Challenges in the implementation of IECEx System in · PDF fileChallenges in the implementation of IECEx System in Brunei Liaw Wai Khiong, CEng MIET BSc Hons (UK, Loughborough). Head

Challenges in the implementation of IECEx System

in Brunei Liaw Wai Khiong,

CEng MIET BSc Hons (UK, Loughborough). Head of Electrical Engineering, Brunei Shell Petroleum Company (27 yrs experience)

Member of Brunei Standardisation Committee (since 2011) Co-Chairman of Brunei Technical Committee (TECO) - Electrical (since 2008)

Chairman of TECO (Electrical) Sub-Committee 3 (Electrical Consumer Product, since 2011) IET Brunei (Hons.) Secretary (2010/11 term)

No, No, we do not want this…!

Source: http://gcaptain.com/wp-content/uploads/2009/11/West-Atlas-Rig-Fire-1.JPG

Scope of this presentation

• Pre-words – Information in this presentation is the presenter’s

private interpretation thus do not necessarily represent the official view of the Brunei Government nor the presenter's employer.

– Most data in this presentations could be obtained from the public domain (internet links given).

– Duration is expected to be <30 minutes • Covers Ex system management in Brunei

– Now – Days Ahead ?

Source: http://www.mapsofworld.com/brunei/brunei-location-map.html

Source: http://upload.wikimedia.org/wikipedia/commons/5/51/Brunei_in_the_World_%28detail%29.png

Brunei Facts & Figures • Capital (and largest city): Bandar Seri Begawan • Official language(s): Bahasa Melayu (Malay) • Government: Unitary Islamic sultanate • Formation: Sultanate 14th century ; End of British protectorate

January 1, 1984 • Area: Total 5,765 km2 (172nd) 2,226 sq mi. ; water 8.6% • Population: 2011 estimate 401,890 (174th) ; 2001 census 332,844 ;

Density 67.3/km 2 (134th) 174.4/sq mi • GDP (PPP) - 2010 estimate: Total $20.382 billion (122nd) ; Per capita

$48.891 (8th) • GDP (nominal) - 2010 estimate: Total $13.022 billion; Per capita $31,238 • HDI (2010): 0.805 (very high) (37th) • Time zone: UTC +8 • Drives : on the left

Source: http://en.wikipedia.org/wiki/Brunei

http://en.wikipedia.org/wiki/Brunei

Ex system in Brunei

• Now • Days Ahead ?

Brunei’s oil/gas Industry • Multi-national corporations

– Royal Dutch / Shell group of companies – Elf Aquitaine(affiliate Elf Petroleum Asia) – UNOCAL, partnered Fletcher Challenge – Brunei Methanol Company (Petroleum Brunei and

Mitsubishi Chemical Holdings Corporation and Itochu Corporation)

• International standard incl. IP15 (referring to IEC), API RP 500, API RP 505, IEC 60079-10, with respective company deviations - self regulating

• Interpretation/compliance varies • No formal national standards nor regulated

Ex system in Brunei – NOW

Source: http://en.wikipedia.org/wiki/Economy_of_Brunei

Who else needs Ex system? • Utilities esp. power plants

– DES; BPMC • Armed Forces (Ammunition Depots) • Construction Sites with fuel storage • Less known:

– Saw mill / paper mills (powder) – Food industries – Printing industries, paper and textiles – Hospital operating theatres – Aircraft refuelling and hangars – Surface coating industries – Sewerage treatment plants – Grain handling and storage – Woodworking areas – Metal surface grinding, especially aluminum dusts and particles

• Own standards, self regulating (IP15, API RP 500, API RP 505, IEC 60079-10, etc.) • Interpretation/compliance varies • No formal national standards nor regulated


Manufacturers (N/A)

• Very few manufacturers – one switchgear & cable manufacturer, importing components from abroad

• Select and import from international market • Import is Project specific / project

requirement • Own records - QA/QC by own factory audits

on validity of manufacturer’s certification


Authorised workshops

• Regional (Singapore/Malaysia) – Incl. IECEx Authorized Workshop (Malaysia (Miri)

Singapore or Thailand) – Own records - QA/QC by own factory audits on

validity of manufacturer’s certification

• OEM (Original Equipment Manufacturers) • International


Competency • Relatively young population • Developing country • Small country thus small market • Who needs Ex competency?

– Oil/gas, petrochemical industries, power plants – Engineering consultants – Construction industries – Vendors – Armed Forces (incl. military, police, narcotics control bureau, etc.) – Fire fighters – Regulating National Authorities – Airlines (Ground Handling Personnel)

• Local facilities – BSP’s Brunei Asia Pacific Shell Learning Hub Asia (BAPSLH; Ex training since 1984 but

yet to get accreditation). • Own standards, self regulating… interpretation/compliances vary • No formal national standards nor regulated • Own records, with peer recommendations on learning center


Logistic

• Offshore (oil/gas only) • Onshore • No approved workshops within Brunei • Certified manufacturers outside Brunei only. • Minimum volume • Own company/ministry coordinated operation • Preparedness varies • No formal national standards nor regulated


ATEX Directives • July 2006, organisations in EU must follow the directives

to protect employees from explosion risk in areas with an explosive atmosphere.

