ExMC/722/R

December 2011

INTERNATIONAL ELECTROTECHNICAL COMMISSION SCHEME FOR

CERTIFICATION TO STANDARDS RELATING TO EQUIPMENT FOR USE IN

EXPLOSIVE ATMOSPHERES (IECEx SYSTEM)

Title: Confirmed Report of the WG10 - Repair and Overhaul – Certified Service Facility Scheme, Sydney Meeting,13th and 14th October 2011

Circulation: IECEx Management Committee (ExMC)

INTRODUCTION

This document contains the Confirmed Report of theWG10 - Repair and Overhaul – Certified Service Facility Scheme, Sydney Meeting, held 13th and 14th October 2011.

This document is issued to the ExMC Members for information.

Chris Agius

IECEx Secretariat

IECEx Secretariat
Standards Australia Building
286 Sussex Street
Sydney NSW 2000
Australia / Tel: +61 2 8206 6940
Fax: +61 2 8206 6272
Email:

October 2011

REPORT OF THE IECEx WG10 MEETING – October 2011

This document contains a report of the ExMC WG10 meeting held in Sydney 13th and 14th October 2011.

Attendance List

Mr. Chris Agius IECEx Secretariat (Acting Convenor)

Mr. John AllenSulzer Dowding & MillsUnited Kingdom

Mr. Heinz S. BergerCerticonsultSwitzerland

Ms. Christine KaneIECEx Secretariat

Mr. Patrick Leroux Total France

Mr. Evans MasseyBaldorUSA

Mr. Allan Ogden Baseefa United Kingdom

Mr. Gerhard SchwarzCooper Crouse-HindsGermany

Mr. Davide TacconiABB Italy

Mr. Peter Thurnherr ThubaSwitzerland

  1. Introduction

The meeting commenced at 9.00 a.m. Mr. Chris Agius, Acting Convenor, welcomed everybody to the meeting saying that it is nice to have the WG in Australia. He also thanked Standards Australia for hosting the meeting. He then extended apologies received from the Convenor, Mr. Theo Pijpker, who had been unable to attend. He commented however, that, although unable to attend Mr. Pijpker had done a considerable amount of work to assist the WG in preparing for the meeting and asked that the thanks of the WG be extended to Mr. Pijpker.

Before commencing Mr. Agius outlined the intent of the meeting saying that the current work is to review the Rules and Operational Documents for the existing scheme covering repair and overhaul of Ex equipment, IECEx 03, and then thereview of documents prepared to support the integration of other services namely inspection, installation and area classification.He remindedthe meeting that in Paris in 2008 the ExMC decision was taken to include these other areas of activity as part of the IECEx Certified Service Facility Scheme. The decision was then reconfirmed in Melbourne in 2009. In Berlin in 2010 following an ExMC request for an update on the status of the work,it was explained that up until now the IECEx emphasis has been on introduction of the IECEx CoPC Scheme which has since been launched and is now running, and that work has now been commenced on the updating of the Service Facility Scheme.

In discussion, comments relating to classification of areas and the regulations in various countries were raised. The convenor commented that many countries do have strict regulations but he reminded the meeting that all IECEx Schemes operate on a voluntary basis worldwide to serve industry needs.

Agenda Item 1. Approval of the draft agenda

The convenor sought approval of the agenda. Before approving the agenda the meeting noted the request from the ExMC 2011 Split Meeting relating to the topic of Energy Efficiency, EE, as relates to Ex motors be referred to WG10. It was agreed that this matter be addressed under relevant items as the meeting progressed. The members then approved the Agenda.

Agenda Item 2. Approval of the Stockholm report + outcome of ExMC Split meeting

The convenor sought apporval of the Stockholm Meeting Report asking if there were any comments. Mr. John Allen commented that the statement contained in the report, relating to overpressure test after welding repair on Ex ‘d’ equipment, is too open, too broad.In noting his comments the meeting agreed however, that the statement reflected the discussions held in Stockholm.

Mr. Evans Massey referred to the topic of Repair of high voltage “e” motors as was discussed during the IECEx 2011 Split meeting. It was noted that the process of how to handle this component certification of insulation systems might best be handled in the repair standard, IEC60079-19 as an informative annex providing guidance to users, as there was very little experience in this voiced during the Split ExTAG meeting. The current state is that users are cautious when using “e” motors due to possible technical problems associated with the repair process. It was noted that IEC standard, IEC60079-19 Explosive Atmospheres-Part 19 Equipment repair, overhaul and reclamation may not undergo revision for another three to four years, so ExMC WG10 may need to provide some guidance information as an interim measure.The meeting was informed that efforts are being co-ordinated through IECTC31WG27,and will involve John Allen, Davide Tacconi and Evans Massey from ExMCWG10, as part of the review process under MT60079-19.

