Hazardous Engineering Solutions

www.hazeng.com Issue 1 | October 2010

The International Magazine For Hazardous Area Professionals www.hazeng.com

EX-cellent CE marking Turn to page 9

News & Products

ATEX

Zoning In

The latest innovations, news stories and tools

Implication for manufacturers

Portable Gas Detection with new 1 Draeger X-zone 5000

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In this issue: News & Products Zoning in on Portable Gas Detection with new Draeger X-zone 5000 EX-cellent CE marking ATEX FANS : MAKING THE RIGHT CHOICE ATEX – Implication for Manufacturers

CONTENTS

Condition monitoring is an insurance policy against unforeseen SO YOU NEED AN INTRINSICALLY SAFE DIGITAL CAMERA …

IECEx Certification of Personnel Competence Scheme A first in the Asia-Pacific Intrinsically safe and explosion proof manual call

Novel connectors simplify commissioning of electrical equipment in hazardous firedamp environments

ExVeritas provide FREE Software to help with ATEX and DSEAR Design and Verification

Specialist Suppliers of Hazardous Area Electrical Products

+ More......

Publisher - Michael Dominguez

Email: paul@engineeringmaintenance.info

Email: michael@hazeng.com Website: www.hazeng.com Editors/Contributers - Jon Barratt, Christer Idhammar, Alan France, Mick Saltzer, Mark Haarman Email: editorial@hazeng.com Ad Manager - Paul Clappison Email: paulc@hazeng.com

MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ Tel: +44(0)1634 731646 Fax: +44(0)1634 731644 www.engineeringmaintenance.info

Online Sales Director - Paul Miles

October 2010 3

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LATEST NEWS & PRODUCTS

BRILLIANT NEW TEMPORARY ATEX LED FLOODLITE

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olf Safety has launched

voltages of 100 to 254V AC or 24 to 48V

the Wolf LED Floodlite,

AC/DC, the Lamp has low power consumption

a high performance, low

at 58 watts, is T4 rated and has a low enclosure

maintenance,

surface temperature, eliminating the risk of

ATEX

compliant Hazardous Area Floodlite, using high

burns.

output, high efficiency LEDs and designed to LED Floodlite is available with a medium flood

be transportable specifically for use in

Supplied as standard with 20 metres of SY

temporary applications and installations.

Cable, ATEX plug, and integral stainless-steel as standard, or a wide angle beam to order. stand; the LED Floodlite can also be fitted with

Other accessories include a sacrificial lens

The Wolf WF-300 LED Floodlite range is CE an ATEX socket, to allow the lamps to be linked

protecting films for grit blasting and painting

marked to the ATEX Directive for use in Zone together for quick and easy setup of multiple applications, magnet fixings and tripod options.

1 and 2 potentially explosive gas and dust LED units in temporary installations.

For more information, please visit the

atmospheres, with 48 ultra bright high power LEDs producing 3,300 lumens of brilliant white Constructed from powder coated marine grade light, brighter than a 200 watt halogen

aluminium alloy and sealed dust and watertight

incandescent lamp.

to IP66/67, this very low maintenance Wolf

Cable powered from

website at www.wolf-safety.co.uk or call the sales office on +44(0)114 2551051.

Nobel Fire Systems solve red hot problem for Avdel UK Ltd drop straight into the oil quench tank which cools them while at the same time altering the chemical structure of the rivets as part of the hardening process. It was recognised that the action of the rivets dropping onto the surface of the preheated oil hen Avdel UK needed constituted a potential fire risk, and it was for this reason that Avdel a fire suppression required a cost-effective and efficient system to protect the new oil quench tank at fire suppression solution. its Warrington based manufacturing plant, the company looked at various While some suppression system suppliers recommended the use of potential solutions offered by a Carbon Dioxide solutions, Nobel Fire number of suppliers. After careful Systems came up with a more examination of the facts, the innovative and effective answer to the Company awarded the contract to Nobel Fire Systems. Avdel’s large oil problem. Nobel recommended the installation of its Stat-X condensed tank is sited on the end of a heat aerosol system. Stat-X is a selftreatment furnace. As red hot rivets contained, environmentally friendly are removed from the furnace they suppression system that has been

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proved to be extremely effective in use. Compared to a CO2 system, StatX doesn’t require intricate pipework and nozzles to be fitted, nor does it require space for the provision of CO2 bottles. In this specific situation, this was a particular advantage as space around the quench tank is at a premium.

In the case of a fire breaking out, Stat-X can be operated both automatically and manually. Stat-X aerosol units require no maintenance and have an expected shelf life of up to 10 years. Where needed, the system’s control panel can be easily connected to the property fire alarm for notification purposes. www.nobel-fire-systems.com Tel: +44(0)1706 625777

WE’LL GET YOU TO NORTH AMERICA A BETTER WAY There are better ways to export your ‘Ex’ products to North America.

CSA marks are accepted by electrical inspectors and regulatory authorities, both in the U.S.A. and Canada.

Sira, a CSA International Company, provides CSA compliance packages to ensure your products reach North America, on-time and on-budget. A better way.

info@siracertification.com www.siracertification.com

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GAS DETECTION

Zoning in on Portable Gas Detection with new Draeger X-zone 5000 Transportable gas detection has entered a new era with the launch of the Draeger X-zone 5000 wireless monitoring unit. Easily positioned and providing clear alarms, these robust, waterproof units ensure increased levels of safety by detecting and communicating the presence of a wide range of toxic, combustible and explosive gases over longer distances.

Bringing Zone 0 ATEX performance, longer sensor life, enhanced battery life and more flexibility to area monitoring, the Draeger X-zone also offers a lower cost of ownership.

