is the intent of measurement comparability. Ideally, different performances of the same measurement determination should provide consistent determinations within the limits of the specified measurement performance. As part of achieving this comparability, the international system of units (SI) offers a globally accepted selection of quantities that are readily realised with appropriate levels of uncertainty. For a given measurement these considerations combine as follows:

* This may be either with or without corrections and adjustments arising from certificates of calibration.

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(i)

SelectionAppropriate measuring equipment selection will be determined by the configuration of the measurement and the desired performance of the measuring equipment. CalibrationMeasuring equipment is required to be calibrated to provide assurance over the operation and performance of the equipment and to provide metrological traceability to the SI system of measurement, allowing comparability between different performances of the same measurement determination. Periodic verification of equipment provides ongoing assurance over the stability and continued acceptability of the equipment.

(ii)

(iii) PerformanceQuality measurement requires skilled operatives working in a suitable environment, using techniques that minimise errors and mitigate the influence of environmental factors. Operatives performing measurements should be familiar with any limitations of the measuring equipment as indicated in the supporting calibration documentation. (iv) RecordsThe records kept on measurement practices and outcomes must reflect as far as possible the value, the range of possible values and the presence of any factors or influences that may cause undue variations in the measurement.

Each of these considerations is dealt with at length in the following Sections. This document also provides background information on the systems supporting traceable measurements. B6.2 The metric system, calibration and traceability Good measurement practice requires that valid measurements are able to be related to common reference units. In Australia, the metric system forms the basis for most measurements and there is a robust infrastructure allowing measurements to be related (traceable) to the national and international Standards for measurement. Establishing the traceability is commonly described as the calibration of the equipment. Formally, calibration means determining and documenting the deviation of the indication of a measuring instrument (or the stated value of a material measure) from a reference or true value of the measure and where critical characteristics impact on measurements, these are confirmed during calibration. Implicitly, for equipment this requires determinations at many points across the scale of the instrument, possibly with multiple determinations at each point. In this regard it may be distinguished from a verification or check, where a single determination at one or two points is considered sufficient to establish the continued performance of the measuring equipment. Figure 1 shows that BIPM manages the fundamental reference standards of the metric system. National calibration laboratories (such as Australias National Measurement Institute) hold national realisations of these standards, from which are calibrated the reference instruments used by accredited calibration laboratories. These reference instruments are then used to calibrate the instruments used by facility centres and end users, either as reference instruments that calibrate measuring equipment, or for directly measuring instruments. Despite the best science, in each calibration or transfer of traceability the uncertainty associated with the transferred value increases. In theory, the chain of calibration can extend through many links. However, in practice the uncertainty increases with additional transfers so rapidly that minimising the number of transfers is essential to preserve the integrity of the measurement.

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BIPM
(Bureau International des Poids et Mesures)

National Calibration Laboratories

Accredited Calibration Laboratories

End users

FIGURE B1 THE SI CHAIN OF MEASUREMENT TRACEABILITY

The use of accredited calibration laboratories is accepted international practice, since such laboratories have demonstrated their competence to perform the calibration and have analysed their calibration techniques in order to estimate and achieve an acceptable uncertainty associated with a calibration. Globally, accreditation through a signatory to the ILAC MRA means that the calibration activities have been assessed and found satisfactory by their peers*. Organisations may operate calibration laboratories for the purpose of managing and controlling their internal equipment, and manufacturers of measuring equipment in particular may establish centres of excellence operating at a very high level to establish the traceability and calibration of their products. Figure 2 indicates how this structure may operate. B7 CALIBRATION PATHWAYS FOR TRACEABILITY B7.1 General Figure 2 is developed to accommodate a global organisation using a very high-level calibration centre. In practice, in the Ex industry most organisations operate through a combination of pathways graded A, B and C. Therefore this Appendix does not consider the use of the calibration centre. In the following pathways, A and B establish traceability to SI. Periodic re-calibration using pathways A or B is necessary for reasons provided earlier in this Appendix. Pathway C may only be used in conjunction with pathway A or B to achieve additional or ongoing assurance of the performance of the equipment.

* See ILAC P10:2002 ILAC: Policy on Traceability of Measurement Results.

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Nat. Metr. Institute National standards

Accredited calibration laboratory Reference standards

Transfer standards

Calibration centre Companys reference standards

In-house calibration laboratory Pathway B Transfer standards Working standards or factory standards Pathway C Transfer standards Pathway A

Companys test equipment

Products to be manufactured

Metrological infrastructure in a country

Domain of the company

FIGURE B2 CALIBRATION PATHWAYS*

B7.2 Pathway A Pathway A involves the accredited calibration authority calibrating the measuring equipment used in performing the measurement. The calibration authority issues an endorsed report for the calibration, including statements of compliance and, as necessary, statements of corrections and the uncertainty with which the calibration has been performed. Formal traceability extends to the measuring equipment used in the measurement. B7.3 Pathway B Pathway B involves the accredited calibration authority calibrating reference equipment used to calibrate and/or verify the equipment for performing the measurement. Traceability is provided in the ILAC P10 sense only as far as the reference or transfer equipment. The final step, from the calibrated reference equipment to the end-user measurement equipment, is performed by in-house operatives. While these people may be suitably qualified, the final transfer is not performed under accreditation and so is not a formal calibration. Pathway B may be used in equipment where, when equipment non-compliance is identified, the equipment is removed from service. Examples of this include dial gauges and feeler gauges. In some organisations operating larger calibration facilities, NATA has accredited the calibration facility. NATA Policy Circular #12, NATA Requirements for the Performance of Calibrations In-house, provides guidance to the relevance of accreditation in these activities.

* Taken from ILAC G2:1994: Traceability of measurements with modifications.

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B7.4 Pathway C Pathway C should be used in conjunction with pathways A and B to provide increased assurance over the performance of the measuring equipment. Pathway C introduces the concept of verification checks to indicate the continued ability of the equipment to perform. A verification at one or two points is often considered sufficient to indicate the continued ability of the equipment to correctly indicate a measurement at other points within the range of the instrument. The adequacy of this belief depends very much on the nature of the equipment and its operation, and the nature of the verification checks. When used in conjunction with a robust equipment assurance program (see B7.4) verification results obtained using pathway C may support varying the frequency of recalibration using pathways A and B. B7.5 Implementation of pathways The presence of the various pathways gives users options regarding calibration. Direct calibration (pathway A) is preferred as the equipment is subjected to additional checks that may not be performed by in-house calibration officers. Verification checks performed inhouse (pathway C) should be performed for a range of reference points and may be used to extend the period between re-calibrations using pathway A or B. Organisations should operate equipment assurance programs that combine full calibration and additional verification checks at a reduced number of reference points to assure an optimal measurement performance. Figure 3 shows a chain of traceability for a length measuring instrument. B8 PERFORMANCE BREAKDOWN AND RE-CALIBRATION The traceability provided by calibration can be disrupted by post-calibration events in the history of the equipment. Performance degradation can occur through mishap, misuse, operational wear and natural phenomena. Calibrated equipment represents a valuable asset, and therefore should be protected from accidental damage by careful storage. Protective packaging and cases can limit damage from accidental bumps and environmental conditions. Controlled access should be established to prevent misuse. Despite these preventive measures, damage may not always be visibly obvious, and periodic verification or re-calibration offers an assurance that equipment continues to function as intended.

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Wavelength standard
National standard

Interference comparator

Reference standard

Laser interferometer

gauge block comparator -differential measurement-

Working standard Factory standard

Dial gauges/dial micrometers test equipment Gauge block acc. 0/l

Test equipment

Dial gauge

Dial micrometer Length measurement probe electr., opt., pneumat.

FIGURE B3 CALIBRATION CHAIN FOR DIMENSIONAL EQUIPMENT*

Regrettably, equipment use and aging will also mean there is a progressive degradation in equipment performance following its calibration. This degradation in performance implies that the uncertainty contributed by the instrument will increase as time goes by. In order to limit the effect of this degradation in performance, traceability must be periodically reestablished. Calibration is, however, expensive in time and money, and so many organisations seek to use additional in-house disciplines (in-house equipment assurance programs) to ensure that (a) (b) equipment remains capable of operating as intended; external calibration intervals may be reasonably extended, allowing reduced total calibration costs by extending the interval between external calibration and including additional in-house verifications.

Figure 2 offers a number of calibration pathways that are further discussed in the next section.

* Taken from ILAC G2:1994: Traceability of measurements

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B9 CALIBRATION OF COMMONLY USED EQUIPMENT B9.1 General Table B1 offers a list of commonly used equipment and the recommended calibration activities and frequencies. Table B1 includes the normal periods between successive calibrations for common items of equipment under ideal conditions. It must be stressed that these periods are generally considered to be the maximum appropriate in each case, based on the assumption that (a) (b) (c) the equipment is of good quality, of proven adequate stability, and is properly housed and used; the organisation has both the equipment capability and staff expertise to perform the requisite in-house checks; and all of the subsidiary checks indicate satisfactory operation.

B9.2 Specifications for calibration Australian Standards detail the performance requirements and calibration methods for some frequently-used types of equipment, as do manufacturers, providing performance specifications and acceptance limits for equipment in associated engineering manuals. Such Standards and documents frequently include checks for wear and degradation that go beyond simple verification of the measuring equipment. Service facilities should be aware that these Standards and specifications may mean that measuring equipment does not match the performance requirements needed to satisfactorily perform the intended measurement. Equipment may be over-specified for a given measurement task, or under-specified. Clearly, under-specification in of concern, since the use of inadequate measurements opens the risk of accepting non-conforming product. In contrast, over-specification indicates that the workshop has invested in the measurement beyond what was theoretically necessary to establish compliance. Where equipment is used for a number of performance tasks, the equipment should be calibrated in order to satisfy the most stringent performance requirements. For this reason, where a Standard for common engineering equipment is available, it will specify a high level of performance, and where such a Standard is widely accepted, it may not be possible to request a lower level of performance at a suitably reduced price. B9.3 Considerations in purchasing calibration services Any purchaser of calibration services should establish that the calibration provider is capable of providing calibration at the required level of performance. Accreditation and timeliness of service are also relevant considerations, but notwithstanding the calibration provider holding an accreditation, purchasers of calibration services should visit and discuss their calibration needs and intended equipment usage with their calibration providers. Guidance is provided later in this Section regarding the effective use of calibration data in the conduct of measurements. B9.4 Outsourcing of verification activities In a number of service facilities, verification activities are outsourced to external suppliers. With low-accuracy equipment this may be sufficient, depending upon a risk analysis of the measurements performed with that equipment. Naturally, such equipment should be marked to prevent its use in measurement tasks that demand a higher level of instrument performance.

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B10 EFFECTS OF UNCERTAINTY ON CONFORMITY DECISIONS B10.1 General Recent metrological theory has applied statistics to measurement*. This recognises that many factors, some controlled and some uncontrolled, influence reliable measurement. By identifying the possible sources of variation and the likely contribution of each source to the final measurement (also known as developing an uncertainty budget) it is possible to establish a range within which the true value is expected at a given level of confidence for a given measurement. Thus, even the best measurements involve three figures: the measured value, the uncertainty and the level of confidence. For example, a length bar may have a measured value of 9.999 mm, with an uncertainty of 0.0013 mm at a 95% confidence level, indicating that there is a 95% probability (i.e. in 20 measurements it is expected that for 19 of them) that the true value lies between 9.9977 and 10.0003 mm. When applied to a single (upper or lower) acceptance limit, this means that the confidence with which a conformity statement can be made must take into account the uncertainty associated with the performance of the measurement. Where there are subsequent calculations applied to a measurement or measurements prior to the determination of compliance, the measurement uncertainties associated with these measurements flow through to the final figures, amplified as appropriate by the calculations. For calculations where two measurements are subtracted to establish a dimension used for conformity (such as in a flamepath gap), the uncertainties of the two measurements are added using the following equation: U total =
2 U12 + U 2

Where the two measurements are close, as expected in the determination of a flamepath gap, the combined uncertainty may approach or even exceed the difference between the measurements. In a flamepath gap determination, the calculated figure offers a one-sided tolerance limit. Often, a guard-band is applied to force removal from service before compliance is threatened. This is usually what occurs in practice in Ex d equipment, where equipment with gaps approaching the maximum permissible usually has the flamepaths re-machined to closer gaps, usually to allow for wear in future service.