• There are two ATEX directives (one for the manufacturer and one for the user of the equipment): – the ATEX 95 equipment directive 94/9/EC, Equipment and

protective systems intended for use in potentially explosive atmospheres;

– the ATEX 137 workplace directive 99/92/EC, Minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres.


Source: http://en.wikipedia.org/wiki/ATEX_directive

Basics of Ex system (typical) • HAC drawings (IP 15, API RP 500, API RP 505, IEC 60079-10, etc.) • Design • Installation • commissioning • Maintenance • Inspection (details normally not recorded) • Non-electrical equipment not considered nor certified (IP15 section 8). Rely on: • Competency

– Approved designs/manufacturers – Authorised repair shops (independently certified by IECEx, UL, etc. in addition to

vendor’s own certification) – uncertified inspectors but with experience – uncertified technicians but with experience … varies in all levels: supervisors/engineers/managers … authorities

No formal national standards nor regulated


Challenges • Self regulating • Knowing doesn’t mean doing • Soft issues • No need to demonstrate to national authorities • Have to technically justify to comply to IP15, IECEx etc. • Have to technically justify to get 3rd party certification

on competencies/training courses, etc. • No firm requirement to keep records for 3rd party

inspectors • Operation priorities verses short/long-term mitigations • Judgmental decisions • High turn over of personnel


Brunei Standardisation Council (MSK)

• Setup (as on Jan 2011) – Content of organization chart

• National Standard Committee • National Accreditation Committee • National Metrology Committee • National Quality and Productivity Committee • National Safety and Protection Committee • Secretariat (ABCi - Authority of Building and Construction

inspection division, MOD)

• Yet to – Establishment of the Brunei National Standards Act


Brunei Standardisation Committee (NSC/KSK)

• Formed 2011 • Setup (as on Jan 2011)

– Content of organization chart: • TECO (Hala)* • TECO (Management System)* • TECO (Health) • TECO (Food) • TECO (Automotive) • TECO (Construction)* • TECO (Telecommunication) • TECO (Electrical)* • Secretariat (ABCi - Authority of Building and Construction




TECO Electrical • Formed 2007

– Appointed by: Office of Ministry of Energy / Ministry of Development • Setup

– Content of organisaton chart • SC1 (Electrical Safety Standards) • SC2 (Electrical Competency) • SC3 (Electrical Consumer Product) • SC4 (Power Quality & Performance) • SC5 (Electrical Wiring Code of Practice)

• Achievement to date – Adopted 74 IEC standards – IEC Affiliate plus – Planned to adopt more Standards – Influencing NSC strategy…



Source: http://www.tecoelectrical.org/

http://www.tecoelectrical.org/

Approval and managing Ex systems

• Engineers approving maintenance strategy / documents are nominated by employer and not by a national registration body.

• Unregulated document approved incl.: – Area Classification drawings – Procedures, – Inspection results, – Maintenance (service, repair, modification, replace

of Ex systems/equipment)


Ex system in Brunei

• Now • Days Ahead ? More questions than answers

Brunei’s oil/gas Industry

• All industries in Brunei including Multi-national corporations, will comply to a common Brunei standard, be it an adoption of International standard IP15, API RP 500, API RP 505, IEC 60079-10, or otherwise

• Minimum company deviations • Regulated

Ex system in Brunei – Days Ahead

Everybody else will catch up… • Utilities esp. power plants

– DES; BPMC • Arm Forces • Construction Sites with fuel storage • Less known :

– Saw mill / paper mills (powder) – Food industries – Printing industries, paper and textiles – Hospital operating theatres – Aircraft refuelling and hangars – Surface coating industries – Sewerage treatment plants – Grain handling and storage – Woodworking areas – Metal surface grinding, especially aluminum dusts and particles


Manufacturers (emerging?)

• Components fabricated locally • Optimize selection and import from

international market • Local and import material for Projects/design • Public records – Local Authority approval of

manufacturer’s certification


Authorised workshops

• Local • Regional (Singapore/Malaysia)

– More IECEx Authorized Workshops – Less relying on own records / audits

• Public records – Local Authority approval • Less relying on OEM • International


Competency • More matured population • Developed country • Small country thus small market • Improved Ex competency

– Oil/gas, petrochemical industries, power plants, arm forces – Engineering consultants – Construction industries – Vendors – Police – Fire fighters – Regulating National Authorities

• Improved Local facilities • Brunei standard, regulated… more consistent interpretation /

minimum compliances variations • More established learning centers


Logistic

• Offshore – faster/cheaper turn around for

essential equipment/material/services • Onshore - similarly, faster/cheaper • Approved workshops within Brunei • Certified local manufacturers, or SE Asia Region • Larger local volume requirement • Improved coordinated operation • Improved local preparedness • Established national standards and regulated


Basics of Ex system (typical) (1/2)

• HAC drawings (IP 15, API RP 500, API RP 505, IEC 60079-10, etc.) • Design • Installation • Commissioning • Maintenance • Inspection (recorded) IEC 60079-17 Electrical apparatus for explosive gas atmospheres – Part 17:

Inspection and maintenance of electrical installations in hazardous areas (other than mines): – Visual external inspection (All - visually inspected every 3 years) ? – Detail Internal inspection (10% sample - when they are serviced, overhauled

or repaired) ?