U

sing a variety of

sensors and a combination, double sensor for

For continuous monitoring of confined

alarms to warn of

CO and H2S, it will provide simultaneous

spaces and other areas that are difficult to

different types of

measurement of gases and vapours such as

access, an optional integrated pump can be

gases, up to 25

hydrocarbons, hydrogen, O2 and other

used for distances of up to 45m. Approved

Draeger X-zones

explosive, combustible or toxic gases.

to IP67 for dust and water ingress, the unit can also be used with external equipment

can be used at

any one time, acting as wireless monitors

Continuous monitoring

such as alarm horns, lamps or traffic lights.

around a specific zone, including those

Deployed at varying distances apart, the

In addition, the fenceline signal and alarm

areas where an explosion hazard might

transportable measuring heads continuously

contact point can be forwarded to a central

exist. This networking and synchronised

monitor a number of different gases. Easy

control room for further management

signalling capability means that people

to see, even from a distance, a green LED

procedures.

can be guided away from the potential

band around the circumference of the unit

hazard.

indicates that the air is clean. As soon as

Low cost of ownership

one of the units detects a gas it immediately

Fast, reliable and accurate, the latest

transmits an alarm to each of the others, the

miniaturised Draeger XXS high

LED bands of the alarming unit change to

performance sensors offer extended life

red while the others show green and red

capabilities of up to 8 years for

signals, and unambiguous visual and alarms

electrochemical sensors, and up to 4 years

are issued. At the same time, a loud

for catalytic sensors.

Allowing gas ingress from every side, independent of wind direction, the units are designed for use with Draeger X-am portable gas detection instruments. When used in conjunction with the Draeger X-am 5000, for example, it can be fitted with up to four sensors to detect as many as five gases at once. In this instance, by using a catalytic Ex-

evacuation alarm is emitted and a patented 360ยบ alarm amplifier ensures that it is heard

Two different types of rechargeable

with the same intensity in all directions.

batteries enable continuous operation for

sensor together with two electrochemical

either 60 or 12 hours and the unit can be Unlike portable instruments which

charged via conventional methods or, for

usually leave the scene with the

maximum convenience and trouble-free

wearer, the units can be left inside

operation, via a modern induction charger.

the zone, constantly issuing an

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alarm as long as the danger exists.

For further information contact Customer

Facilitating an easy, unmistakable

Service, Draeger Safety UK Limited,

evacuation in the event of a gas

Ullswater Close, Blyth Riverside Business

hazard, they also alert other

Park, Blyth, Northumberland, NE24 4RG.

personnel to the presence of a

Tel: 01670 561200, fax: 01670 356266,

danger zone.

www.draeger.com.

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EX

EX-cellent CE marking EX product certification for Europe is governed by the ATEX equipment directive 94/9/EC under the European Commission’s new approach (CE marking) regime. However it is just one of a handful of directives or requirements that may apply to equipment for use in potentially explosive atmospheres.

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ypically manufacturers may also have to consider the design, documentation, manufacturing and quality system implications for EMC, machinery safety, electrical safety and radio/telecoms compliance before applying the CE mark. Since the beginning of 2010, there are new requirements, set out in Council Decision 768/2008 which should guide us all in our CE work, not the least because the Decision sets out restriction, prohibition and recall provisions for persistent non-compliance in respect of both equipment safety and its supporting documentation (including the Declaration of Conformity). The Council Decision is likely to be applied to current directives by way of a new “omnibus” directive that will update a number of directives using a single document introduced in the next twelve months.

For many years, TRaC has provided notified body, certification body and testing laboratory services for some of the most commonly use of these complementary directives. In parallel to these regulatory aspects, functional (e.g. radio/telecoms) and/or environmental performance criteria (e.g. vibration, shock, wind, rain) may also need to be applied.

Manufacturers can get help and guidance on all of these areas from our experts based at TRaC’s seven sites across the UK (Hull, Malvern, Ringwood, Up Holland, Warwick, Watford and Wimborne).

This article discusses the CE model and provides some suggestions for the application of best practice.

The CE mark The principles of the new approach (“CE marking”) directives were originally outlined in European Council Decision 93/465/EEC which laid down rules for affixing the CE conformity marking concerning the design, manufacture, placing on the market and entry into service of a product. This Decision was repealed with effect from 1 January 2010 and replaced by Council Decision 768/2008 which sets out a general framework for future CE marking legislation, the CE marking processes, the conformity assessment procedures and their enforcement provisions.

The CE mark is not a purchasing mark but a free trade mark. It is intended to assist customs officials and enforcement agencies in their work and hence there is no obligation placed upon the manufacturer to provide much of the supporting documentation.

However, in practice it is used for purchasing purposes as users try to satisfy their own legal obligations.

The application of the CE mark to any piece of equipment means that the manufacturer has applied all of the requirements of all of the applicable directives. The visible CE mark is the same for all directives. Whilst the mark itself is common, it can be suffixed with the 4 digit number of the notified body (e.g. for TRaC 0891) if one is involved in the conformity assessment procedure for one or more of these directives.

The Declaration of Conformity The Declaration of Conformity is probably the most critical part of the CE mark system.

The detail of the directives that have been applied and often the standards used in support of them is described on the manufacturer’s official EC Declaration of Conformity. There is only one EC

Declaration of Conformity document per product. The content requirements for the declaration are set out in each directive even though (unfortunately) the detail is not the same for all of them. Council Decision 768/2008 confirms that a single Declaration of Conformity be drawn up in respect of all applicable directives to the product. It also sets out the model layout and text to be followed for an EC Declaration of Conformity (based on ISO/IEC17050). This is a change to previous practice but reinforces the key elements needed to demonstrate compliance. Figure 2 shows the key elements of the Declaration of Conformity.

Under specific directives, other declaring documents are also specified. Two examples are the Declaration of Incorporation (DoI) used for incomplete assemblies under the Machinery Directive and the Certificate of Attestation (AoC) used for components under the ATEX directive. These related documents should not be confused with the Declaration of the Conformity because their requirements are legislation specific and replace the requirements of the Declaration of the Conformity. However, these documents are intended to serve a similar purpose and hence the content and intent is very similar.

In almost all cases, the information on the Declaration of Conformity provides a good

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EX indication (to regulators, enforcement agencies, customs officials, customers and competitors) as whether the CE marking process has been completed properly. If the Declaration of Conformity (the simple administrative, restatement of facts) is incorrect then this must raise questions as to whether the technical aspects of the CE conformity have been understood and properly applied. Consequently the content of your Declaration of Conformity can act either as a public statement of compliance or as a public confession of guilt.

It is this worth paying attention to the content of your Declaration.

administrative. For example, in the case of the ATEX directive, its conformity assessment procedures do not extend to the Low Voltage Directive element; instead, compliance for this requirement is determined on the basis of declaration by the manufacturer against the relevant Low Voltage Directive standard. The details of Low Voltage Directive standard are included on the Declaration of Conformity and the supporting evidence for compliance retained by the manufacturer in their technical file (under their sole responsibility). However, no further assessment is required by the ATEX directive.