* See, for instance the ISO Guide to the Expression of Uncertainty in Measurement (ISO GUM) and a range of interpretive documents such as the UKAS document M3003: The Expression of Uncertainty and Confidence in Measurement As detailed in Clause 9.3 and Appendix Z of AS/NZS 3800.
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C m = T/(4 m) 40 30 20 p c = 95 % for points on curve 10 9 8 7 6 5 4 p c < 95 % in shaded region 3 2

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1 0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

y = ( h m T )/T

NOTE: The measurement capability index Cm = T = (4u m ) versus the span of a two-sided tolerance, showing the locus of constant 95 % conformance probability pc. The curve separates regions of conformity and nonconformity at a 95 % level of confidence (From JCGM 106 Figure 7).

FIGURE B4 PROBABILITY OF COMPLIANCE, MEASUREMENT CAPABILITY AND TWO-SIDED TOLERANCE.

A recent work* has examined the impact of this probabilistic approach to the issue of determining conformity with a specification. It offers the chart provided in Figure B4. This indicates that for a two-sided tolerance, where the standard uncertainty (Um) associated with the measuring instrument is expressed as a ratio of that tolerance span T (on the yaxis, a value sometimes described as TUR, or test to uncertainty ratio) and the tolerance is expressed as a unit range from 0 (the lower limit) to 1.0 (the upper limit), the indicated measurement must lie within the unshaded region in order to have a 95% or better confidence that the true value lies within the tolerance. As measurement performance improves (i.e. uncertainty is reduced or the upper and lower limits separate, effectively increasing the TUR), the tolerance limits may be approached with confidence. Note also that where the uncertainty exceeds the value of the tolerance, it is not possible to determine compliance with 95% confidence and a lower confidence level is delivered. As an example, for a measurement of a dimension of, say, 10 mm with a tolerance of 0.5 mm (so T = 1.0 mm), and using a measuring technique with a standard uncertainty of 0.1 mm (so C m = (1.0/0.1) = 10), true dimensions will be within tolerance 95% of the time (or better) when indicated measurements lie between 0.05 and 0.95 of (so that indicated measurements are between 9.55 and 10.45 mm). Should a measurement technique be selected with a larger measurement uncertainty be selected (say 0.25 mm, making C m = 4)
* Evaluation of Measurement datathe role of uncertainty in conformity assessment JCGM 106 Draft May 2009 Note that the equation uses 4u m which represents the full span (or the combined tolerance), attributed to the expanded uncertainty at 95% confidence levels where these are distributed normally Note that this still allows for a 5% probability that the true value lies outside the tolerance
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true dimensions will be within tolerance 95% of the time (or better) when indicated measurements lie between 0.1 and 0.9 (so that the range for acceptable indicated measurements is reduced to between 9.6 and 10.4 mm).
NOTE: Both determinations judged by eye from the graph of Figure 4.

B10.2 Assumptions The calculations supporting this graph are based upon assumptions that the equipment calibration is the dominant source of uncertainty and that there are symmetrical, normal distributions of uncertainty using a single instrument in a single determination. These assumptions are open to question under workshop conditions in service facilities. One possible response is the determination of guard-bands that further limit the tolerance in order to accommodate the uncertainties associated with the measurement, and thus provide a level of confidence that the true values lies within the specified tolerance. However, uncertainties are usually calculated under assumptions of symmetrical, normal distributions of uncertainty using a single instrument in a single pair of determinations at a single point in time under equilibrium conditions. These assumptions are open to question when measurements may be performed using different configurations of equipment, different operators and possibly different days and environmental conditions to perform the measurement. Even the use of guard-bands, while offering a somewhat conservative approach, may be insufficiently conservative depending upon the basis and assumptions considered in the selection of the size of the guard-band. B11 MEASUREMENT CONSIDERATIONS B11.1 General The key message of this Appendix is to reinforce the basis of good measurement practice, notably the selection of appropriate techniques and suitable measuring equipment to achieve an adequate level of confidence in the validity of measurements taken. Measurements may be used in a range of situations, as follows: (a) In many situations, measuring equipment will be indicative, and neither accept/reject criteria, nor compliance data, will be derived from the measurement. Under these conditions calibration and measurement performance are probably not relevant. In most inspections it is sufficient that measuring equipment be demonstrated to comply with a recognised Standard. Typically, this approach will use a maximum permissible error or a limit of performance philosophy. Uncertainties of measurement arising from calibration are normally much less than instrument errors and may be reasonably ignored. In some inspections where a higher level of measurement is required, the inspector will apply the corrections provided in the calibration certificate. Under these circumstances the corrected value will have a corresponding uncertainty. Workshops are reminded that uncertainties reported in calibration certificates relate to the calibration system operating under calibration-laboratory conditions. Uncertainty in outputs from measuring devices in uncontrolled environments such as are encountered in the field or a workshop may be much greater than those achievable under ideal conditions. In some instances the performance of the measuring instrument will be significantly better than that demanded by the application. Under these circumstances an evaluation of the risks associated with variation in measurement may suggest that a relaxation of the acceptance requirements for instrument performance will not deleteriously affect the quality or acceptability of measurements. Such a relaxation is acceptable where documentary records of the evaluation are retained.

(b)

(c)

(d)

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Workshops are reminded that the number of digits displayed is not a valid reflection of the accuracy of measuring equipment. Manufacturers specifications may provide further information upon the uncertainties associated with measuring equipment. In accordance with international practice, where uncertainties of measurement are relevant they are understood to be at a 95% confidence level. B11.2 Analysis of measurement tasks Each measurement task that relates to a conformity decision must be conducted in a manner that supports the reliability of the measurement outcomes. A significant amount of confidence can be determined prior to commencing any measurement, through careful review of the measurement tasks, the expected measurement performance and the selection of measurement equipment and techniques returning appropriate levels of measurement performance. B11.3 Considerations Considerations during the review phase should include the following: (a) (b) Identification of anticipated measurement quantities (length, voltage, temperature etc.). Identification of anticipated measurement ranges and confirmation of equipment capability, considering both specific measurement equipment and relevant support equipment such as jigs and rigs. Determination of tolerances and consideration of measurement performance capability. Determination of any relevant guard-bands to be applied.

(c) (d)

For common measuring equipment under routine applications, much of this analysis may be performed once and used to establish a workshop performance envelope. It may be, for instance, that a workshop does not undertake repairs on equipment where the specified maximum gaps are below 0.15 mm, due to the type and performance capability of its measuring equipment. B11.4 Selection of measuring equipment When an organisation seeks to acquire measuring equipment, consideration should be given to the intended use and the measurement performance required to fulfil the measurement task. Clearly, the selection of adequate measuring equipment is related to the performance of the equipment, tempered by the cost of the measuring technique. This cost extends not only to the physical cost of the equipment, but also to the ongoing costs of calibration and verification of the equipment, and the costs of establishing and maintaining the environment and measurement practices necessary to support higher performance measurements. Historically, in performing a measurement where a known accuracy is desired, instruments were selected with a readability of 4 to 10 times that of the desired accuracy. These figures and the effect upon the measurement performance are reflected in the example provided above. B11.5 Use of user-adjustable equipment (zero and span) Some equipment includes user adjustments to set zero and span points. These adjustments provide compensation for environmental factors and gradual drift in equipment performance, allowing ongoing confidence in the reliability of the equipment performance. Where such equipment is used in measurement, the following points are relevant: (a) (b) Measurement procedures must include these adjustment steps. Operatives must be aware of the effects of, and need for, the adjustments.
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(c)

Records must explicitly demonstrate that such adjustments have been made.

Failure to perform these adjustments may invalidate any measurement outcome. B11.6 Application of correction factors In some cases calibration certificates will be provided with correction factors that should be applied to achieve the best possible measurement. It should be noted, however, in light of the discussion regarding Specifications for calibrations in a BXX.X that generic equipment documents frequently over-specify the measurement performance of equipment. Correction factors may not be needed, although there should be some thought and a recorded justification to support any decision not to apply correction factors. Repair facilities should note that the ANZEx Scheme Rules for recognition of repair facilities detailed in MP 87-2 requires the use of correction factors where these are provided in calibration certificates. B11.7 Environmental influences Service facilities are reminded that the environment can significantly influence the reliability of measurement tasks. Temperature, vibration, electric and magnetic fields, stray voltages and adherent dirt/dust can all influence the quality of figures. Most calibration documents indicate that the calibration is valid at a given temperature, and this usually reflects laboratory conditions. Workshops must be aware of the possibility of measurement activities being undermined by the measurement environment. Differences in temperature, for instance, may contribute to variations in compliance. In a worst-case scenario, a temperature variation of potentially 50C is possible, leading to variations in measurement greater than 0.25 mm* over a 500 mm span. B11.8 Environmental monitoring equipment It is possible to use environmental monitoring equipment to establish, for example, stability of temperature in a chamber or space. This equipment typically is protected against physical damage, but may be impaired by lack of variationsprings and bearings in mechanical systems need exercise. Such equipment may be periodically checked by comparison using suitable reference equipment. These checks are usually sufficient to establish traceability, however in some high-performance applications the monitoring equipment should be removed and separately calibrated. Where spatial performance is required within 5C, attention should be paid to the monitoring equipment, and tighter performance criteria demand significantly closer attention to the chamber and the monitoring equipment. B11.9 Use of hired equipment Equipment will usually be hired when a workshop has a temporary need for measuring equipment (due to un-availability of their existing equipment or unexpected workload), or where the workshop is attempting measurements outside its normal range or existing measurement capability. Under the latter conditions, workshops are reminded that measurement capability is only a subset of the competencies relevant to extending their operations and any attempt to change the broader workshop capability should be performed in the context of an orderly and managed development that considers, for example, access to relevant expertise and appropriate safety and technical procedures. This paper does not attempt to guide workshops in the development of additional capabilities. Where equipment is borrowed or hired to address a temporary need for measuring equipment, there are no additional calibration or check requirements for equipment that has

* This may be possible in measuring a spigoted lid and matching box, one in a cold environment using a hot vernier, and one in a hot environment using a cold vernier. With a total temperature difference of 50C and a 500 mm nominal span, thermal differences may cause significant dimensional variations. Often these are transient variations and may be reduced by allowing measuring equipment time to come to a similar temperature as the measured item, prior to measuring.
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been hired or borrowed either from within or externally from an organisation. A workshop must be able to provide documentary evidence that the equipment has been appropriately calibrated and/or checked. Equipment users must document if any additional checks are required (due to transportation, rough handling, temperature variations, etc.) in order to validate the calibrations that normally apply. B11.10 Determination of calibration intervals As has previously been noted in B8 above, equipment performance degrades over timein effect, the uncertainty of a measurement using any instrument normally increases with time since the last calibration or verification activity. In high reliability applications it is common practice to manage calibration intervals following a sequence of steps. These include the following: (a) (b) Identify a minimum acceptable level of equipment performance/uncertainty which is then set as a guard-band on the equipment performance. Select a mathematical model for the degradation of equipment performance over time (using an estimated rate of degradation based upon known sources of changed performance and experience and then approximating these to an equation of degradation). Set the calibration frequency based upon a risk modified determination considering the intersection of the projected degradation and the guard-band.