Mr. Allen also raised the point that with Low Voltage machines TE time was also a concern that needed to be addressed. After further discussion realting to EE and rewind of motors, an action item was assigned to Mr. John Allen and the secretariat, to prepare a statement for inclusion in the Revision of OD 015,relating to guidance on how to rewind motors without adversely affecting their efficiency. Mr. Allen advised that an EASA publication document realting to this topic is freely available on the EASA web site.

Agenda Item 3. Actions taken since Stockholm

The convenor suggested that the Stockholm Action Items be discussed under the respective agenda items. The meeting agreed.

Agenda Item 4. Review of DRAFT IECEx 03 – Edition 3.0

The convenor reminded the meeting that when dealing with Agenda items 4, 5, 6, 7 + 8 they need to be aware that we are considering only Repair and Overhaul as the coverage of additional service activities of Area Classification, installation and inspection are the subject to separate WG10 agenda items..

The Draft document was considered during the meeting with only minor changes being made, other than the agreement that each Workshop/Service Facility Location be covered by their own FAR and Certificate of Conformity, noting that current practice has been to allow one certificate to cover multiple locations.

In light of the Decision taken under Agenda item 13 – Documentation Structure, the new edition of IECEx 03 covering Repair Services only should be numbered as IECEx 03 – 5.

The Meeting agreed that the document proceed to the ExMC for approval.

Agenda Item 5. Review of Draft Ex OD 013 Version 3

The Draft document was considered during the meeting with various changes agreed including the following.

  • Change to Step No. 4 Section 1delete Repair and overhaul and modification….
  • Change to Step No. 5 Section 1 to include Where a Service Facility operates multiple sites then each site shall be separately assessed and covered by their own FAR and CoC. A CoC covers one site only. Also add each site shall have its own FAR issued.....

Reason- scope of each site varies.

  • Change to Step No. 8 Section 1 addwith each site covered by its own FAR and CoC
  • Changes to Section 2 a) Annaul audits and b) 3 Year Re-assessment
  • Secretariat to conduct an editorial review to ensure that this principle is carried throughout the document [Secretariat Note: new IECEx 03 may need updating to reflect the proposed requirement for each site to have their own IECEx Certificate]
  • The flowcharts contained in the document to be updated
  • Version 2 in Headers of Section 1, 2 and 3 to be changed to Version 3

Before commencing review of the next document the meeting noted the use of Clause numbers and was advised that in the future, references will be to Clause titles.

Note: The above changes will result in changes to the Flowcharts. Similar changes will be required for other Operational Documents being reviewed.

The Meeting agreed that once recommended changes are made the document proceed to the ExMC for approval

Agenda Item 6 Review DRAFT OD 014 – version 3 – 2011-09

This Draft document was considered during the meeting with various changes agreed including the following.

  • Change under Clause 3.1.2 reference to IEC 60079-19 added
  • Change under Clause 3.4 Bullet point addition as follows measurement/test/inspection facilitiesavailable
  • Change under Clause 8.4addition as follows as - required by IEC 60079-19
  • Change under Clause 8.5 reference to OD 015 deleted replaced with requirements of IEC 60079-19.
  • Changes under Clause 8.6 to final paragraph
  • Changes under Clause 8.7 second paragraph also to include the deletion of reference to OD 015 andinclusion of IEC 60079-19
  • The removal of Annex A and the replacment of the wording making reference to Certificate of Competence to Unit 5 of the CoPC Scheme or other appropriate assessment of skills and knowledge, that address the competency requirements of Unit 5. Secretariat to finalise wording.

The Meeting agreed that once recommended changes are made the document proceed to the ExMC for approval.

Agenda Item 7. Review DRAFT OD 015 – Version 3

This Draft document was considered during the meeting with major changes agreed including the following.