TRaC have produced a paper discussing this subject in more detail and outlining a model for the Declaration of Conformity (and Declaration of Incorporation and Certificate of Attestation) that covers most of the common directives. The paper is available by email from atex@tracglobal.com.

It is the manufacturer’s responsibility to determine which directives should be applied.

This choice will be guided by the both the technology and end-use location of the equipment.

Best practice guide: Take great care with your Declaration of Conformity (or similar declaration). Review and update all of your Declarations using the new ISO/IEC17050 model.

The Directives The relationship between the directives can be quite complex, e.g. some directives are mutually exclusive (e.g. machinery safety and low voltage directive), but most are applied in parallel. Where there is exclusivity, provisions are made with the predominant directive to encompass the essential requirements of both directives are addressed. For example, the Low Voltage Directive has an exclusivity application with both the Machinery and ATEX directives. However, within both directives the technical requirements of the Low Voltage Directive (usually detailed in harmonised standards) are called up with the essential requirements and hence in reality the effect of non-application is largely

Best practice guide: Review all of the directives that you apply. Ensure that any changes introduced by directive revisions have been applied to your equipment, documentation and systems.

Conformity Assessment Procedures The new approach directives provide for eight assessment procedures or "modules" (A-H) which cover the design and production control phases. The specifics of each directive differ and each uses one or more of these modules to demonstrate conformity. Modules can be applied separately or in conjunction with other modules. The application of the modules can involve third party, notified bodies who supervise and verify the correct application of the modules. However, there is a general new approach principle (reinforced within Council Decision 786/2008) to avoid imposing modules which would be too burdensome in relation to the risks covered by the legislation concerned. Hence conformity assessment procedures must be appropriate to the degree

of risks present. There are hundreds of notified bodies across the EU. TRaC is a notified body for a number of directives including the ATEX, EMC, Low Voltage, Machinery, Radio & Telecoms and Noise directives.

Only module A (internal production control) does not involve a notified body in some form. However it is the most commonly applied module and forms the basis for many directives including Low Voltage, EMC and Machinery Safety. Module A crops up as Annex VIII of the ATEX directive for category 3 (lowest risk) equipment. For equipment with higher risks, one or more of the other modules/Annexes are applied.

It is worth noting that the general principles of product conformity are the same regardless of the modules applied (i.e. product testing, documentation and ongoing control of production). The main distinction between modules is commonly the degree of third party supervision. Consequently, even for modules that permit self-attestation by the manufacturer, best practice guidelines can be adopted from the appropriate third party supervised module.

A good example from an ATEX perspective is the production control requirement of Annex VIII. Here the requirement is very open and vague. However, by applying the requirements from Annexes IV – VII (albeit without involving a third party) then best practice production control can be achieved utilising standard EN13980. This best practice approach is supported within the UNECE endorsed IECEx system which requires the same production control approach (using a technically equivalent standard OD005) regardless of “category” or equipment risk.

Technical documentation is now required by the conformity assessment procedures of most of the key directives. The recent updates to these directives have harmonised the content requirements to some extent. However it is worth noting that creation and maintenance of these files is mandatory and manufacturers should be mindful of the renewed importance of documentation in the eyes of enforcement agencies.

Normally the details of the applicable modules are outlined in the conformity assessment annexes (e.g. the ATEX directive utilises six of the eight modules as set out in its Annexes III-IX). The choice and application of directives can sometimes be quite difficult and manufacturers often find it useful to consult with multi-directive notified bodies, such as TRaC, at an early stage.

Best practice guide: Whichever modules are applied, review the requirements and adopt the most coherent methods for your own use even if they would normally be overseen by

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www.hazeng.com third parties. Ensure that your technical documentation is complete and fulfils the requirements of all of the directives.

Essential (health and safety) requirements (E(HS)R) The essential requirements (or essential health and safety requirements) of directives are normally worded precisely enough to create legally binding obligations. They are constructed to make it possible to assess conformity with them even in the absence of harmonised standards or where the manufacturer chooses not to apply a harmonised standard. The degree of detail of the wording depends on the characteristics of the industry sector and risk. This principle, originally set out as part of the new approach, is re-iterated in the new Council Decision.

The E(HS)R’s permit conformity assessment without standard – a route historically used for machinery safety; not the least because equipment standards were initially few and far between. For most other directives, and increasingly for the some machinery, harmonised EN standards are widely available. Recent versions of all EN’s which relate to directives now carry informative annexes that detail which E(HS)R’s have been addressed by that standard. The ATEX directive has been well supported by a raft of EN standards. However, there are many instance where application of the E(HS)R’s in ATEX Annex II are applied (although normally not entirely remote from reference standards for component parts and assemblies).

Best practice guide: Apply harmonised standards wherever possible. However, recognise that the requirements of the directive are the E(HS)R’s and not the standards. Hence manufacturers need to take a broad view of both sets of requirements to prove full compliance.

Control of production and factory audits At a basic level, all of the directives require some form of production control for series manufactured equipment. In the case of most equipment covered by the EMC, Machinery Safety and Low Voltage directives (module A) this usually means some form of product assurance or quality assurance to ensure that all production units conform to type.

However, module A leaves the exact implementation up to the manufacturer. Best practice requires the use of recognised product quality systems to support the ongoing conformity requirement even for module A. For other modules, some form of third party (notified body) involvement may be required and this may include the use of ISO9001 as the basis for determining compliance. This is

EX the case with some of the Annexes of the ATEX directive.

Whether you apply a formal quality assurance system, or not, the underlying principles of ISO9001 represent a best practice approach.

These key principles include control of purchasing of critical parts, training of production staff, use of production procedures, engineering change control and document control. We have already explored earlier in this article the value of using standard EN13980 for all types of ATEX equipment, regardless of category or risk. If other directives are applied (even if only under module A) then the guidelines for a good ATEX system will equally apply to these less prescriptive regulations. IECEx document OD005 is in most respects technically equivalent to EN13980 and is currently available for free download from the IECEx website www.iecex.com.

One the important elements drawn out by EN13980 and OD005 is the need for regular and rigorous internal audit of equipment and documentation. Internal audit in fact applies to the production control within all directives even though can be the forgotten element.

many of the concept standards in production or recently issued. It is important for manufacturers to keep up to date with changes to standards so that their designs can evolve in parallel with them. This is particularly important where changes to standards are frequent (as they have been with ATEX in recent years) and multiple editions of standards are current. Global harmonisation means that new requirements that previously would only have been applied in overseas markets may suddenly be applied in your own.