(c)

Commonly used equations of degradation include linear, logarithmic or Weibull degradation rates, but other models for degradation may be used. The projected intersection point is rarely taken as the absolute time for the next calibration; normally intervals are reduced to ensure that calibration is performed well before non-conforming performance occurs. Calibration intervals may be further modified based on as found data from the calibration laboratory and accumulated experience. One common model for varying calibration intervals uses a stepped approach to extending or reducing calibration intervals based on the results returned for multiple instruments *. Other schemes for varying intervals have been used. Analysis suggests that no scheme is universally accepted, and this is possibly due to the variation in the principle degradation mechanisms encountered in differing items of equipment. Typically these calibration intervals are supported by data gathered from multiple instruments. At a simpler level, the following guidelines may be of assistance: (i) (ii) Start with the manufacturers recommended re-calibration interval. If no interval is provided, a nominal 1 year for mechanical devices or 2 years for electrical devices may be an acceptable starting point.

(iii) Noting that displayed digits is no indication of accuracy or stability, where any measurement is approaching the limits of capability of the instrument (i.e. pass/fail depends on the last significant figure) then change the measuring technique. If this is not possible, reduced calibration intervals should be applied. (iv) Similarly, where any measurement is well inside the limits of capability of the instrument (i.e. pass/fail depends on the second or third significant figure) then an increased calibration interval may be applied. Apply reduced intervals between calibrations or checks when the equipment operates under less than ideal conditions.

(v)

* See NCSL document RP-1.

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(vi)

If any suspicion of damage arises, the equipment must be re-calibrated immediately and thereafter at reduced intervals until it is shown that stability has not been impaired.

(vii) Reduced intervals between calibrations or checks may also be required in particular applications or with particular equipment configurations. (viii) Any extension of calibration intervals should be based on factors such as history of stability, frequency of use, accuracy required, ability of staff to perform in-house checks and successful participation in relevant proficiency testing programs. B12 EQUIPMENT ASSURANCE PROGRAMS B12.1 General Users of equipment needing calibration are invited to develop their own programs that optimise the expense of calibration and checking against the assurance of measuring equipment accuracy. This may lead to extensions of the intervals between complete recalibration. An equipment calibration and check program should cover (a) (b) (c) (d) (e) commissioning of new equipment (including initial calibration and checks after installation); operational checking (checking during use with reference Standards or reference documentation); periodic checking (interim but more extensive checking, possibly including partial calibration); scheduled maintenance by in-house or specialist contractors; and complete re-calibration.

The tabulated checks and calibration requirements set out in Table B1 below to this document apply unless specific requirements are noted in a method. B12.2 Suspending calibration or checks It is recognised that there are times where it is appropriate for the calibration or checks of some items of equipment to be temporarily suspended (for example, due to low frequency of testing and high cost of calibration). A scheduled calibration or check may be left undone provided that the facility documents both the reason for deferring a calibration or check and that the item must be calibrated prior to use. Items of equipment, where the calibration or check has been suspended, should be marked either as being out of calibration, or as requiring calibration before use. B12.3 Integration of calibration activities with workshop measurement In addition to the consideration of calibration intervals and acceptability of calibration data, it is worth considering how calibration data may affect measurement performance. Regrettably, calibration providers compete on price as well as achievable levels of uncertainty, and it has become common practice in some industries to reduce costs by reducing the range of calibrations performed on a multi-range instrument. Thus, for instance, calibration on a multimeter with many ranges may be offered either as a comprehensive calibration of the instrument covering all ranges, or calibration on a selected few. Recipients of calibration certificates and users of calibrated equipment should examine the relevant certificates to confirm the continued fitness-for-purpose of calibrated equipment. Where a limited number of ranges are traceably calibrated, this should be indicated on or along with the equipment to prevent accidental use in a non-calibrated range.
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B13 COMMENTARY ON MEASUREMENT TASKS B13.1 General SAA/SNZ HB 86The selection, care, calibration and checking of measuring instruments in industry is relevant and should be considered in attempting any measurement task. In the course of assessing workshop practices a number of areas of measurement have been identified as being relevant to service facilities, as outlined in B13.1 to B13.8. B13.2 Length Large span length measurements are among the hardest to perform reliably. The need for rigid instruments means the instruments are typically of a massive nature, making delicate adjustments difficult. Alignment to ensure precise measurement can prove difficult. Gauge blocks are an expensive and easily damaged asset and should be stored and handled to prevent corrosion, handling and impact damage. A typical storage method is in individual spaces in a sponge-filled box. B13.3 Surface roughness In general, surface roughness can be satisfactorily judged by reference to comparison blocks. In cases of dispute, additional determinations may be made using a calibrated stylus system. B13.4 Thread gauges Thread gauges are an expensive and easily damaged asset and should be stored and handled to prevent corrosion, handling and impact. An appropriate storage method is in individual spaces in a sponge-filled box. B13.5 Torque The adequacy of fastening depends upon the application of an appropriate torque. Torque indicators can use a number of techniques for indication of torque, but few industrial instruments are capable of better than 5% repeatability. B13.6 Electrical High voltage tests are potentially hazardous, and care must be applied to establish that testing staff are not at risk of electrical shock. Safe work statements for the use of insulation testers and the conduct of withstand voltage tests should address connection sequences during testing and include checks that tested items have fully discharged. B13.7 Temperature Temperature measurements are particularly tricky. Contact methods (e.g. thermocouples) must be managed to ensure good contact at the measurement point and insulated to prevent heat loss from allowing an under-reading. Thermocouple points must be checked for damage and should be used inside a thermal mass to minimise fluctuations due to application or environment. Non-contact thermal measurement typically uses infra-red technology. While use of these hand-held instruments appears straightforward, accurate measurement is dependent upon ensuring that the measurement is taken orthogonally to the emitting area, and that appropriate corrections for surface finish are made. B13.8 Balancing Frequently, the balancing of rotating equipment uses proprietary equipment that is calibrated by the OEM.

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B13.9 Pressure testing Bourdon pressure gauges combine elastic and mechanical mechanisms. Regardless of usage the internal elastic tube will relax over time, changing the performance of the gauge, while the precision bearings require regular exercise to ensure continued smooth operation. Regular calibration of Bourdon pressure gauges is therefore necessary to ensure continued performance at an acceptable level. B14 COMMENTARY UPON MP 87-2 MP 87-2 has some interesting requirements relating to calibration and measurement. For clarity these are presented as follows: (a) (b) (c) (d) Equipment used to establish Ex properties should be identified and calibrated. Calibrations should be traceable to the National Measurement Institute (NMI). Equipment should be periodically calibrated by a NATA-accredited (calibration) laboratory. It recommends in the Note to 3.3.6.2. (d) that service facilities hold a calibrated master instrument set and use this to periodically check working instruments, and also exempts working instruments from external calibration if this regime is followed. This might work for some equipment, but because the verification checks do not address the full range of issues covered during a calibration, unfortunately it offers a lower confidence in the measurement outcome than might otherwise be achieved. Service facilities should have procedures for calibration and review of certificates. Correction factors should be applied. Calibration providers should be reviewed of as sub-contractors. Service facilities are required to have sufficient equipment to perform measurements related to the overhaul, and that equipment is required to be capable of discriminating between compliant and non-compliant dimensions.

(e) (f) (g) (h)

B15 EQUIPMENT RECORD KEEPING Equipment checks performed in-house should record the following information: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Name of equipment. Identification of equipment (for example, serial number, nameplate information, etc.). Location of equipment, if important. Specification (including year) where appropriate. Indication of the acceptance criteria used on the records. Identification of personnel carrying out the work. Identification of reference equipment used (for example, vernier callipers 36101, reference thermometer A227, etc.). Procedure used or reference to documented procedure. Date the check was performed. Results obtained. Statement of acceptability or otherwise of the check. Any follow-up action required to correct deficiencies.

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B16 REFERENCES AS 1290 1290.4 1349 1655 1984 2102 2103 AS/NZS 3800 MP 87 MP 87.1 MP 87.2 HB 86 HB 86.1 HB 86.2 BS 1041 1041.5 4035 4372 Linear measuring instruments used in construction Part 4: Retractable steel pocket rules Bourdon tube pressure and vacuum gauges Feeler gauges (metric units) Vernier callipers (metric series) (ISO 3599) Micrometer callipers for external measurement (ISO 3611:1978) Dial gauges and dial test indicators (metric series) Title Electrical equipment for explosive atmospheresRepair and overhaul Australian/New Zealand Certification Scheme for explosion-protected electrical equipment (ANZEx Scheme) Part 1: Product Certification ProgramBasic rules and procedures Part 2: Recognized Service Facilities ProgramBasic rules and procedures A guide to the selection, care, calibration and checking of measuring instruments in industry Part 1: General principles Part 2: Simple length and angle measuring instruments Temperature measurement Part 5: Guide to the selection and use of radiation pyrometers Steel measuring tapes, steel bands, retractable steel pocket rules Specification for engineers steel measuring rules

BIPM, IEC, IFCC, ISO, IUPAC, IUPAP, OIML. Guide to the Expression of Uncertainty in Measurement. International Organisation for Standardization, Geneva, Switzerland. ISBN 92-67- 10188-9, First Edition 1993. ILAC P10:2002 ILAC Policy on traceability of Measurement Results ILAC G2:1994: Traceability of measurements Evaluation of Measurement data the Role of uncertainty in conformity assessment JCGM 106 Draft May 2009 NATA Policy Circular #12 - NATA Requirements for the Performance of Calibrations Inhouse NCSL RP-1 Establishment and adjustment of Calibration Intervals UKAS M3003 The Expression of Uncertainty and Confidence in Measurement, EDITION 2, JANUARY 2007

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TABLE B1 EQUIPMENT CALIBRATION TABLEMETHODS AND INTERVALS

Item of equipment Calibration interval (years) Checking interval (months) Procedures and references

Callipers including vernier callipers and digital callipers (Required Accuracy of Measurement) Callipers ( 1 mm or greater) Initial 24 On use Callipers (better than 1 mm, down to 0.1 mm) Initial For the initial check, see entry under Rules below. As for initial check. Must be checked visually on use for correct closure of jaws. Initial endorsed calibration certificate to ensure required accuracy (refer Table 5 AS 1984 for 0.05 mm vernier callipers). In-house checks over a minimum of 3 points covering the working range against reference equipment with an accuracy of 0.02 mm or better and supported by an endorsed certificate of calibration. Must be checked visually on use for correct closure of jaws. AS 1984

6 or less depending on use

On use Vernier callipers (better than 0.1 mm, down to 0.001 mm) Initial 2 or more frequently depending upon use On use Dial gauges 2 On use. 6

Check visually for correct closure of jaws. AS 2103 Set zero point. Check at zero and one point against a gauge block or length bar and record results. Inspect anvils. If the gauge block or length bar is not externally calibrated check it immediately after callipers are calibrated and use for the sixmonthly check.

Displacement transducers (including LVDTs)

2 On day of use Against length standard.

(continued)

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TABLE B1 (continued)
Item of equipment Calibration interval (years) Checking interval (months) Procedures and references

Displacement transducers 6 or on use In-house checks over a minimum of 3 points covering the working range against reference equipment with an accuracy of 0.02 mm or better and supported by an endorsed certificate of calibration.

Electrical instruments Digital multimeters 1 Calibrate over all ranges and parameters of use. Calibration must include linearity. 6 Analogue meters 2 6 Data loggers 1 6 Insulation tester 1 Check at two points over the range. Also check that the applied voltage is within manufacturers specification Compare with meters of similar resolution. Compare with meters of similar resolution.

Feeler gauges 1 Check using calibrated micrometer; check edges for burring. AS 1655 may be used as an alternative Gauge blocks, jigs, go/no-go gauges, thread gauges Used as reference standards Used as working equipment Micrometers 10 5 5 On use 12 AS 2102 Zero point. Check zero and one point against gauge block and record results. Inspect anvils. If the gauge block or length bar is not externally calibrated check it immediately after callipers are calibrated and use for the annual check. Pressure equipment Test gauges used for calibration of industrial gauges Industrial gauges not subject to shock loading 1 1 AS 1349 for Bourdon tube types. AS 1349 for Bourdon tube types.
(continued)

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TABLE B1 (continued)
Item of equipment Calibration interval (years) 6 months 1 1 Checking interval (months) Procedures and references

Industrial gauges subject to shock loading Digital pressure gauges Pressure transducers

AS 1349 for Bourdon tube types. Using method based upon AS 1349; Using method based upon AS 1349; transducer and readout to be calibrated together Using method based upon AS 1349;

Pressure transmitters Pyrometers Reference Electronic Working Rules

3 1 6 Initial

BS 1041, Part 5. Calibration by an approved testing authority. As per manufacturers guidance Check against reference pyrometer. Initial check against reference equipment with accuracy of 0.1 mm or better. The reference equipment used must be supported by an endorsed calibration certificate. Check at a minimum of 5 points over the entire length. A visual inspection for the other points is required. AS 1290.4 24 to 60 Check at maximum length, depending on use and accuracy required.