• Non-electrical equipment considered and certified (IP15 section 8)


Basics of Ex system (typical) (2/2) Rely on: • Certified Competency

– Approved designs/manufacturers – Authorised repair shops (independently certified to IEC and UL

requirement in addition to certification by vendor.) – Certified inspectors – Certified Competent technicians … from all levels: supervisors/engineers/managers/management … authorities?

• Formal national standards and regulated


Maintenance incident

• EEx ‘e’ Junction Box


Maintenance incident Ex system in Brunei – Days Ahead

Installation incident Ex system in Brunei – Days Ahead

Challenges • Regulated • Ex system/equipment is well maintained and we know it? • Minimum soft issues • Could demonstrate compliance to national authorities • A norm to comply • A norm to get 3rd party certification on competencies/

training courses • A norm to keep records for 3rd party inspectors • Operation priorities verses short-term mitigations are

faster and more transparent because they are based on legal requirement

• Could help reduce high turn over of personnel


Brunei Standardisation Council (MSK) • Setup (as on Jan 2011)

– National Standard Committee, incl. Ex requirement – National Accreditation Committee , incl. Ex requirement – National Metrology Committee – National Quality and Productivity Committee , incl. Ex

requirement – National Safety and Protection Committee , incl. Ex

requirement – Secretariat (ABCi - Authority of Building and Construction


• Implemented – Establishment of the Brunei National Standards Act


Brunei Standardisation Committee (NSC/KSK)

• Formed 2011 • Setup (as on Jan 2011)

– Ref. organisaton chart • TECO (Hala)* • TECO (Management System)* • TECO (Health) • TECO (Food) • TECO (Automotive) • TECO (Construction)* • TECO (Telecommunication) • TECO (Electrical)*, incl. Ex requirement • (new) process technology and technical safety, incl. Ex requirement? • Secretariat (Authority of Building and Construction inspection division,

MOD) • Implemented

– Establishment of the Brunei National Standards Act


TECO Electrical • Formed 2007

– Appointed by: Office of Ministry of Energy / Ministry of Development

• Setup – Ref. organisaton chart

• SC1 (Electrical Safety Standards) • SC2 (Electrical Competency) • SC3 (Electrical Consumer Product) • SC4 (Power Quality & Performance) • SC5 (Electrical Wiring Code of Practice) • SC6 (Ex system)

– IEC Member • Implemented

– Establishment of the Brunei National Standards Act


Professional order (2011)

• Only Professional engineers to approve maintenance strategy's, incl.

• key drawings incl. HAC – procedures, – inspection results, – maintenance (service, repair, modification,

replace of Ex systems/equipment)


Finishing Question… Is adopting IEC(Ex) Brunei’s best solution ?


Source: http://www.iecex.com/

http://www.iecex.com/

Thank You / Terima Kaseh

• Question and Answers

BACKUP

MIPR: National Standards Centre Division

Source: http://www.bruneimipr.gov.bn/index.php?option=com_content&view=article&id=68&Itemid=98

http://www.bruneimipr.gov.bn/index.php?option=com_content&view=article&id=68&Itemid=98

MOD: Standards and Conformity Assessment

• Standards, Guidance Documents and General Specifications • Information on Standards, Guidance Documents and General Specifications • Contact Points • Information on contact points on Standards and Regulatory Bodies/Agencies. • Quality Management System • List of Quality Management System Certification Bodies, Consultant and Training

organisation. • Laboratory Accreditation Scheme • List of Laboratories under the Laboratory Accreditation Scheme • List of Government Departments/ Companies certified to ISO 9000/ ISO 14001/

OHSAS 18001 by registered/ Approved Third party Certification Bodies • Information on Government Departments/ Companies under Ministry of

Development/ Companies certified to ISO 9000/ ISO 14001/ OHSAS 18001 by registered/ Approved Third party Certification Bodies

Source: http://www.mod.gov.bn/index.php?option=com_content&view=article&id=502&Itemid=234

http://www.mod.gov.bn/forms/List_of_PBD_&_GD.pdf

http://www.mod.gov.bn/forms/List_of_ContactPoint.pdf

http://www.mod.gov.bn/index.php?option=com_content&view=article&id=499&Itemid=237



Maintenance incident Ex system in Brunei – NOW