TRaC have produced a paper that reviews recent changes to ATEX standards. The paper is available by email from atex@tracglobal.com.

Best practice guide: Use your quality system and internal audit process to ensure that you have reviewed the all of standards that you use on an annual basis. Build in a process for implementing revisions in to the design if you can. Consult with notified bodies for advice on changes to standards.

Summary Best practice guide: Ensure that your production control follows the basic principles of ISO9001 (and supporting standards such as EN13980 when they are applicable). Ensure that your internal auditing systematically reviews your processes.

Standards CE marking legislation and directives generally avoid going into technical detail but limit themselves to the expression of essential requirements (E(HS)R’s). The new Council Decision sets out that these E(HS)R’s, where appropriate, have recourse to harmonised standards. These harmonised standards provide a presumption of conformity with the E(HS)R’s. Harmonised standards for each directive are identified in the Official Journal of the European Communities and are also listed on the relevant directive page on the Europa website.

The ATEX directive is supported by electrical and mechanical standards (EN60079 and EN13463 serries). Like the other electrical safety directives, the electrical standards are largely based on international IEC standards.

The mechanical standards are currently based on CEN produced standards but in the future could relate to international ISO mechanical standards.

Standards change over time. Sometimes these changes are small but equally they can be quite substantial. The ATEX standards are currently in state of flux with new versions of

CE marking isn’t a new phenomena however it can be a complex one. This complexity has increased due to the significant changes that have been made to several directives and the standards that support them in recent years. In order for manufacturers to stay compliant it is important that everyone reviews the impact of these changes. Furthermore, when establishing an ongoing compliance plan account needs to be taken of all of the directives that apply to a product and how they affect the design, documentation and production control. The best practice guidelines above will assist in the process.

Such a review of CE processes is also important if manufacturers are considering export outside of the EU. Whilst the basic principles of product conformity remain the same almost everywhere, a review of export requirements shows that in many cases the regulatory regimes applied in overseas markets (e.g. USA) are in fact more arduous than for the CE mark in terms of third party testing and auditing. However, for those with a rigorous CE system this should present few problems whether applying directly for overseas certifications or using the IECEx or IECEE schemes (further information on these schemes is available from TRaC).

Simon Barrowcliff is Director of Safety for TRaC

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ATEX FANS

ATEX FANS : MAKING THE RIGHT CHOICE Specifying ATEX fans is difficult enough given the need to understand and meet the various directives and regulations.

O

nce having found an ATEX fan that satisfies a particular risk assessment there is the added problem to find sufficient choice of fan to meet all criteria.

Axair Fans can help you avoid making the inevitable compromises by providing a greater range of ATEX fans than any other source.

Axair manufactures two ranges of centrifugal fans in carbon-loaded moulded polypropylene.

They are available for Category 3G-Zone2 applications with the option of EEx-nA or EEx-d motors, covering air flow rates up to 10000m³/h and pressures to 2000pascals.

Axair supplies Sodeca ATEX centrifugal fans in both steel and aluminium construction. Fan components are either prevented from contact sparking in normal operation or are made of non-sparking copper and aluminium. All Sodeca ATEX fans can be specified for Sodeca HCDF/ATEX (up to Ø560), Category2 Zone1, with the option of EEx-e or HDF/ATEX (to Ø900) and HCT/ATEX (to EEx-d motors. Ø1000) offer volumes up to 72000m³/h Sodeca CMP multi-vane, CMR backwardcurved and CMA forward-curved fans are available to 30000m³/h and up to 4000pascals pressure.

Axair stocks Sodeca plate and cased axial fans Being corrosion resistant Axair ATEX for building or room ventilation. EEx-d motors polypropylene fans can handle aggressive are standard on the plate fans. Cased models chemical fumes internally, whilst being weather offer a choice of EEx-d or EEx-e motors protected externally.

Axair distributes Rosenberg ATEX fans in a wide variety of designs for Category3 Zone2applications. The fans are dimensionally compact to save space in equipment and are driven by external rotor motors of the EEx-e type.

AXAIR FANS UK LIMITED Tel : 01782 349430 www.axair-fans.co.uk

ExVeritas provide FREE Software to help with ATEX and DSEAR Design and Verification ExVeritas, the UK’s leading Hazardous Area Design Consultancy, has developed a range of free software to assist people involved in the design or verification of ATEX and IEC products or sites with explosive atmospheres. he software runs ‘on line’ or can be downloaded as a desktop application under Windows. The software will also run as an iPhone Web Application! Currently the software includes:

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and inductance to use when designing a circuit to be energy limited or Intrinsically Safe

FlamCal: ATEX and IEC Flammable Properties Application

This application is designed to provide a designer or an inspector with an indication of the correct maximum safe gap for any selected Flamepath type.

This application allows the user to select from several hundred common flammable substances to determine the physical properties that may be required for ATEX or IEC equipment selection or area classification.

You would need 30+ A2 ATEX Posters to hold this much information!

IntrinsiCal: ATEX and IEC Intrinsic Safety Circuit Evaluation Application This application gives an indication of the maximum safe voltage, current, capacitance

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MESGCal: ATEX and IEC Flameproof Design Application

SILCal: Safety Integrity Level (SIL) Determination This application is designed to assist you in the process of determining SIL in accordance with the guidance in IEC 61508. By select event scenarios, a target SIL will be given.

The download version can print files for recording assessment.

The software can be run on line without registering or downloading or downloaded as

a desktop application from www.exveritas.com ExVeritas was formed by former ATEX Notified Body owners Sean Clarke and Stephen D’Henin and provides a range of technical and management services which include ATEX Product Design and ATEX and CE Compliance Management.

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EXPLOSION PROOF MANUAL

Intrinsically safe and explosion proof manual call E2S,development the leading European manufacturer of warning devices for use in hazardous areas, has extended its capabilities with the of intrinsically safe and explosion proof manual call points, certified to both ATEX and IECEx standards.

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he IS-CP4 intrinsically safe units are approved for use in Zones 0, 1 and 2 environments and the BExCP3 Ex e d explosion proof versions for Zones 1 and 2. Both types are available with either break glass or push button operation. The devices are manufactured from corrosion proof, copper free, marine grade LM6 alloy and are sealed to IP66, enabling them to be used in both offshore and onshore installations.