Tape measures and retractable pocket rules

Initial

Temperature measurement Working, digital indicating systems, with or without a temperature sensor, hand held or bench type, single and multichannel. (Includes temperature loggers) 2 1 NATA accredited facility. Calibrate every 12 months if the facility does not have a reference device. 6 Check against a reference device at the temperature of use. If used at more than one temperature, choose the most critical temperature. Check at ice point if the facility does not have a reference device. (For data loggers the reference device cannot be another data logger of the same type). As per manufacturers guidance

Torque wrench

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APPENDIX C

SAMPLE CERTIFICATES AND FORMS

(Informative)
TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR FLAMEPROOF MOTORS (Ex d)
Report no.: ................. Certificate no.: ................ Name of overhaul service facility................................ .................................. Service facility recognition no.: Address: ................................................................... ................................................................................ .................................. Postcode: ................... Telephone no:: ............ Fax No.: ..................... Motor description: ..................................................... Serial no.: ................Owner: .................................. Order no.: .......................... Date received: ............ Motor condition when dismantled: Bearings and sealsD.E.: Bearing journals..... D.E.: N.D.E: ...... Seals journals D.E.: D.E.: ... N.D.E: ........ N.D.E.... Bearings housings N.D.E. ... Flameproof motors: Shaft F.L.P. Gland diametral clearanceD.E.: ..... mm N.D.E.:........ mm End plate spigot diametral clearanceD.E.: ........ mm N.D.E.:........ mm Cable gland and gland spigot diametral clearance:mm Screwed cable gland no. of threads engaged: ............ Screwed hand hole covers no. of threads engaged..... Condition of bolt holes: ............................................. Terminal box: Deviation of flanged joint surfaces (max): ............ mm Flamepath gap after assembly: ........................... mm Water jacket: Jacket volume test before descaling: ................. litres Jacket thickness: ................................................ mm Jacket pressure test: .............. kPa at: .................. C Pass: ............. Fail: ...................... Jacket descaled by using: ......................................... Volume test after descaling: .............................. litres Flow test: ................................................... litres/min Static pressure test: Terminal boxes:.................................................. kPa Motor enclosures:............................................... kPa Tests: Insulation test to frame: ..........................Volt megger Stator/fields:.............. Rotor/Armature: ...................... Test run for 1 hourphase Currents A: ..................... B: ..................... C: ..................... Core teststator: Previous core testStator: Rotor: ............... Rotor: ...............

Stator and windings:.................................................. ................................................................................ ................................................................................ Rotor/armature and windings: .................................... ................................................................................ ................................................................................ Items missing on receipt of motor:.............................. ................................................................................ ................................................................................ General motor condition: ........................................... ................................................................................ ................................................................................ Details of motor repair: .............................................. ................................................................................ ................................................................................ Bearing make and no.:D.E.: ... N.D.E.: ................. Seal make and no.D.E.:......... N.D.E.: ................. Replacement shaft manufacturer:.................

Certification/approval drawing no(s).: .............................................................................................................. Remarks: ....................................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.: ...........................................................................
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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR FLAMEPROOF ENCLOSURE (Ex d)

Report no.: ................................................................................................................................ Certificate no.: ........................................................................................................................... Name of overhaul service facility: ............................................................................................... Service facility recognition no.: ................................................................................................... Address: ................................................................................................................................... Postcode: ...................... Telephone no.:................................. Fax no.: ..............................

Enclosure description: ............................................................................................................... Serial no.: .......................................... Owner: .................... Date received: ...................................... Remarks

Order no.: ................................................................ Item (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) Description of check Check of external and internal damage Dimensional check Corrosion on flamepaths Result of static pressure test Check of flanged joint surfaces Check of all threaded holes Check of all windows and lenses Check of breathers Check of all bolt holes, studs, screws, etc. Check of all gland entries and fixing holes Check of all cables glands Check of all hand hole and inspection covers Check of all mechanical interlocks Check of all flamepath gaps

Main control panel: 1 Max. out of plane of box flanges: .......................................................................................... 2 3 4 5 6 7 Max. out of plane of cover: ................................................................................................... Max. flameproof gap when bolted up: .................................................................................... Max. diametral clearance of spindles: ................................................................................... Max. diametral clearance of gland to gland apertures: ........................................................... Static pressure testpressure: ............................................................................................. Water jacketpressure test: .......................................................... Capacity: .....................

Certification/approval drawing no(s).:........................................................................................... Remarks: ................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. .......................................................... Signature of competent person Identification no.: ............................................................................ Date: ............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN FLAMEPROOF ENCLOSURES (Ex d)
Report no.: ................................................................................................................................ Certificate no.: ........................................................................................................................... Name of overhaul service facility: ............................................................................................... Service facility recognition no.: ................................................................................................... Address: ................................................................................................................................... Postcode: ..................... Telephone no.: ................................ Fax no.: ..............................

Description of unit: .................................................................................................................... Owner: ...................................................................................... Order no.: ...........................

Serial no of enclosure this test certificate applies to.: .................................................................. Enclosure test certificate no.: ...................................................... Item (a) (b) (c) Description of check Isolator mechanism and switch operation Earthing device and operation All auxiliary mechanisms, trip bars, latching arrangements, etc. All locking devices, function and operation All parts for mechanical condition All insulation checkedno heat, cracks, etc. Phase barriers fitted correctly and functional Oil levels and/or gas pressure Gas pressure-sensing devices All wiring and terminations Earth continuity; phase/earth fault lock units Overcurrent, overload and earth-fault devices Earth-fault trip devices Timing devices Temperature-sensing devices Transformer connections, bolts, tapes, bracing, insulators and fittings etc. Installation Machine cables and glands Date received: ....................... Repaired Replaced (R) Modified (M)

No work Overhauled required

(d)

(e) (f)

(g)

(h) (i) (j) (k)

(l)

(m) (n) (o) (p)

(q) (r)

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Details of overhaul, repair or modification (attach extra pages if required): Results of insulation resistance tests on transformers: Transformer ratio: ............................... Manufacturer: ..................................... Tested with: ....................................... Capacity: ................. Serial no: ..........................

Type of cooling: ..................................................... V (megger)

Primary winding to secondary winding: ...................................... M Primary winding to earth: .......................................................... M Secondary winding to earth: ...................................................... M Earth continuity of earth screen to core: .......................................... Assembled unit tested for insulation resistance with:V megger, and power frequency tested on the following circuits: Insulation resistance Circuit description M Test voltage Test frequency kV Hz Result

Certification/approval drawing no(s).:............................................................................................. ................................................................................................................................................... Remarks: ..................................................................................................................................... ................................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. .......................................................... Signature of competent person Identification no.: ............................................................................ Date: ..............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INTRINSICALLY SAFE EQUIPMENT (Ex i)
Report no.: ......................................................... Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: .................... Telephone no.: ................................ Fax no.: ............................

Equipment description: ............................................................................................................ Owner: ............................................................... Serial no.: .......................................................... Condition upon receipt:........................................ Order no.: ................................................ Date received: .......................................... Old repair label details:.............................. Cert no.: ................................................... Reported fault (if any): .............................................................................................................. Repair action: .......................................................................................................................... Parts replaced:......................................................................................................................... Tests performed: ...................................................................................................................... Results: ................................................................................................................................... Certification/approval drawing no(s).: ........................................................................................ ............................................................................................................................................... Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:.............................................................................. Date:.............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INCREASED SAFETY MOTORS (Ex e)
Report no.: ......................................................... Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: ..................... Telephone no: ................................ Fax no.: ............................

Motor description: .................................................................................................................... Owner: ............................................................... Serial no: ........................................................... Motor condition when received: Old repair label no.: External surfaces cleaned for inspection Fan cowls and fans: ................................................................................................................. Stator case and cooling fins: ................................ End shields and fasteners:................................... Ducts and piping: ................................................ Corrosion:................................................. Bearing caps:............................................ Grease relief: ............................................ Order no.: ................................................ Date received: ..........................................

Terminal box cover and gaskets: ............................................................................................... Gland entries: ..................................................... Glands:.....................................................

General external condition: ....................................................................................................... Missing parts: .......................................................................................................................... Motor dismantled:................................................ Degree of protection: IP............................

Internal conditionEvidence of dust or liquids: .......................................................................... Bearings and seal D.E.: ............................ N.D.E.: ......................... Seals journals D.E.: ............................ N.D.E.: ......................... Bearing housings Bearing journals D.E.: ..................... NDE.: .................... D.E.: ..................... N.D.E.: ..................

Stator windings and iron circuit: ................................................................................................ Rotor cage and iron circuit: ....................................................................................................... Internal fan clearance: .............................................................................................................. Details of motor repair: ............................................................................................................. ...............................................................................................................................................

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Ex e motor Cover and fasteners: ........................................... Gasket:............................................................... Terminals type: ................................................... Cable lugs type: .................................................. Condition of fastener holes: ....................... Gland entries: ........................................... Certificate no.: .......................................... Sleeving fitted ...........................................

StatorDia: ............................................................................................................................. Winding to original certification/approval:.............. or modified:...............................................

RotorDia: .............................................................................................................................. Radial gap: .............................................................................................................................. ReplacedRadial gap: ........................................ Tests: Resistance cold (ohms)Amb. Temp ..................C Phases Core test A ......... B .......... C .......... Overload type: ..........................................

Previous stator:...................................... Rotor:........................................ Present stator: ....................................... Rotor:........................................

Insulation test to frame: ......................................... Phase/Phase: A .......... B .......... D .......... H.V. test to AS 2380.6: ........................................ No load runningVibration: ................................. Phase balanceReduced voltage: (at full load amps) (Locked rotor) OR Rated full load: Temperature increase testFull load: .................. Locked rotor: ........ A .................... B .............. C ................. K Temperature class: T ......................... IA/IN tE............................................secs. kV for 1 minute. Noise:................... Bearing heat: ...........

A .................... B .............. C .................

Certification/approval drawing no(s).: ........................................................................................ ............................................................................................................................................... Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: ...............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR INCREASED SAFETY ENCLOSURES (Ex e)
Report no.: ......................................................... Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: ..................... Telephone no: ................................ Fax no.: ............................

Enclosure description: ............................................................................................................. Owner: ............................................................... Serial no: ........................................................... Order no.: ................................................ Date received: ..........................................

Enclosure condition when received: Old repair label no.: ........................................................... External surfaces cleaned for inspection Covers and fasteners: ......................................... Threaded holes: .................................................. Surface coating: .................................................. Base of enclosure: .................................... External corrosion: .................................... Gland entries and glands: .........................

General external condition: ....................................................................................................... Enclosure dismantled: ......................................... Internal conditionDust: ..................................... or, evidence of liquids:......................................... Degree of protection: IP............................ Corrosion:................................................. Heat: ........................................................

Missing parts: .......................................................................................................................... Cables and terminations: ..................................... Earth terminals:................................................... Windows and seals:............................................. Ex de parts:....................................................... Lamps:...................................................... Switches: .................................................. Relays: ..................................................... Luminaire:........................................................... Transparent part: ................................................ Terminal blocks:........................................ General insulation: .................................... Actuators and seals:.................................. Meters: ..................................................... Transformers: ........................................... Other: ....................................................... Interlocks: ................................................. Lamp type and power (W): ......................... Lamp holders: ...........................................