  • Change of Title from Requirements to Information
  • Delete Clauses 5 to 12 with the exception of Item 5.3 Machining limits for Flameproof surfaces which is to be renumbered as 5.1
  • Change to ANNEX B B.1.4 Opening paragraph addAs required by 60079-19...
  • Overpressure Testing from Split Meeting – Task Group to be formed, Mr. John Allen and the Secretariat, to prepare wording for inclusion in the draft revision of OD 015.
  • Discussion took place relating to the report form examples conatined in OD015.The meeting agreed that examples of report forms are necessary. Thedecision was taken that, at this time,and in the absence of any otherdocuments, the initial versions of examples are still appropriatefor guidance.The meeting will, however, ask the ExMC to approve the removal of the examples from the document for separate posting on the IECEx web site, similar to the ExTAG ExTRs, and that like the ExTRs they will be password protected.
  • Examples of reports, when being revised, will need to be adjusted to comply with the newly worded 8.6 of Draft OD 014.

The Convenor will prepare a revised document for consideration by WG10 prior to circulation to the ExMC for approval.

Agenda Item 8.Review DRAFT OD 016 – Version 2

This Draft document was considered during the meeting with various changes agreed including the following.

  • Change to title from modification to reclamation and throughout the document
  • Change to Section 1 Step 1 additional informationIECEx 03 Applicant ExCBs shall also provide details of the proposed IECEx 03 ExCB Assessors to undertake IECEx 03 audits...
  • Change to Section 1 Step 10 add TGD 60079-19
  • Change to Section 2 2.2.2 delete CBs add ExMC Secretary
  • Change to Section 2 2.2.2 delete paragraph beginning Where the original...
  • Change to Section 2 2.2.2 delete beginning Where non-conformance.
  • Change to Section 3 3.2.1 and 3.3 to include additional paragraph relating to assessor requirementsbeginning IECEx 03 Applicant....
  • Change to ANNEX A A.1.5 add TGD 60079-19
  • Change to ANNEX A A.1.9 delete Associated Testing Laboratories
  • Change to add a new A.2.5 Name and Competence...
  • Renumber Annex as appropriate

The Meeting agreed that once recommended changes are made the document proceed to the ExMC for approval

Agenda 11.Review of FAR formatDRAFT FAR 60079-10- version 2

In agreeing with the combining of FAR and CRF into one report the new draft report form was considered during the meeting with various changes agreed including the following.

  • Change toTitle making the document specific to IEC60079-19 Ed. 3
  • Add the following Percentage of Business related to Ex:
  • Add the following Operatives:<list the Operatives, according to IEC 60079-19 that have been assessed. This list must be reviewed each surveillance audit>
  • Change under Scope of Repair…. add and any Limitations
  • Change under Audit Criteria delete version number
  • Chages to Section 1 Summary Report add Summary of observations:

State the most important results of the compliance/surveillance audit

  • Chages to Section 1 -non-conformance references with terms minor and major deleted also throughout the document where relevant
  • Changes to Section 2 Audit Data to include refernece to Service Facilities without a current ISO 9001
  • References to Annexes 1,2 and 3 deleted add where relevant retained on the Applicants file by the ExCB.
  • Change to Section 3 Assessor’s Report3.1 format to include reference to OD 014 and (The requirements of each of the following Clauses are detailed in OD 014)
  • Change to Section 3 3.2 Assessment to OD 015...deleted
  • Change to Section 3 3.3 add the following (The requirements of each of the following Clauses are detailed in IEC 60079-19)
  • Changes throughout Section 3 relating to the deletion of the terms N/A and No and other changes including renumbering required
  • Agreement for the proposed combining of the CRF and FAR into one report form

The Meeting agreed that once recommended changes are made the document proceed to the ExMC for approval

Agenda Item 12.Review of FAR 60079-19 NCR(Non Conformance Report)

This Draft document was considered during the meeting with various changes agreed including the following.

  • Change to Paragraph titled - Non Conformity Number:add mm/yyyy/xx and (Month/Year/No. issued)
  • Change to Paragraph titled - Requirement reference: add (e.g. IEC 60079-19 Clause… or OD 014 Clause ….. or ISO 9001 Clause ……)
  • Paragraph titled - Term for closure: and ExCB Verification by: to be deleted with Response Time by Auditee : to be added
  • Change to Paragraph titled -Response of Service Facility delete 1) Summary results analysis of cause and extent… add 1) Proposed Corrective
  • Action + Timeframe: Include a statement describing actual corrective action. Also add Service Facility Representative and ExCB Auditor
  • Changes to Paragraph titled 2) Corrections and Corrective actions:deleteState the actions taken to correct the….add Include a statement describing actual corrective/preventative action implemented......
  • Changes to 3 Delete 3) Self assessment of effectiveness of actions. After implementation of the corrective actions taken under 2) above…., change to

3) Verification of Corrective and Preventive Action by ExCB. Also add Service Facility Representative and ExCB Auditor

  • Delete 4)Identification......
  • Delete Results of ExCB.....