A comprehensive range of standard accessories and options can be specified; they can be fitted with a stainless steel lift flap and series and EOL resistors in a range of different values can be fitted as required. The units can be fitted with stainless tag and duty labels and, normally finished in red powder coat finish, special colours can be specified to enable rapid visual identification of special functions.

The introduction of this new family complements the well-established BEx range of explosion proof sounders, beacons and loudspeakers and the IS-mini modular sounder and beacon family.

For further information: Neal Porter European Safety Systems Limited Impress House Mansell Road London W3 7QH Tel: + 44 (0)20 8743 8880 Fax: + 44 (0)20 8740 4200 sales@e2s.com www.e2s.com

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CERTIFICATION

IECEx Certification of Personnel Competence Scheme A first in the Asia-Pacific The Managing Director of a Thailand-based company has become the second person in the world to be certified under the IECEx Certification of Personnel Competence Scheme (CoPC).

M

r WiroteWannasiwaporn, Managing Director of MARC Thailand Co Ltd, completed the first unit of the scheme in September 2010 and becomes the first person in the Asia- Pacific region able to prove their competence in the field of explosion safety, using the IECEx scheme as evidence.

MARC Thailand is based in the Nakornpathom region of Thailand and provides electrical repair, overhaul and engineering services. In 2008, Sira also issued MARC Thailand with the world’s first IECEx Service Facility Certificate, a scheme which covers Service Facilities for the repair and overhaul of equipment for use in Explosive Atmospheres.

The IECEx Certification of Personnel Competence Scheme is the world’s first international scheme for the certification of personnel associated with equipment, installations and servicing used by Ex industries.

This newly launched scheme provides companies with independent proof that a person holding an IECEx Certificate of Personnel Competence has the knowledge and skills necessary to implement the International Ex Standards.

This can be especially important for contracting staff.

Certification Body, Sira, is an Steve Wordley of Petroplus receiving the world’s first IECEx Competence certificate, July 2010. approved provider of IECEx personnel certification, and knowledge test. Candidates who successfully issued the world’s first IECEx Competence meet the certification criteria will be awarded certificate to Steve Wordley at Petroplus in an IECEx Certificate of Personnel July 2010.

Competence. Regular re-assessment ensures that the certified person maintains their Speaking about his achievement, Mr competence.

Wannasiwaporn said “demonstrating competence is vital, particularly in the Ex field, where safety is paramount. Thai industry has recognised and adopted IECEx standards for products and facilities for several years and the extension of the IECEx scheme into personnel competence is an excellent progression”.

Sira Director, Bob Cooper, presents Wirote Wannasiwaporn with his IECEx Competence Certificate

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To obtain an IECEx Certificate of Personnel Competence, a candidate prepares an application form and submits it to Sira, an approved IECEx Certification Body. An assessment of qualifications and experience will be conducted, followed by a

More information about the scheme can be found here http://www.siraenvironmental.com/personn elcompetence.aspx To apply for the scheme, or for more information, please contact Sira: Tel: +44 (0) 1322 520 500 Email: info@siraenvironmental.com Web. www.siraenvironmental.com

WE’LL GET YOU TO NORTH AMERICA A BETTER WAY Wherever you are located, exporting product to the U.S.A. and Canada requires compliance to applicable U.S. and Canadian standards, and recognised approval marks that end-users will accept.

But with many approval bodies in the marketplace, it’s difficult to know which approval mark applies, and which ones will be accepted in North America for both the U.S.A. and Canada.

Sira Certification, a CSA International company, provides test, assessment and certification services that get your products to North America using the CCSAUS mark - one mark to access both the U.S. and Canadian markets and maximise sales.

Who is CSA International?

CSA International is a global testing and certification service provider offering the widely recognized and accepted CSA certification marks that appear on billions of qualified products around the world.

CSA International provides conformity assessments solutions for the U.S., Canadian and International markets.

CSA International is accredited as a Certification Body in the U.S. by OSHA as a NRTL, in Canada by the SCC and internationally under the IECEx scheme.

The Route to North America The CSA International mark is a well-recognized and widely accepted mark, indicating that products meet U.S. and Canadian standards, including UL, ANSI, CSA and other applicable standards.

It is the only mark you need to gain access to both

What to do next Who is Sira?

Sira is a leading provider of ATEX/ IECEx certification. With over 25 years experience conducting product approvals, Sira has helped thousands of companies get their products to market, on time and on budget. In 2009, Sira became a CSA International company and provides certification to North American

info@siracertification.com www.siracertification.com

To find out how the CCSAUS mark can save you time and money, and get you into the Canadian and U.S. market, please contact Sira.

Tel: +44 (0) 1244 670 900 Email: info@siracertification.com Web (Sira): www.siracertification.com Web (CSA): www.gethazloc.com

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ELECTRICAL PRODUCTS

Specialist Suppliers of Hazardous Area Electrical Products A.S.P. Electro-Technology Ltd, founded in 1991, has been built on many years of experience within the UK and International Oil & Gas Hazardous Area markets.

We have enjoyed many years of steady growth and look forward to future success.

O

ur philosophy is simple, we provide our customers with the right products at the right price with the right lead times. Our many years of experience enable us to provide the best possible support and assistance for all our customers Hazardous Area applications no matter how big or small the project.

We are extremely pleased to announce that we are now Approved Assemblers of Weidmuller EExe Certified Junction Boxes.

Whether your requirement is for Stainless Steel or GRP Junctions boxes our aim is to provide our customers with an unbeatable service in the supply of junction boxes.

I trust you will find these details of interest and should you require further information please do not hesitate to contact either of our offices where we will be pleased to discuss your application in more detail and the ways in which we can help and assist.

Please view our website: www.asp-electrotech.com where you can find details of the products we supply. Please do not hesitate to contact us if the product you are looking for is not on the website, we work closely with all major UK, European and USA manufacturers.

We aim to supply the widest range of Hazardous Area electrical products in the market.

Andrew Rowley Sales & Marketing Director We are Specialist Suppliers of a whole range of Hazardous Area Certified, Explosion protected ATEX, IECEx, UL, CSA and other nationally Approved Electrical Products & Instrumentation suitable for use in the Oil & Gas, Petrochemical, Pharmaceutical, Process, Food & Drink or Mining Industries.

We provide the highest level of quality in our service and in the products we offer, ensuring that every client receives an efficient and reliable standard of customer care. We only offer equipment produced by Quality Assured, Internationally Approved manufacturers ensuring peace of mind and compliance with relevant directives.