Ballasts: ........................................ Capacitors: ............................ Batteries: ......................... Certification/approval drawing no(s).: ........................................................................................ Remarks: ................................................................................................................................. I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:............................................................... Date: ............................................

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TYPICAL OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN INCREASED SAFETY ENCLOSURES
Report no.: ......................................................... Certificate no.: ...............................................

Name of overhaul service facility: ................................................................................................... Service facility recognition no.: ....................................................................................................... Address: ....................................................................................................................................... Postcode: ..................... Telephone no: ................................ Fax no.: ..................................

Description of unit: ........................................................................................................................ Owner: ............................................................... Serial no of enclosure this test certificate applies to: Enclosure test certificate no.: .......................................................................................................... Date received: .................................................... Item (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Description of work Ex de lamp Ex de switch Ex e metercalibrate Switch actuatorcheck all seals and action Terminal blockscheck for heat and insulation cracks Bushings and insulation condition Cablesinsulation, lugs and sleeving Transformer connections, tapes, bracing insulators, terminal Temperature sensing devices Mechanical interlocks All insulation checkedno heat Heaterscheck condition No work Overhauled required Repaired Replaced (R) Modified (M) Order no.: ......................................................

Details of overhaul, repair or modification (attach extra pages if required): ........................................ I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:............................................................................ Date: ..................................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR PRESSURIZED ENCLOSURES (INCLUDING PRESSURIZED TRANSFORMERS) (Ex p)

Report no.: .........................................................

Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: .................... Telephone no.: ................................ Fax no.: ............................

Equipment description: ............................................................................................................ Owner: ............................................................... Serial no: ........................................................... Condition upon receipt: Order no.: ................................................ Date received: .......................................... Old repair label details:.............................. Cert no.: ................................................... Reported fault (if any): .............................................................................................................. Repair action: .......................................................................................................................... Parts replaced:......................................................................................................................... Test performed:........................................................................................................................ Results: ................................................................................................................................... Certification/approval drawings no(s): Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: ...............................

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HB 239:2011

TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR NON-SPARKING MOTORS (Ex n)

Report no.: .........................................................

Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: .................... Telephone no.: ................................ Fax no.: ............................

Motor description: .................................................................................................................... Owner: ............................................................... Serial no: ........................................................... Motor condition when received: Old repair label no.: External surfaces cleaned for inspection Fan cowls and fans: ................................................................................................................. Stator case and cooling fins: ................................ End shields and fasteners:................................... Ducts and piping: ................................................ Corrosion:................................................. Bearing caps:............................................ Grease relief: ............................................ Order no.: ................................................ Date received: ..........................................

Terminal box cover and gaskets: ............................................................................................... Gland entries: ..................................................... Glands:.....................................................

General external condition: ....................................................................................................... Missing parts: .......................................................................................................................... Motor dismantled:................................................ Internal conditionDust: ..................................... or, evidence of liquids:......................................... Bearings and seal D.E.: ............................ N.D.E.: ......................... Seals journals D.E.: ............................ N.D.E.: ......................... Bearing housings Bearing journals D.E.: ..................... NDE.: .................... D.E.: ..................... N.D.E.: .................. Degree of protection: IP............................

Stator windings and iron circuit: ................................................................................................ Rotor cage and iron circuit: ....................................................................................................... Internal fan clearance: ..............................................................................................................

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Details of motor repair: ............................................................................................................. ............................................................................................................................................... Ex n motor Cover and fasteners: ........................................... Gasket:............................................................... Terminals type: ................................................... Cable lugs type: .................................................. Condition of fastener holes: ....................... Gland entries: ........................................... Certificate no.: .......................................... Sleeving fitted: ..........................................

StatorDia: ............................................................................................................................. Winding to original certification/approval:.............. or modified:...............................................

RotorDia: .............................................................................................................................. Radial gap: .............................................................................................................................. ReplacedRadial gap: ........................................ Tests: Resistance cold (ohms)Amb. Temp ..................C Phases Core test A ......... B .......... C .......... Overload type: ..........................................

Previous stator:...................................... Rotor:........................................ Present stator: ....................................... Rotor:........................................

Insulation test to frame: ......................................... Phase/Phase: A .......... B .......... D .......... H.V. test to AS 2380.9: ........................................ No load runningVibration: ................................. Phase balanceReduced voltage: (at full load amps) (Locked rotor) OR Rated full load: Temperature increase testFull load: .................. A .................... B .............. C ................. K Temperature class: T ......................... kV for 1 minute. Noise:................... Bearing heat: ...........

A .................... B .............. C .................

Certification/approval drawing no(s).: ........................................................................................ ............................................................................................................................................... Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: .............................

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HB 239:2011

A TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR NON-SPARKING ENCLOSURES (Ex n)

Report no.: .........................................................

Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: .................... Telephone no.: ................................ Fax no.: ............................

Enclosure description: ............................................................................................................. Owner: ............................................................... Serial no: ........................................................... Order no.: ................................................ Date received: ..........................................

Enclosure condition when received: Old repair label no.: ........................................................... External surfaces cleaned for inspection Covers and fasteners: ......................................... Threaded holes: .................................................. Surface coating: .................................................. Enclosure dismantled: ......................................... Internal conditionDust:: .................................... or, evidence of liquids:......................................... Cables and terminations: ..................................... Earth terminals:................................................... Windows and seals:............................................. Ex n parts:......................................................... Lamps:...................................................... Switches: .................................................. Relays: ..................................................... Luminaire:........................................................... Transparent part: ................................................ Enclosure assembled: Restricted breathing test:................ Type of test:..................................................................... Certification/approval drawing no(s).: ........................................................................................ Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:...........................................................................
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Base of enclosure: .................................... External corrosion: .................................... Gland entries and glands: ......................... Degree of protection: IP............................ Corrosion:................................................. Heat: ........................................................ Terminal blocks:........................................ General insulation: .................................... Actuators and seals:.................................. Meters: ..................................................... Transformers: ........................................... Other: ....................................................... Interlocks: ................................................. Lamp type and power (W): ......................... Lamp holders: ...........................................

General external condition: .......................................................................................................

Missing parts: ..........................................................................................................................

Ballasts: ........................................ Capacitors: ............................ Batteries: .........................

Date: ..............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN NON-SPARKING ENCLOSURES (Ex n)

Report no.: .........................................................

Certificate no.: ...............................................

Name of overhaul service facility: ................................................................................................... Service facility recognition no.: ....................................................................................................... Address: ....................................................................................................................................... Postcode: .................... Telephone no.: ................................ Fax no.: ..................................

Description of unit: ........................................................................................................................ Owner: ............................................................... Serial no of enclosure this test certificate applies to: Enclosure test certificate no.: .......................................................................................................... Date received: .................................................... Item (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Ex n lamp Ex n switch Metercalibrate Switch actuatorcheck all seals and action Terminal blockscheck for heat and insulation cracks Bushings and insulation condition Cablesinsulation, lugs and sleeving Transformer connections, tapes, bracing insulators, terminal Temperature sensing devices Mechanical interlocks All insulation checkedno heat Heaterscheck condition Description of work No work Overhauled required Replaced (R) Repaired Modified (M) Order no.: ......................................................

Details of overhaul, repair or modification (attach extra pages if required): ........................................ ..................................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date:......................................

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HB 239:2011

TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ENCAPSULATED EQUIPMENT (Ex m)

Report no.: .........................................................

Certificate no.: ...............................................

Name of overhaul service facility: ................................................................................................... Service facility recognition no.: ....................................................................................................... Address: ....................................................................................................................................... Postcode: .................... Telephone no.: ................................ Fax no.: ..................................

Equipment description: .................................................................................................................. Owner: ............................................................... Serial no: ........................................................... Condition upon receipt:........................................ Order no.: ...................................................... Date received: ................................................ Old repair label details:.................................... Cert no: .......................................................... Reported fault (if any): .................................................................................................................... Repair action: ................................................................................................................................ Parts replaced:............................................................................................................................... Tests performed: ............................................................................................................................ Results: ......................................................................................................................................... Item (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Description of check Cracks in compound Crazing Exposure of encapsulated parts Flaking Shrinkage Swelling Decomposition Discolouration Failure of adhesion Change in hardness Remarks

Certification/approval drawing no(s).: .............................................................................................. ..................................................................................................................................................... Remarks: ....................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: .....................................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR DIP MOTORS

Report no.: .........................................................

Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: .................... Telephone no.: ................................ Fax no.: ............................

Motor description: .................................................................................................................... Owner: ............................................................... Serial no: ........................................................... Motor condition when received: Old repair label no.: External surfaces cleaned for inspection Fan cowls and fans: ................................................................................................................. Stator case and cooling fins: ................................ End shields and fasteners:................................... Ducts and piping: ................................................ Corrosion:................................................. Bearing caps:............................................ Grease relief: ............................................ Order no.: ................................................ Date received: ..........................................

Terminal box cover and gaskets: ............................................................................................... Gland entries: ..................................................... Glands:.....................................................

General external condition: ....................................................................................................... Missing parts: .......................................................................................................................... Motor dismantled:................................................ Internal conditionEvidence of dust or liquids: ..... Bearings and seal D.E.: ............................ N.D.E.: ......................... Seals journals D.E.: ............................ N.D.E.: ......................... Bearing housings Bearing journals D.E.: ..................... NDE.: .................... D.E.: ..................... N.D.E.: .................. Degree of protection: IP............................

Stator windings and iron circuit: ................................................................................................ Rotor cage and iron circuit: ....................................................................................................... Internal fan clearance: .............................................................................................................. Details of motor repair: ............................................................................................................. ...............................................................................................................................................

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HB 239:2011

1.

Ex d motor with DIP terminal box: (Refer to FLP Certificate for Ex d): Condition of fastener holes: ....................... Gland entries: ........................................... Certificate no.: .......................................... Sleeving fitted: ..........................................

Cover and fasteners: ........................................... Gasket:............................................................... Terminals type: ................................................... Cable lugs type: .................................................. 2. DIP Motor Item 1 plus:

StatorDia: ............................................................................................................................. Winding to original approval:................................ or Modified:...............................................

RotorDia: .............................................................................................................................. Radial gap: .............................................................................................................................. ReplacedRadial gap: ........................................ Tests: Resistance cold (ohms)Amb. Temp ..................C Phases Core test A ......... B .......... C .......... Overload type: ..........................................

Previous stator:...................................... Rotor:........................................ Present stator: ....................................... Rotor:........................................

Insulation test to frame: ......................................... Phase/Phase: A .......... B .......... D .......... H.V. test ............................................................. No load runningVibration: ................................. Phase balanceReduced voltage: (at full load amps) (Locked rotor) OR Rated full load: Temperature increase testFull load: .................. A .................... B .............. C ................. K Temperature class: T ......................... kV for 1 minute. Noise:................... Bearing heat: ...........

A .................... B .............. C .................

Certification/approval drawing no(s).: ........................................................................................ ............................................................................................................................................... Remarks: ................................................................................................................................. ............................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: ...............................

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TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR DIP ENCLOSURES

Report no.: .........................................................

Certificate no.: .........................................

Name of overhaul service facility: ............................................................................................. Service facility recognition no.: ................................................................................................. Address: ................................................................................................................................. Postcode: ..................... Telephone no: ................................ Fax no.: ............................

Enclosure description: ............................................................................................................. Owner: ............................................................... Serial no: ........................................................... Order no.: ................................................ Date received: ..........................................

Enclosure condition when received: Old repair label no.: ........................................................... External surfaces cleaned for inspection Covers and fasteners: ......................................... Threaded holes: .................................................. Surface coating: .................................................. Base of enclosure: .................................... External corrosion: .................................... Gland entries and glands: .........................

General external condition: ....................................................................................................... Enclosure dismantled: ......................................... Internal conditionDust: ..................................... or, evidence of liquids:......................................... Degree of protection: IP............................ Corrosion:................................................. Heat: ........................................................