The Meeting agreed that once recommended changes are made the document proceed to the ExMC for approval

Agenda Item 13. Discussion on IECEx 03 Scheme – proposed structure and related documents to integrate Installation, Area Classification and Inspection activities

In discussing the integration of area classification, installation and inspection activities into the IECEx 03 Services Scheme, the meeting considered an appropriate documentation structure agreeing that “installation Design and Selection” be treated seperately to the act of Equipment installation.

As a result the WG agreed to the following proposed changes to the structure of documentation for use in the Scheme.This proposal will be circulated to the ExMC for appropval.The

documents are then to be published individually. The WG acknowledges that at this time there will be an overlap of information within the documents at this initial stage with a future review to be undertaken to consider developing a “General Requirements” document for rules common accross all Service Facility activities.

The agreed documentation structure for proposal to ExMC is as follows-

  • IECEx 03-1 Rules of procedure - Area Classification Service
  • IECEx 03-2 Rules of procedure - Design + Selection
  • IECEx 03-3 Rules of procedure - Installation and/or Maintenance Service
  • IECEx 03-4 Rules of procedure - Inspection Service
  • IECEx 03-5 Rules of procedure - Repair Service
  • Supporting Operational Documents to be numbered accordingly

The decision was to prioritise the work on these documents as follows

  • Priority 1 = -5
  • Priority2 = -3
  • Priority3 = -4
  • Priority4 = -2
  • Priority5 = -1

Agenda Item 14. Review of IECEx 03DRAFT IECEx 03 – Edition 4.0 to integrate Installation, Area Classification and Inspection activities

This Draft document was considered during the meeting with the following agreed.

  • Following on from the decision taken under Agenda Item 13, the Convenor of WG10, Mr. Theo Pijpker and the IECEx Secretary are now to prepare initial drafts for IECEx 03 - 2 Design + Selection and IECEx 03 - 3 Installation and/or Maintenance Service
  • Change of Title to replace the term ‘erection’ with ‘installation’ in this document and in all WG10 related documents
  • WG 10 Members invited to assist with the preparation of documents IECEx 03 - 1 Area Classification Service and IECEx 03 - 4 Inspection Service with membesr asked to particiapte.
  • IECEx 03 Version 3 to become IECEx 03 - 5 Repair Service. A note of expalnation as to the changes to be included when circulated to the ExMC.

Agenda Item 16. Review of revised draft OD 60079-14 V1 to integrate Installation, Area Classification and Inspection activities

This Draft document was considered during the meeting with major changes agreed including the following.

  • Change in Title‘installation and/or maintenance’as well as throughout the document
  • Changes to proposed numbering system for referenced documents throughout e.g. IECEx 03-3
  • Addition of requirements to include 60079-17 e.g. IEC 60079-14 or IEC 60079-17throughout document
  • Changes to Terms and Definitions Clause 3 with some definitions being deleted
  • Changes to Quality system requirements Clause 4
  • Changes to Management responsibility Clause 5
  • Changes to 6.2.2 relating to competence
  • At present the document is numbered according to the Standard number it was agreed to change the numbering.

A further action as an outcome of this discussionrelates to the preparation of OD 013-3 that an addional requirement be included that a Service Facility demonstrate industrial electrical installation capability according to IEC 60364 or national equivalent.

The IECEx Secretary is to prepare a revised document for circulation to the WG for comment. Comments received will then be dealt with during the next WG10

Agenda Item 15. Review ofDRAFT OD 016 – version 3 to integrate Installation, Area Classification and Inspection activities

This Draft document was considered during the meeting with various changes agreed including the following. At the same time the members agreed that the recommendation beforwarded to

the ExMC for approval; that at the early stages assessments are to be carried out by assessorsdrawn from WG10 much the same as is the current practice in the CoPC (WG12). A further significant change agreed was that all ExCBs seeking to participate in the IECEx 03 Services Scheme for the activities of Area Classification, Installation and Inspection, should be subjected to a site assessment by an IECEx Assessment team comprising of at least one expert from WG10. This requirement to be applied even where the ExCB is already participating in another IECEx Scheme.