From both of our locations we are able to offer a custom build facility for a large range of Control Stations, Control Panels & Systems, Motor Starters, Junction Boxes, and help with Product Selection. We also provide Lighting Design schemes.

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A.S.P. Electro-Technology Ltd. (UK) Sapcote Road, Burbage, Hinckley, Leicestershire. LE10 2AU Tel: +44 1455-635796 Fax: +44 1455-251110 Email: sales@asp-electro-tech.com

A.S.P. Electric Pte Ltd. (Singapore) 60 Albert Street, #14-07 OG Albert Complex, Singapore 18996 Tel: +65 6338 2877 Fax: +65 6337 6608 Email: sales@asp-electric.com

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Novel connectors simplify commissioning of electrical equipment in hazardous firedamp environments

A

range of innovative,

The new eXLink Mining connector from

electrical device with power consumption up

explosion-proof

Cooper Crouse-Hinds is certified for use in

to 16A – light fittings, alarms, sensors, motors

connectors has been

hazardous firedamp areas. The connector

and drives – can simply be plugged in and out

developed, which

enables engineers to commission and

using the connector.

simplifies the

decommission a wide range of electrical

commissioning and decommissioning of

equipment in underground mines, without

For more information on Cooper Crouse-

electrical equipment installed in hazardous

having to use any special tools and without

Hinds’ eXLink Mining connectors, please

firedamp environments, including

having to isolate, then disconnect the

contact the UK sales office on 02476

underground mines.

equipment. This means the installation,

308930 or email sales@ceag-crouse-

maintenance and repair of any electrical

hinds.co.uk or visit www.ceag.de

Firedamp is a flammable gas predominantly

apparatus in firedamp areas

found in coal mines, which normally

can be carried out in a simple,

comprises a number of different flammable

safe but cost-effective manner.

gases, particularly methane. Firedamp is commonly found in areas where the coal is

The eXLink Mining connector

bituminous. The gas accumulates in pockets

is designed with armoured

in the coal and adjacent strata, and when

cables, which are certified for

these are penetrated, the release of the gas can

use in hazardous firedamp

trigger an explosion.

areas. This means that any

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INTRINSICALLY SAFE

SO YOU NEED AN INTRINSICALLY SAFE DIGITAL CAMERA …

W

hen it comes to choosing an intrinsically safe digital camera, what should you look for beyond ATEX certification to ensure you the best possible performance in the field?

Battery Intrinsically safe devices come with caveat that only the batteries specified in the user manual must be used. Failure to comply renders it unsafe and negates the camera’s ATEX certification.

Some manufacturers specify third-party batteries for their products. However, just because an IS digital camera uses AA batteries, it doesn’t mean it can use any AA battery! If the specified battery is not readily available the IS device cannot be fitted with ‘look-alike’ without invalidating the certification. Ongoing expense is another consideration. Over time replacement batteries add substantially to the cost.

You buy a digital camera to perform a task over its lifespan which may be measured in several years. The best option to minimise added cost is to choose a camera that uses reliable, rechargeable battery packs manufactured and certified by the camera manufacturer.

Review Firstly, make sure your chosen camera has both a viewfinder and display so you can check your images once you’ve taken them. It allows you to review your work for focus, scene accuracy and light levels so that shots can be re-taken if necessary.

Macro Close-up imaging of a rating plate for example is a common requirement of the industrial digital camera user. Most digital cameras are equipped with a macro mode to achieve this. However, with automatic focussing a good image is difficult to achieve.

A far better solution involves the use of a specialist macro lens to enlarge the close-up target. So to maximise your options choose a camera with interchangeable lenses.

Safety Your digital camera must contribute to your safety not detract from it. Make sure the digital camera has power and shutter buttons that are sufficiently spaced apart so they can be easily located and operated even when you’re wearing heavy gloves.

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Detail As with any digital camera, greater resolution equals image quality. This is especially important when you are trying to resolve small details which may need to be enlarged and then cropped to highlight important sections of equipment. It’s therefore best to opt for a 5 megapixels camera with adjustable resolution.

Memory Also consider memory, the recommended minimum for the maintenance professional is 2Gb. And if your camera is capable of shooting videos, its onboard storage capacity is even more important with up to 1Gb required to record every 40 minutes of footage.

Follow these guidelines and you will have a camera that has all the right credentials to help you do your job quicker, easier and with the utmost efficiency.

Nick Copeland CorDEX Instruments Ltd Tel: +44 (0) 1904 749020 Fax: +44 (0) 1904352415 E-mail: nick.copeland@cord-ex.com Website: www.cordexinstruments.com

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CONDITION MONITORING

Condition monitoring is an insurance policy against unforeseen By using the latest condition monitoring systems and automatic lubrication systems for bearings, oil and gas processing companies can reduce the risk and costs associated with unforeseen breakdowns to critical production plant and machinery, says Kate Hartigan, Managing Director of Schaeffler (UK) Ltd.

W

hen it comes to

Ask the question of your finance director:

owning and

‘What will it cost the company in lost

managing a high

production if I lose that critical pump or motor

The data recorded by sensors on rotating plant

cost item such as a

for five hours?’ Or ‘What would you be

is subjected to initial assessment by FAG

car or home, most

prepared to pay as an insurance premium, to

ProCheck and if defined alarm limits are

of us are comfortable with paying insurance

secure the running of the plant and to protect

exceeded, alert warnings are automatically

premiums, to help safeguard us against

it against unforeseen breakdowns?’ You may

generated and sent to defined interfaces,

unforeseen accidents or breakdowns. The

get some very positive responses.”

where they undergo further assessment. The

policy we take out is a type of risk

system can be configured and adapted either

management policy that invariably helps us to

“Most companies work in a breakdown

by the end user customer or by Schaeffler’s

sleep better at night.

culture which is reactive rather than

maintenance and asset management service

proactive,” she continues. “Rather than

division, FAG Industrial Services (F’IS). The

Although the cost of a machine component

boasting about how rapidly they can repair or

stored algorithms process the data to extract

such as a bearing, pump or electric motor is

replace components and get machinery or

the necessary information on the condition of

very small compared to the total cost of the

pumps back into production, maintenance

the machine. This initial check is independent

machinery, the cost of production downtime

teams need to be asking themselves ‘How can

of connection to a server PC, which holds the

and any consequential losses as a result of the

we prevent the problems occurring in the first

configuration and analysis software. This

bearing failure, are often significant. For

place?’ CM is the most effective solution.”