Missing parts: .......................................................................................................................... Cables and terminations: ..................................... Earth terminals:................................................... Windows and seals:............................................. DIP parts: ........................................................... Lamps:...................................................... Switches: .................................................. Relays: ..................................................... Luminaire:........................................................... Transparent part: ................................................ Terminal blocks:........................................ General insulation: .................................... Actuators and seals:.................................. Meters: ..................................................... Transformers: ........................................... Other: ....................................................... Interlocks: ................................................. Lamp type and power (W): ......................... Lamp holders: ...........................................

Ballasts: ........................................ Capacitors: ............................ Batteries: ......................... Certification/approval drawing no(s).: ........................................................................................ Remarks: ................................................................................................................................. I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:........................................................................... Date: .............................

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HB 239:2011

TYPICAL REPAIR/OVERHAUL AND EXAMINATION REPORT FOR ELECTRICAL EQUIPMENT INSTALLED WITHIN DIP ENCLOSURES

Report no.: .........................................................

Certificate no.: ................................................

Name of overhaul service facility: ................................................................................................... Service facility recognition no.: ....................................................................................................... Address: ........................................................................................................................................ Postcode: ..................... Telephone no.: ................................ Fax no.: ..................................

Description of unit: ......................................................................................................................... Owner: ............................................................... Order no.: .......................................................

Serial no of enclosure this test certificate applies to: ........................................................................ Enclosure test certificate no.: .......................................................................................................... Date received: .................................................... Item (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Lamp Switch Metercalibrate Switch actuatorcheck all seals and action Terminal blockscheck for heat and insulation cracks Bushings and insulation condition Cablesinsulation, lugs and sleeving Transformer connections, tapes, bracing insulators, terminal Temperature sensing devices Mechanical interlocks All insulation checkedno heat Heaterscheck condition Description of work No work Overhauled required Replaced (R) Repaired Modified (M)

Details of overhaul, repair or modification (attach extra pages if required): ........................................ ..................................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. .......................................................... Signature of competent person Identification no.:........................................................................... Date: .....................................

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TYPICAL CABLE REPAIR REPORT

TYPICAL CABLE REPAIR WORKSHEET Date In:............................. Cable Identification:........................................................................................... Date Out:.......................... Customer:............................................................................................................ Last Cond: .............................................. Minimum Length: ......................................... metres Cable Make:........................................... Last Length:.................................................. metres Maximum Length: ........................................ metres Insulation Phases HV Test Continuity Last Present E A B C Leakage P-E and Pilot ( ) ( ) Pilot ( )( )( )( ) P-P Earth ( ) ( ) System Test Phase Barrier A ( ) A ( ) ( )( ) Voltage kV E ( ) B ( ) ( ) 440 ( ) 1.5 A ( ) To Earth B ( ) ( ) ( ) ( ) C ( ) 1100 ( ) 3.5 Phase A ( ) ( ) 3300 ( ) 11 B ( ) B ( ) ( ) ( ) ( ) C ( ) ( ) Test Voltage: 500 V ( ) V( ) 6600 ( ) 20 Armour ( ) ( ) 11000 ( ) 28 C ( ) ( ) ( ) Rotation/Polarity P( ) F( ) 22000 ( ) 43 Test Time: . . . . . . . . Pulse Voltage: . . . . . . Pulses: . . . . . Partial Break P( ) F( ) ( ) P. Proof Test (1.5 kV) P( ) F( ) Symmetrical Load Test F( ) Before:. . . . . . A After:. . . . . . . A P( ) Pilot A B C ( ( ( ( Insulation E )( ) ) ) Phases A )( ( B )( )( ( C ) ) ) HV Test Leakage P-E and

. . . . . . mA . . . . . . mA

Test Voltage: 500 V ( ) V( )

P-P System Test Voltage kV E 440 ( ) 1.5 A ( ) ( ) ( ) 1100 ( ) 3.5 3300 ( ) 11 B ( ) ( ) ( ) 6600 ( ) 20 11000 ( ) 28 C ( ) ( ) ( ) 22000 ( ) 43 Test Time: . . . . . . . . Pulse Voltage: . . . . . . Pulses: . . . . .

Initial Test by: .............................

Date: ......................................

Cond: Replace 2 3 4 5 6 7 8 9 New

Cable Arrived:...................................................................................................................................................... Sheath Test by: .......................... Final Length: ............................... Date: ................................... Sheath Hardness: ........................... Test Voltage: ....................... Initial Length: ..................mtrs

Cable Sheath Cond: Replace 2 3 4 5 6 7 8 9 New

Comments: ............................................................................................................................................................. Final Test by: .......................................................................................................... Date:..............................

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HB 239:2011

Continuity ohms........................................ Rotation/polarity Pilot ( ) P( ) Earth ( ) Phase Barrier A( ) To Earth B( ) Phases A ( ) B ( ) C ( ) Meter Used: ............... F( )

Insulation E Pilot A B C ( ( ( ( )

Phases A ( ) ( ) ( ( B ) ( ) ) C )

HV

) ( ) )

Test Voltage: 500 V ( )..... V( ) Armour ............. Meter Used: ......................................

Test Leakage P-E and P-P System Test Voltage kV E 440 ( ) 1.5 A ( ) ( ) ( ) 1100 ( ) 3.5 3300 ( ) 11 B ( ) ( ) ( ) 6600 ( ) 20 11000 ( ) 28 C ( ) ( ) ( ) 22000 ( ) 43 Test Time: . . . . . . . . Pulse Voltage: . . . . . .. Symmetrical Load Test P( ) F( ) A ............................. mA

Final Length: ................................... metres Overall Cable Cond: Replace 2 3 4 5 6 7 8 9 New

Flamepath: Contacts/Screws: Plug Body/Bolts: Grommets/Contacts: Tags/I.Ds:

A( A( A( A( A(

) ) ) ) )

B( B( B( B( B(

) ) ) ) )

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Sheath Repairs

0-250 mm 250-500 mm 500-750 mm >750 mm

Copper Repairs

Pilot Cond Earth Cond Earth Screen Power Cond

Splice

Pilot Cond Earth Cond Earth Screen Armour Power Cond

Re-insulate

Pilot Cond Earth Cond Semi Cond Earth Screen Power Cond

Full Splice Distance From End A Cable Repairer Vulcaniser No. Cable Internal Condition: 1 2 3 4 5 6 7 8 9 New Repair Hardness:..................................................... Date: ..................................... Plug Parts: End B: .............................. ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ ............................................................ Colour:..................

Customer Contract Review By: .............................................................................................. Brand MM Joy Macey Other Res CR Bolted Other Tags Voltage Amps End A ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) End B ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) Plug Parts: End A:............................... ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. ............................................................. Replug Assemble D, CandC CandC Repair Paint Fit Tags ( ( ( ( ( ( ( ) ) ) ) ) ) ) ( ( ( ( ( ( ( ) ) ) ) ) ) )

Paint Cable:......................................... by: ........... metres

Plug Repairer: ...................................................................................................... Comments:........................................................................................................... Cable Despatched:............................................................................................... Final Insp by: ........................................... Date:...............................................

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HB 239:2011

TYPICAL PRESSURISED TRANSFORMER OVERHAUL INSPECTION FORM

TYPICAL PRESSURISED TRANSFORMER OVERHAUL INSPECTION REPORT Customer Order No: Transformer Description Component Description Component Location Drawing Numbers Previous O/Haul Reference EXTERNAL EXAMINATION Flange examined for Ex.d Compliance Condition of Cooling Fins Condition of Tap Changer Cover Pressure Monitoring Equipment Gate Valves etc. Contact Job No: TXF Plant No: Certification No: Results

Pass

Fail

Compliance Document

Pass

Fail

INTERNAL EXAMINATION Internal of Tank for signs of moisture and corrosion HV Bushings LV Bushings Core and Coils All Connections ELECTRICAL TESTING HV Winding Resistance LV Winding Resistance A Ohms A Ohms Ambient Temperature Degrees Centigrade HV Insulation to Frame A Megohms LV Insulation to Frame A Megohms HV Insulation to LV A Megohms HV Test to 2380.6; High Voltage test for 1 minute LV Test to 2380.6; High Voltage test for 1 minute Repeat HV Test to A Frame Megohms Repeat LV Test to A Frame Megohms Repeat HV Test to LV A Megohms Temperature Monitoring Device B Ohms B Ohms B Megohms B Megohms B Megohms C Ohms C Ohms C Megohms C Megohms C Megohms

B Megohms B Megohms B Megohms

C Megohms C Megohms C Megohms

Certification/approval drawing no(s).: .............................................................................................. Remarks: ....................................................................................................................................... I ____ confirm that the above equipment has been [repaired/overhauled/altered] (delete as appropriate) in accordance with the relevant requirements of standard [AS/NZS 3800/other] (identify specific documents). Subject to the remarks above, the equipment conforms to the [certification documents/equipment standards] (identify specific documents) and has been marked as required by the relevant overhaul standard. This report has been recorded in the logbook of the service facility. ........................................................... Signature of competent person Identification no.:..................... Date: ................

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TYPICAL PRE-OVERHAUL AUDIT REPORT SHEET

As Per Requirements of AS/NZS 2290.1 Category Ex.d/Ex.e Gas Group CH4 NOTE: Circle the relevant requirement Machine type: Customer Date of Last Overhaul Mines Overhaul period Previous Audit date Previous Audit Cert No. EQUIPMENT INSPECTED Comments/deterioration notes including hand-hole cover threads SERIAL No. Any Items that show deterioration should show up here Plant No. Order No. Job No. Date of Audit Next Audit*/Overhaul * Due

DESCRIPTION

EQUIPMENT: ................................

PLANT No....................

JOB No. .........................

The flameproof enclosures have been inspected in accordance with AS/NZS 2290.1 and have been found to comply with the approval conditions. This inspection covered all accessible components. Cable glands, lens, etc. were not dismantled and inspected NOTE: Motors Are not Subject to Pre-overhaul audit and must be changed out at nominated dates. Recommendations: Date next Audit:.............................................................. Date next AS3800 overhaul: ............................................ Competency No.: ............................................................ Inspected by: ..................................................................... Date: ................................................................................. Signature: ..........................................................................

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EQUIPMENT NOT INSPECTED (motors, I.S Equipment, Glands, lens These Items must be tested at normal inspection periods DESCRIPTION SERIAL No. COMMENTS/Audit Dates on Motors

CIRCUIT BREAKER and OVERLOAD TESTS (Units May need to be removed to a test facility or substituted) CIRCUIT BREAKER CB*********** CB************* CB************** TYPE EXTERNAL CONDITION INTERNAL CONDITION CONTACT TIPS

CIRCUIT BREAKER SETTINGS

% CURRENT

INJECTION TESTS CURRENT TEST CURRENT SETTINGS AMPS AMPS

TRIP TIME SECONDS

FINAL CHECKS TESTED TO TRIP CURVES C/BREAKER OPERATION CLEANED EXTERNAL AND INTERNAL C/BREAKER SETTINGS ARE RETURNED TO ORIGINAL

PASS PASS

FAIL FAIL

PASS

FAIL

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OVERLOAD TYPE EXTERNAL CONDITION INTERNAL CONDITION CT RATIO OVERLOAD SETTINGS

O/L***********

O/L*************

O/L**************

% CURRENT

INJECTION TESTS CURRENT TEST CURRENT SETTINGS AMPS AMPS

TRIP TIME SECONDS

FINAL CHECKS TESTED TO TRIP CURVES OVERLOAD OPERATION PHASE IMBALANCE OVERLOAD SETTINGS ARE RETURNED TO ORIGINAL EQUIPMENT USED FOR TEST EQUIPMENT NO. and DESCRIPTION: CALIBRATION DUE DATE:

PASS PASS PASS

FAIL FAIL FAIL

DIMENSIONAL CHECKS ORIGINAL RESULTS of Maximum Out of Plane or clearance THESE RESULTS of Maximum Out of Plane or clearance

ITEM

DESCRIPTION

LOCATED

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EARTHING CONTINUITY CHECKS TESTS FROM MAIN RECEPTACLE EARTH TO ALL EARTH POINTS MAXIMUM RESISTANCE FOUND Previous Reading Comments: Current reading

PASS

FAIL

TESTS OF TRANSFORMERS PRIMARY TO SECONDARY WINDINGS and to EARTH and to CORE Transformer ID Primary to Secondary Primary to Earth Primary to Core Secondary to Earth Secondary to Core

Comments/any signs of heating or cracking

TEST EQUIPMENT USED Equipment No. and description Calibration due

INTERLOCK TESTS ELECTRICAL INTERLOCKS TESTED MECHANICAL INTERLOCKS TESTED RESULTS Comments:

PASS

FAIL

RESULTS Comments:

PASS

FAIL

FASTENER CHECKS (to correct size length and tensile strength) FASENERS CHECKED SIZES LENGTH TENSILE STRENGTH

Comments

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ANY GENERAL COMMENTS ABOUT THE EQUIPMENT CONDITION

Name of Authorised Person: ................................. Competency No.: ................................................. Signature: ........................................................... Date:...................................................................