means all FAG ProCheck systems in a

example, take a petrochemical processing

network can operate independently of a server

plant. The typical cost of production

If a process plant plans to achieve very high

connection and store their data on a permanent

downtime can be anything from £100,000 to

production efficiencies, predictive

memory medium. Depending on system

£500,000 per day. Total maintenance costs for

maintenance is critical. Unforeseen plant

configuration, the data can be held locally for

a typical oil and gas processing plant are

breakdowns simply cannot be tolerated. In

up to several weeks.

around 10 to 15 per cent of total costs.

order to help companies monitor vibration levels on critical rotating plant or machinery,

“Plant managers and maintenance managers

including electric motors, drives, bearing

For more information on Schaeffler’s range

need to justify any expenditure on condition

arrangements, gearboxes, pumps, generators,

of bearings, condition monitoring systems

monitoring systems and services, to their

ventilators and fans, Schaeffler has developed

and automatic lubricators, please visit

finance director or MD,” says Kate Hartigan,

the ‘FAG ProCheck’ online monitoring

www.schaeffler.co.uk or telephone the

Managing Director of precision bearings and

system.

marketing department on 0121 313 5870 or

automotive components manufacturer Schaeffler (UK) Ltd. “We would suggest using a risk management approach for this.

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email info.uk@schaeffler.com .

So how does it work?

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FOCUS ON - MANUFACTURING

ATEX – Implication for Manufacturers

By Charles Halstead, BEng, AMI MechE, Halifax Fan Ltd 1. INTRODUCTION: With the introduction of the ATEX Directives in 2003, mechanical equipment for use in hazardous areas will be subject to similar certification as now applies to electrical equipment.

This paper aims, by using the manufacture of industrial fans as

an example, to highlight areas of interest and concern to manufacturers.

A

s fans are used over a wide range of industries, and are often seen as a major “ignition source”, CEN TC 305 have commissioned a specific standard “Design of fans working in potentially explosive atmospheres” and it is this standard which forms the basis of this paper. It is hoped however, that some of the principles will be applicable to other industrial products.

2. CURRENT STANDARDS Whilst electrical equipment is presently covered by current Hazardous Area Certification (Exn, Exd, Eexde etc.,), no such certification exists for non electrical machinery, including fans. Where specified manufacturers may offer spark reducing features, that vary from brass rubbing strips to more sophisticated levels of security, the degrees of protection vary widely. Often, in more demanding applications, the final specification is arrived at by consultation between interested parties.

3. INFORMATION REQUIRED FROM END USER The term “end user” can be taken literally; often on large projects a

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supply chain will be in existence ie. user – main contractor – major contractor – equipment manufacturer – equipment manufacturer. Whatever the supply chain, the equipment manufacturer will require additional information for equipment to be used in hazardous areas.

3.1 Zones and Categories The familiar Zones 0, 1 and 2 are retained for gases and vapours and 20, 21 and 22 for dusts. The categories 1, 2 or 3 are introduced to give an indication as to the level of security. The category is a function of the zone – the likelihood of the presence of an explosive mixture – and the consequence of an explosion.

Table 1 shows the normal relationship between category and zones.

Directive 94/9/EC Group II fans classification Directive 1999/92/EC Area classification gas, vapour, mist category 1G zone 0 category 2G zone 1 category 3G zone 2 Directive 94/9/EC Group II fans classification Directive 1999/92/EC

Area classification dust category 1D zone 20 category 2D zone 21 category 3D zone 22

Table 1 : Zones and categories for gas, vapour and dust In some cases the category may be higher or lower than that shown. For example, a Zone 1 fan in a hospital laboratory might be built to Category 1. Alternatively a unit supplied on a remote plant might be manufactured to a lower category. In either of these cases, it is the responsibility of the user to specify to the manufacturer the Zone and category required.

3.2 Gas and Dust Groups As with existing electrical equipment, the manufacturer must be informed of the nature of the

explosive component. This could include gas group, auto ignition temperature and dust type.

3.3 Normal and Expected Operating Conditions In order for the equipment manufacturer to carry out a full risk assessment, all normal and anticipated operating conditions must be considered. For the case of industrial fans, two specific examples are given.

3.3.1 Changes in Duty Point In the case of, say, a centrifugal fan operating a solvent extract system, figure 1 shows the usual fan performance curves - volume– pressure and volume-power, with an additional line showing temperature rise across the fan.

Figure 1 – Effect of change in duty point on temperature rise across a typical centrifugal fan

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FOCUS ON - MANUFACTURING 4.0 MANUFACTURERS RESPONSIBILITY 4.1 Risk Assessment This is required to identify significant hazards and possible hazardous events that may occur.

In the standard for industrial fans, this has been carried out as part of the standard. It is however, the manufacturer’s responsibility to ensure that ALL significant risks have been covered for the particular machine in question. The risk assessment also includes measures to prevent an ignition source from becoming effective.

See appendix for typical example of risk assessment.

With a design duty point as shown, the temperature rise across the fan is t1 ºC. If due to, say, a number of extract legs being shut down, the system curve steepens, the fan will now operate at duty point 2, with a corresponding temperature rise of t2. Whilst the fan standard covers some deviation from the normal operating point, as can be seen, major changes from design duty point could cause increased heating within the fan.

Should such changes be envisaged by the end user, these must be brought to the attention of the manufacturer.

3.3.2 Inverter Drives With the increase in use of inverter drives, another potential hazard is increased temperature generation within a motor. It is

a common mis-conception that all fans follow a variable square torque characteristic with varying speed. Whilst this is true for a fixed system, i.e., an extract fan, for other duties this is not the case. A typical example may be an induced draught fan on an incinerator. In many cases these are used to give a constant negative pressure in the combustion chamber at varying flow rates and flue gas temperatures. Often the motor may be required to run at 50% speed and produce well in excess of the 25% full load torque that would be available from a conventional variable torque rated motor. Table 2 gives a

Speed (RPM) Temperature (ºC) Fan Absorbed Power (kW) Torque (Nm) 2950 315 31 100 2450 140 24 93.5 2100 20 20 90

typical range of duties required from a 762mm diameter fan used to generate a constant negative pressure of 5 KPa.

event that the motor was outside the scope of supply the relevant information would need to be passed to the motor supplier.