Verified by:......................................................... Competency No.:................................................ Signature: .......................................................... Date: .................................................................

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CIRCUIT BREAKER TEST REPORT

JOB No.: CUSTOMER: VOLTAGE: SERIAL No.: INSP. DATE: DESCRIPTION:

All Items must be filled in or crossed N/A to conform with QA requirements Circuit breakers MUST be returned to the original settings after testing unless advised otherwise INITIAL INSPECTION CIRCUIT BREAKER TYPE: EXTERNAL CONDITION: INTERNAL CONDITION: CONTACT TIPS: CIRCUIT BREAKER SETTINGS: INJECTION TESTS % CURRENT CURRENT SETTINGS AMPS TEST CURRENT AMPS TRIP TIME SECONDS CB*********** CB************* CB**************

FINAL CHECKS TESTED TO TRIP CURVES: C/BREAKER OPERATION: CLEANED EXTERNAL AND INTERNAL: C/BREAKER SETTINGS ARE RETURNED TO ORIGINAL: EQUIPMENT USED FOR TEST EQUIPMENT NO. AND DESCRIPTION: CALIBRATION DUE DATE:

PASS PASS PASS

FAIL FAIL FAIL

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COMMENTS:

Name of Authorised Person:................................... Competency No.: ................................................... Signature: ............................................................. Date:.....................................................................

Verified by:........................................................ Competency No.:............................................... Signature: ......................................................... Date: ................................................................

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CURRENT TRANSFORMER TEST SHEET

JOB NO.: CUSTOMER: MODEL No.: RATIO: CT TYPE: TEST CURRENT: TEST AMPS: OUTPUT AMPS: PHASE A:

SERIAL NO.: INSP. DATE: ACCURACY CLASS: ACCURACY:

PHASE B (IF APPLICABLE):

PHASE C (IF APPLICABLE):

TESTED BY:

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EARTH LEAKAGE TRIP TIME TESTS

Job No.: Date: Tested by: Location Description: Circuit Name: Relay Name: Sensitivity (mA): Set: Value: Delay (mS): Set: Value:

Order No.: Customer: Customer Contact:

Test: (ma)

Test: No.: 1 2 3

Trip: Time (mS)

Avg: (mS)

Circuit Name: Relay Name: Sensitivity (mA): Set: Value: Delay (mS): Set: Value: Test: (ma) Test: No.: 1 2 3 Circuit Name: Relay Name: Sensitivity (mA): Set: Value: Delay (mS): Set: Value: Test: (ma) Test: No.: 1 2 3 Test Equipment: Comments: Trip: Time (mS) Avg: (mS) Trip: Time (mS) Avg: (mS)

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OVERLOAD RELAY TEST REPORT

JOB No.: CUSTOMER: VOLTAGE: SERIAL No.: INSP. DATE: DESCRIPTION:

All Items must be filled in or crossed N/A to conform with QA requirements Overloads MUST be returned to the original settings after testing unless advised otherwise INITIAL INSPECTION CIRCUIT BREAKER TYPE: EXTERNAL CONDITION: INTERNAL CONDITION: CT RATIO: OVERLOAD SETTINGS: INJECTION TESTS % CURRENT CURRENT SETTINGS AMPS TEST CURRENT AMPS TRIP TIME SECONDS CB*********** CB************* CB**************

FINAL CHECKS TESTED TO TRIP CURVES: OVERLOAD OPERATION: PHASE IMBALANCE: OVERLOAD SETTINGS ARE RETURNED TO ORIGINAL: EQUIPMENT USED FOR TEST EQUIPMENT NO. AND DESCRIPTION: CALIBRATION DUE DATE:

PASS PASS PASS

FAIL FAIL FAIL

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COMMENTS:

Name of Authorised Person:................................... Competency No.: ................................................... Signature: ............................................................. Date:.....................................................................

Verified by:........................................................ Competency No.:............................................... Signature: ......................................................... Date: ................................................................

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PROTECTION RELAY REPORT

Job No.: Date: Tested By: Location: Description: Relay Details Make: Model Number: Type (Inverse, Ext. Inverse ttc): C.T ratio: Serial number: Serial number: Serial number: Phase/Earth fault testing (1A/5A): Current Setting (plug) A: Time Setting (multiplier): Instantaneous setting A: Calculated pick up current A: Calculated Trip current at 2x test A: Calculated Trip current at 5x test A: Calculated Trip current at 10x test A: Calculated earth fault trip current A: Calculated inst. trip current A: Breaker trips: TEST RESULTS: PHASE PICK (AMPS) (R) (W) (B)

Order No.: Customer: Customer Contact:

Over-current

Earth fault

(E/F) (E/F) (E/F)

UP OPERATING TIME (SECONDS) 2x 5x 10x

INST SETTINGS TRIPS AT (A)

TEST EQUIPMENT USED:

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CURRENT INJECTION TESTING

Adjust the check the trip times at various points over the range of the circuit breaker and plot them on the results graph Note: There should be sufficient check points so that a true representation of the curves is able to be interpreted

Current injection tester

Load

Overload

S O L I D - S TAT E OV E R C U R R E N T R E L AYS

90 80 70 60 50 40 30 20

T I M E - C U R R E N T C H A R AC T E R I S T I C S

18 0 0

10 9 8 7 6 5 4 3 2
TIME IN SECONDS

600

300

1 0.9 0.8 0 .7 0.6 0.5 0.4 0.3

60

5 4 3
30

0.2

1
0 .1 0.09 0.08 0 . 07 0.06 0.05 0.04 0.03 0.02 1 2 6 5 4 3

0.5 0.6 0 .7 0.8 0.9 0 .1

30

60 70 80 90 10 0

40

50

6 7 8 9 10

20

C U R R E N T I N M U LT I P L E S O F S E T T I N G T Y P E 51l I N V E R S E

FIGURE C1 USING THE CURRENT INJECTOR TESTER

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0 . 01

CYC L E S

10 9 8 7 6

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WARNING: USING HIGH VOLTAGE OR HIGH CURRENT DEVICES HAS ITS ASSOCIATED DANGERS OF ELECTRIC SHOCK. WHEN ANY EQUIPMENT IS INSTALLED, FOR THE PURPOSES OF TESTING, IT IS HIGHLY RECOMMENDED THAT OH&S ISSUES FOR THE SAFETY OF THE OPERATORS OF THE DEVICES AND ANY BYSTANDERS BE ADDRESSED TO ENSURE THAT PERSONS ARE NOT INJURED BY THE EQUIPMENT. SEE PLANT SAFETY IN YOUR OH&S REGULATIONS.

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APPENDIX D

HISTORICAL INFORMATION RELATING TO EQUIPMENT APPROVAL SCHEMES

D1 GENERAL Because of the clear risks associated with mining, specific Acts and regulations were developed for this industry. It was only later that the need for explosion-protected electrical equipment in non-mining applications became apparent. In Australia, therefore, two separate regimes of regulation developed (a) (b) equipment for use in coal mines and regulated by the various state coal mining Acts; and equipment for use in areas other than coal mines and covered by AS/NZS 3000 (wiring rules).

Both applications fell generally within the ambit of occupational health and safety (OHS); an area that was retained by the states to regulate at Federation. Each state and territory enacted relevant Acts of parliament with associated regulations. Each Act and regulation was tailored to the specific needs and nuances of the industry within the enacting state at the time of assent. Not surprisingly, the content of each Act and regulation was different and, even when similar, the implementation and enforcement of the requirements were not nationally consistent. Each state supporting an underground mining industry operated a system of equipment approval. With the increasing standardisation of mining equipment and the need to hold a single approval for equipment nationwide, by the 1950s, the need for the regulatory authorities to participate in a national certification/approval scheme emerged. A series of equipment certification/approval schemes developed, run in parallel with approval schemes managed by state authorities. These certification/approval schemes relied on national and international Standards. As global equipment supply became more common, Australia adopted the requirements of international Standards, including adopting internationally accepted conformity assessment schemes. It has only been since 1990 that efforts have been made to establish an encompassing approach to the management of electrical equipment for hazardous areas. Because repair and overhaul activities are usually applied to equipment that has been in service, sometimes for many years, this Appendix will summarise the operation of a number of now superseded schemes. D2 STATE AUTHORITY APPROVALS D2.1 History In NSW, regulation of electrical equipment in mines has involved approval of various types since the first Act in 1908. In the early years, the British system of equipment approval was accepted and implemented without relying on Australian input. To serve local manufacturers and demand, in the 1950s the testing laboratory of the Sydney County Council started testing and issuing certificates for flameproof equipment. In the 1960s, the NSW and Queensland Departments of Mines started testing laboratories in support of their flameproof approval systems. The NSW Department of Mines started intrinsic safety testing in NSW, before the Sydney County Council laboratory took on this work*.

* Lloyd, 2nd conference of the IEE Electrical Safety in Hazardous Environments December 1975.
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As late as 1975, the NSW Department of Mines would not allow Ex e, Ex q or Ex m in NSW coal mines. The NSW Department of Mineral Resources continued to issue approvals and supplementary approvals for equipment intended for use in NSW coal mines until 2006. This system offered a highly adaptable approach, suited to the every mine unique industry structure in vogue at that time. D2.2 Overview A NSW Mines Department approval consists of attesting formally that a specified item of electrical apparatus (i.e. electrical appliance, machine, fitting) conforms to the requirements of the Chief Inspector of Coal Mines. These requirements may take the form of Australian or other Standards either in whole or part. Approval does not necessarily mean compliance with a Standard. All approvals have conditions or recommendations regarding use of the equipment. For equipment that only has NSW MDA approval it is essential that the drawings identified on the approval documents are used in the overhaul, repair or modification processes. The use of Standards only is not sufficient because the approved equipment may not comply with the Standard and alternative risk controls may be identified on the approval documentation (including drawings). Therefore, it is essential that equipment that only has an approval is checked for compliance with the approval documentation (including drawings). D2.3 Handling changes The approvals system typically allowed for incremental changes to equipment through the issuance of supplementary approvals. Over time, equipment could be progressively modified until many supplementary approvals were issued for a particular product family, although for any particular item of equipment a limited number of supplementary approvals may be relevant. Care should be exercised to (a) (b) ensure that details of all supplementary approvals are held before an overhaul is commenced; and ensure that all relevant supplementary approvals are identified in statements of conformity arising from an overhaul.