Table 2 – 762mm diameter fan duties to give constant negative pressure of 5 KPa over range of operating temperatures From the above table it can be seen that the required torque is almost constant. Clearly the manufacturer would need to ensure that the motor is capable of providing the required torque over the speed range. In the

4.2 Design Specification It may be that some industrial equipment will require very little in the way of design changes.

However, in the case of industrial fans this is not the case. In order to certify units ATEX compliant, and dependant on the category supplied, previous industry standards will not be applicable.

Whilst it is not the purpose of this paper to list the required design details, some of the more far reaching changes are worthy of comment i.e. ∙ Gas tight fan cases ∙ Impellers capable of overspeed testing ∙ Preferred materials for rotating – non rotating parts ∙ Bearing design ∙ Drive arrangement ∙ Impeller attachment The final execution of the design lies with the manufacturer.

Where, as is the case of fans, a specific standard exists, this can

be used as basis for the design.

For more specialised machinery, the design features are left to the manufacturer. In this latter case

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FOCUS ON - MANUFACTURING the manufacturer would need to work within the relevant general European Standards.

4.3

Testing and Certification Coupled with the increased design specification are increased testing requirements. Where testing requirements are clearly defined it is the manufacturer’s responsibility to ensure these are carried out.

In the absence of a specific standard, it is the responsibility of the manufacturer to ensure that suitable testing is carried out, the aim of which is to show that ignition sources are prevented from becoming effective during normal operating malfunction and rare malfunction. Clearly the degree of testing is open to some interpretation and in these cases liaison between concerned parties may well be necessary.

Unfortunately this does not specify : a) How long a file should be held. b) The degree of detail to be held by either the manufacturer or the certified body.

It may well be that these questions are not resolved until a failure occurs and are then addressed in court.

4.6 Marking and Labelling It is a requirement that each machine is fitted with a clear nameplate giving the following information.

∙ reference to instructions for installation, commissioning and maintenance; ∙ safety marking; Additionally for category 1 and 2 fans the rating information shall be on the nameplate (see pr EN 14461). (Note this standard is not yet published).

4.6 Installation There is a responsibility placed on the manufacturer that consideration is given to activities that may cause additional risks once the equipment has left the place of manufacture and testing.

This could be damage in transit, erection, handling or incorrect installation. The ATEX standard

∙ Storage instructions. ∙ Erection and commissioning manual. ∙ Operating and maintenance manual.

Again there is a responsibility on the supplier to take into account possible occurrences once the equipment has left the factory that may affect the integrity of the equipment. Whereas in the past such occurrences may have effected a claim under the manufacturer’s warranty, there is now a much greater onus on the supplier to make the user aware of such pitfalls, and to some extent make provision for them during the design stage.

4.4 Third Party Certification In some cases, typically Category 1 fans, a degree of third party certification is required. This should be carried out by the relevant notified body.

Whilst type testing is acceptable and is well established for electric motors where large quantities of identical units are supplied, for other equipment i.e. fans, pumps, mills, filters etc., this is somewhat impractical. Often units are one-off designs, and as such each will require third party certification.

4.5

Documentation Requirements Dependant on the degree of protection the following apply to industrial fans.

Category 3 - Technical Documentation held by manufacturer Category 2 - Technical Documentation held in sealed envelope by notified body Category 1 - Notified body to ascertain by EC – type examination that relevant appl icable safety provisions are met.

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∙ name and address of the manufacturer; ∙ mandatory CE marking of the fan when being supplied to an EC country; ∙ year of construction; ∙ designation of series or type (if any); ∙ serial of identification number; ∙ rating information (casing pressure and temperature); ∙ conditions of use; ∙ reference to relevant standards;

advises that users request assistance from the supplier with the onsite installation of category 1 and 2 equipment. Whether this will become the norm remains to be seen but in any event, the manufacturer has a duty to provide full installation instructions.

4.8 Information for Use This follows on from the above sub section. In addition to the information required above, manufacturers will need to supply. ∙ Shipping instructions.

5.0

CONSEQUENCES OF CHOICE OF CATEGORY Table 3 shows a simple cost analysis for a typical centrifugal fan.

Table 3 Cost comparison between Safe Area and ATEX Fans This however, only gives part of the story. At present there are fewer than half a dozen manufacturers in Europe than can produce a Category 1 Fan. This type of fan probably represent

www.hazeng.com less than 0.5% of total fan applications. Will this change?

Zone 0 and Zone 20 are defined as areas with the permanent presence of explosive mixture.

This could be interpreted such that many thousands of dust handling fans or extract fans would be classified into Category 1, with the expense, complexity and long lead time associated with this.

FOCUS ON - MANUFACTURING been supplied with spark minimising features. This may have added approximately 5% to overall cost. If now ATEX is applied, and the view taken that in its normal operation the fan handles an explosive mixture, would this make it a Category 1 fan ? From a manufacturer’s view point no clear guidance exists. There may be a tendency to adopt a ‘better safe than sorry’ attitude, but, even removing commercial considerations, there is probably not enough capacity in test houses alone to certify all the units that could fall in this category.

equipment category operating conditions and any other details that may affect operation of the equipment and its ability to prevent it becoming a possible source of ignition.

They will then be required to : 1) Carry out a risk assessment regarding ignition sources and effective preventative measures 2) Carry out best practice design.

3) Carry out suitable testing.

4)

6.0 5)

An example could be a fan handling air from a dryer. The air stream could contain both flammable gases and/or dust.

Historically the fan would have

CONCLUSION In order to satisfy the new ATEX directives manufacturers will require : 1) Full instruction from the user with regard to zone classification,

To hold necessary design information for future inspection.

Provide detailed instructions for the installation commissioning and use of equipment within their scope of supply.

Taking industrial fans as an example, the new ATEX Directive will call for manufacturers to take extra responsibility for their products.

The user will see additional expense, complexity and longer lead times.

Finally, in many uses there will be the need for increased dialogue between purchaser and supplier at the design stage to enable the correct specification to be arrived at.

Charles D Halstead BEng AMIMechE Halifax Fan Ltd Mistral Works Rookery Lane Salterhebble Halifax HX3 OPY Telephone No. 01422 348321 Fax No. 01422 348366 email : charles@halifaxfan.co.uk website : www.halifaxfan.co.uk

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PLEASE FAX BACK ON +44(0)208 711 3153 31

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