D3 P/3 APPROVALS COMMITTEE (19601987) D3.1 History During the 1960s, Standards Australia set up an approvals-type scheme for Ex equipment other than that used in mines, referred to in later years as the P/3 Scheme, as it operated under the direction of the Standards Australia P/3 Committee, Certification of ExplosionProtection Electrical Equipment. This Committee comprised representatives from state electrical and mining regulatory authorities. It was responsible for considering applications for certification and for authorising the issue of certificates of compliance or statements of opinion. It also advised regulatory authorities and industry on matters relating to the application of Australian Standards to electrical equipment or use in hazardous areas. D3.2 Overview Under the scheme the Committee met every two months to consider applications using test reports and (in most instances) samples to arrive at a decision to approve equipment for use. The decisions made in this Committee were based on the judgment of the Committee. Often some discretion was applied and equipment approved by the committee may not have been checked for full compliance with the then Standards. This was addressed by an evolutionary change, described in following sections.
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Committee P/3 administered the certification of explosion-protected electrical equipment from 1986. Between 19601986, different designations were used for the Committee. Standards applicable to the explosion-protected area are prepared by Committees EL/14 Electrical Equipment in Hazardous Areas, and EL/23 Electrical Equipment in Coal Mines. D4 P/3 AUSEx SCHEME (19871993) Between 1987 and 1993, the P/3 Committee continued its activities, but allowed for two paths: an approval path as outlined above, or a certification path in which the committee certified that a sample of the equipment, and the manufacturers drawings, complied fully with the requirements of the relevant Australian Standards. Reference: [SAI Ex Workshop notes, 2001] D5 AUSEx SCHEME 19932003 D5.1 History and overview In 1993 the AUS Ex scheme was introduced. This was managed by Standards Committee P/8 and administered by Quality Assurance Services (QAS) in accordance with MP 69 Explosion protected electrical equipmentCertification schemePolicy. The scheme sought to demonstrate compliance of electrical equipment through measurement of key dimensions, a range of type tests and submission of relevant documentation. The sample was considered a realisation of a design (or type), which was approved if the sample was found to be compliant. This scheme certified that both the sample of the equipment and the manufacturers drawings complied fully with the requirements of the relevant Australian Standards. [SAI Ex Workshop notes, 2001]. Certificates of conformance were issued on the basis of a type test only, with no assurance regarding continued conformance during production, i.e. product quality assurance. The applicant undertook to ensure that, in production, every item would comply with the drawings specified in the certificate, and that production models would be identical to the model submitted for testing and examination, complying with relevant Australian, New Zealand or Joint Standards. [MP 69:1993 Clause 2.4] While there was the scope for manufacturers to voluntarily fulfil defined requirements leading to the application of an Ex mark, this was not generally taken up by Australian industry. Certificates of conformance that were issued had a limited validity of 10 years. This was applicable to the manufacturer, not the owner/operator. Since certificates of conformity were issued as late as December 2003, manufacturers are able to continue to manufacture in accordance with the AUS Ex scheme until December 2013. Related documents included Q7133:1993, Application procedures for Ex mark and Q7134:1994, Application procedures for Australian Ex certificate of conformity. D5.2 Documentation AUS Ex-approved equipment is required to be labelled with: (a) (b) (c) (d) The manufacturers name. Name or symbol of the certifying authority. Certificate reference. The letter X, where appropriate.

NOTE: Where certification conditions apply AUS Ex certificates include an X, e.g. AUSEx 99998 X
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In some situations the certificates include a U, indicating that only components (rather than a complete assembly) have been covered by the certification. D6 ANZEx SCHEME 2001 Internationally IECEE was moving towards establishing the IECEx scheme, which was to be an implementation of an ISO Type 5 Certification System (sometimes referred to as Full Certification) based on the ISO/IEC Conformity Assessment Committee (CASCO) System 5 specification. In anticipation of this development, the P/8 Committee revised the AUSEx Scheme to include surveillance of manufacturers. This revised scheme, known as the ANZEx Scheme, is managed by Standards Committee P-008 and administered by SAI Global in accordance with MP-87, Australian/New Zealand certification scheme for explosion-protected electrical equipment (ANZEx Scheme)Basic rules and procedures. In general the ANZEx Scheme (a) (b) (c) certifies that both the sample of the equipment and the manufacturers drawings comply fully with the requirements of the relevant Standards; certifies that the manufacturer has a quality system that ensures that the manufacturer will be able to manufacture the items as they were certified; and includes surveillance of the manufacturers factories to confirm that the manufacture is in accordance with the certification [SAI Ex Workshop notes, 2001].

However, provision remains for an ISO Type 1 (Type test) Scheme to cover one off situations, which may lead to the issue of a restricted type test certificate. The ANZEx Scheme establishes certification bodies that are (on the basis of suitable evidence, principally reports from approved testing laboratories and manufacturers documentation) able to issue certificates of conformity for electrical equipment. These certification bodies are required to conduct periodic surveillance on manufacturers holding a certificate of conformity for electrical products. The certificate of conformity provides distinctive third-party confirmation of a manufacturers claimed compliance to the relevant Standards and that product is manufactured under the ANZEx quality management system requirements. Applications for amendments to certificates for non-expired AUS Ex certificates are exempt, since such certificates were issued under the previous phase of the ANZEx scheme and have a 10-year life from issue date. D7 HANDLING CHANGES Certification bodies are able to amend a certificate of conformity at the request of the holder of the original certificate of conformity. Amendments to certificates of conformity are generally issued to cover the following: (a) (b) (c) (d) (e) (f) (g) A modification to certified equipment. An extension to certified equipment in the form of a new model or a new option. A change in one or more of the components which form part of the certified equipment. A change of catalogue or part number. A change of brand or trade name. A change in name or address of the certificate of conformity holder. A change of name or location of manufacturer.

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In use, modifications to equipment may be of three types: (i) (ii) Modifications within certification. Modifications not within certification. In this case the equipment no longer complies with the original certification and that an application for new certification should be made. Should the owner/operator not wish to proceed with re-certification, the apparatus is no longer suitable for use in a hazardous area and the Ex marking is to be removed from the apparatus.

(iii) Modification by competent person assessment, Ex d protection only, can be considered providing the requirements of AS/NZS 3800 are met. Because of the role and responsibilities of the certificate holder, modification demands consultation and provision of suitable advice to the certificate holder. Some modifications may mean the equipment no longer complies with the original certification. Examples of modifications requiring competent person assessment may include the following: (A) (B) (C) A modification to the equipment such as the addition, omission or relocation of hinge supports mounts and glands. Replacement of internal electrical equipment by an engineering equivalent such as power contactors, overloads, control and monitoring apparatus. Alterations to the layout form or function of the internal electrical arrangement under certain restrictions detailed in AS/NZS 3800.

D8 RELEVANT INTERNATIONAL SCHEMES D8.1 UK Testing of flameproof equipment in the UK commenced in 1924 at Sheffield University. Certificates of compliance were issued and the scheme was taken over by an industry group before becoming the responsibility of the mining regulator*. In July 1967, the HQ Acceptance Scheme was launched. In this scheme drawings of all equipment were examined and the manufacturer gave an undertaking that the equipment manufactured would be in accordance with the provided drawings. The UK regulator also operated a system where workshops were authorised and the proposed overhaul/rectification process was to be approved by a government inspector before it was performed. D8.2 IECEx Formed in response to a 1991 international survey, the IECEx Scheme is operated in accordance with IECEE 04 Rules and procedures of the scheme of the IECEE for certification of Standards for electrical equipment for explosive atmospheres (first published March 1995) and the more recently published IECEx 01 Basic rules of the IECEx scheme, and IECEx 02 Rules of procedure of the IECEx scheme (published October 1999). The IECEx Scheme: (a) (b) (c) Certifies that both the sample of the equipment and the manufacturers drawings comply fully with the requirements of the relevant [IEC] Standards. Certifies that the manufacturer has a quality system that ensures that the manufacturer will be able to manufacture the items as they were certified. Includes surveillance of the manufacturers factories to confirm that the manufacture is in accordance with the certification.

* A V Jones and R P Tarkenter, Electrical technology in Mining: the dawn of a new age, Peter Peregrinus Ltd 1992
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APPENDIX E

HISTORICAL INFORMATION RELATING TO SERVICE FACILITY APPROVAL SCHEMES

There are various authorities in Australia and New Zealand concerned with the safety of electrical installations in hazardous areas. These include the electrical regulatory authorities, mine regulators, OHS regulators and the insurance industry. Where there is a potential for an explosive atmosphere, or the risk of an explosion from an electrical source of ignition, one of the key risk controls is the use of explosion-protected electrical equipment. As the consequences of an explosion at a mine or other industrial facility can be catastrophic (numerous deaths and injuries), it has been accepted that a high degree of confidence in the explosion-protected properties of electrical equipment should be maintained. This high degree of confidence has been established through published Standards, competent independent facilities to assess the design against the Standard (Ex test labs) and competent independent recognition of the design and testing through certification or approval (AUS Ex, ANZEx, IECEx, MDA approval). However, the certification or approval of equipment only encompasses the design part of the life cycle. The selection, installation, inspection, use and maintenance of the equipment has been covered by published Standards such as AS/NZS 2381, IEC 60079.14 and 17 and AS/NZS 2290 (for coal mines). The only parts of the life cycle not covered were overhaul, repair and modification. The Australian coal mining industry recognized the importance of these elements of the life cycle and developed a coal-mine-specific Standard, AS 2290.2, for the overhaul and repair of explosion-protected equipment for coal mines (Group I). To support this Standard, the NSW mining regulator implemented a program of approved Ex service facilities in the late 1970searly 1980s, where facilities that overhauled and repaired explosion-protected equipment for NSW coal mines had to have facilities (including premises and tools), and competencies to conduct the overhaul and repair work in accordance with AS 2290.2. This program included the competent persons programme, where individuals had their knowledge of the repair, overhaul and modification of Ex equipment assessed by oral and/or written examinations. During the mid-to-late 1980s the NSW mining regulator reviewed the requirements for Ex service facilities approval and introduced requirements for the implementation of certified quality management systems. Throughout the 1990s, AS 2290.2 evolved into AS/NZS 3800 and encompassed both Group I and Group II industries. At the same time non-regulatory bodies such as NATA and SAI Global began providing accreditation/certification services for facilities that overhauled and repaired Ex equipment. National competency Standards were also established for hazardous area electrical equipment. With all of this, mining regulators have recognized the need to fully embrace the equipment certification and Ex service facilities recognition capabilities available. It is now recognized that the infrastructure is in place and is mature enough to consolidate the recognition of Ex service facilities that repair, overhaul or modify hazardous area equipment. It is due to this set of circumstances that the Joint Policy Committee, P-008, endorsed the inclusion of Ex service facilities and their recognition within its scope of activities. As a result owner/operators can have a high degree of confidence in the explosion-protected properties of hazardous area equipment that they purchase, or have overhauled, repaired or modified where the equipment certification schemes and Ex service facilities recognition schemes are used. It is also recognized that the IECEx Scheme has been expanded to encompass Ex service facilities. As such it is envisaged that, as this scheme and the IECEx Scheme evolve, there will be close alignment between the two.
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NOTES

Standards Australia Standards Australia is an independent company, limited by guarantee, which prepares and publishes most of the voluntary technical and commercial standards used in Australia. These standards are developed through an open process of consultation and consensus, in which all interested parties are invited to participate. Through a Memorandum of Understanding with the Commonwealth government, Standards Australia is recognized as Australias peak national standards body.

Standards New Zealand The first national Standards organization was created in New Zealand in 1932. The Standards Council of New Zealand is the national authority responsible for the production of Standards. Standards New Zealand is the trading arm of the Standards Council established under the Standards Act 1988.

Australian/New Zealand Standards Under a Memorandum of Understanding between Standards Australia and Standards New Zealand, Australian/New Zealand Standards are prepared by committees of experts from industry, governments, consumers and other sectors. The requirements or recommendations contained in published Standards are a consensus of the views of representative interests and also take account of comments received from other sources. They reflect the latest scientific and industry experience. Australian/New Zealand Standards are kept under continuous review after publication and are updated regularly to take account of changing technology.

International Involvement Standards Australia and Standards New Zealand are responsible for ensuring that the Australian and New Zealand viewpoints are considered in the formulation of international Standards and that the latest international experience is incorporated in national and Joint Standards. This role is vital in assisting local industry to compete in international markets. Both organizations are the national members of ISO (the International Organization for Standardization) and IEC (the International Electrotechnical Commission).

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