HB 239:2011
Guidance on the repair and overhaul of electrical equipment for explosive atmospheres
Provides guidance for the repair and overhaul of explosion-protected electrical equipment used in hazardous areas, as defined in AS/NZS 60079.0. It covers equipment with a Group I designation for coal mining, Group II where flammable gases and vapours may be present, and Group III which includes equipment used in the presence of combustible dusts. It gives details of the methods of overhaul, repair, examination and the testing required to ensure safety and compliance with the relevant Standards for the different equipment explosion-protection techniques. It covers the several types of explosion-protection techniques currently in use and provides guidance for repair and overhaul service facilities.
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HB 239:2011 GUIDANCE ON THE REPAIR AND OVERHAUL OF ELECTRICAL EQUIPMENT FOR EXPLOSIVE ATMOSPHERES
PREFACE
CONTENTS
SECTION 1 GENERAL
1.1 SCOPE
1.2 REFERENCED DOCUMENTS
SECTION 2 DEFINITIONS
2.1 GENERAL
2.2 ADDITIONAL DEFINITIONS
2.2.1 Verification Dossier
2.2.2 Metal spray (also known as thermal spray)
2.2.3 Laser welding
2.2.4 Solder
2.2.5 Controlled temperature burn-out
2.2.6 Final inspection
2.2.7 Competent person
2.2.8 Special processes
SECTION 3 TECHNICAL PRINCIPLES AND PROCESSES
3.1 INTRODUCTION
3.2 BACKGROUND
3.3 COMPETENCIES
3.4 SERVICE FACILITY RELATIONSHIPS WITH THE EXPLOSION-PROTECTED EQUIPMENT OWNER/OPERATOR
3.5 CONSULTATION WITH OTHER PARTIES: MANUFACTURERS AND REGULATORS
3.6 DOCUMENTATION—VERIFICATION DOSSIER
3.7 TRANSITION OF STANDARDS
3.8 SELECTION OF SERVICE FACILITY
3.9 SERVICE FACILITY CAPABILITIES
3.10 WORK FLOW
3.10.1 Overview
3.10.2 Initial inspection
3.10.3 Failure analysis
3.10.4 Determination of conformity
3.10.5 Determination of pass/fail criteria
3.10.6 Exceptional circumstances
3.10.7 Resolution of Scope of Works
3.10.8 Changes to equipment
3.10.9 Repair
3.10.10 Verification of repair
3.10.11 Justification for the omission of verification tests
3.10.12 Final inspection
3.10.13 Equipment compliance reporting
3.10.14 Equipment compliance labelling
3.10.15 Pre-delivery inspection
3.11 COMMENTARY ON MATERIALS
3.11.1 Introduction
3.11.2 Aluminium and light alloys
3.11.3 Cast irons
3.11.4 Corrosion inhibitors (‘grease’) and their application
3.11.5 Insulation materials
3.11.6 Plastics and rubber
3.12 COMMENTARY ON INSPECTION TECHNIQUES
3.12.1 General
3.12.2 Mechanical inspection techniques and equipment
3.12.3 Electronic inspection techniques
3.13 MECHANICAL REPAIR PROCESSES
3.13.1 General
3.13.2 Welding
3.13.3 Metal spraying
3.13.4 Sleeving
3.13.5 Thread repair
3.13.6 Bolt fit—Fixing bolts, studs and nuts
3.13.7 Distortion repair
SECTION 4 GENERIC TESTING PROCESSES FOR VERIFICATION OF EXPLOSION-PROTECTION TECHNIQUES
4.1 NON-DESTRUCTIVE TEST (NDT)
4.2 DIELECTRIC WITHSTAND (HIGH POTENTIAL OR HI-POT) TESTING
4.2.1 General
4.2.2 Hi-pot (high voltage, line frequency or Dielectric Withstand) test
4.3 INSULATION RESISTANCE
4.4 COMPONENT TESTING
4.4.1 Circuit breakers
4.4.2 Overloads
4.4.3 Current transformers
4.5 TEMPERATURE MEASUREMENT
SECTION 5 OVERHAUL OF ROTATING MACHINES
5.1 GENERAL
5.2 REPAIR/OVERHAUL
5.3 OWNER/OPERATOR RESPONSIBILITIES
5.4 QUALITY-MANAGED ASSESSMENT STRATEGIES
5.5 EVALUATION PROCEDURES FOR ROTATING MACHINES
5.5.1 General
5.5.2 Before power shutdown (typically for large machines only, i.e. ≥1 MW
5.5.3 After shutdown
5.5.4 Before dismantling
5.5.5 Rewinding
5.5.6 Removal of windings
5.5.7 Before winding
5.6 ADDITIONAL NOTES FOR COPY WINDING
5.7 AFTER WINDING
5.8 REPAIR OF ROTORS
5.9 TEMPERATURE SENSORS
5.10 ENCLOSURES
5.11 SPECIFIC TESTS APPLICABLE TO ROTATING MACHINES
5.11.1 General
5.11.2 Core loss testing
5.12 SPECIFIC REQUIREMENTS FOR REPORTING ON ROTATING MACHINES
5.13 SPECIFIC REQUIREMENTS FOR PACKAGING AND DESPATCH OF ROTATING MACHINES
5.14 REINSTALLATION RECOMMENDATIONS FOR ROTATING MACHINES
SECTION 6 EX 'd' FLAMEPROOF EQUIPMENT
6.1 INTRODUCTION
6.1.1 General
6.1.2 Without suffering damage
6.1.3 Without causing ignition
6.1.4 Overhaul pre-requisites
6.1.5 Initial inspection
6.2 OVERHAUL
6.3 REPAIR
6.4 RECLAMATION
6.5 CATEGORIES OF REPAIR
6.6 CHECKS AND REPORTING
6.6.1 General
6.6.2 Flameproof motors
6.6.3 Maximum surface temperature
6.6.4 Fixing bolts, studs and nuts
6.6.5 Breathing devices
6.6.6 Flamepaths
6.7 IN-SITU TEMPORARY REPAIR FOR HOLE OR THREAD
6.8 HYDROSTATIC PRESSURE TESTS
6.8.1 General
6.8.2 Testing personnel
6.8.3 Test procedure
6.8.4 Reporting of results
6.8.5 Interpretation of results
6.9 FINAL VERIFICATION
6.10 PACKAGING AND DESPATCH
SECTION 7 EX 'e' INCREASED SAFETY
7.1 INTRODUCTION
7.1.1 General
7.1.2 Arcing or sparking parts
7.1.3 Insulation
7.1.4 Temperature
7.1.5 Terminals and terminations
7.2 OWNER/OPERATOR
7.3 INSPECTION/OVERHAUL
7.3.1 Insulation material
7.3.2 Insulation clearances
7.3.3 Insulation creepage
7.3.4 Physical damage
7.3.5 Temperature sensing devices
7.3.6 Terminals and terminations
7.3.7 Glands
7.3.8 Seals and IP rating
7.4 SPECIFIC ISSUES FOR ROTATING MACHINES
7.4.1 Rotor
7.4.2 Stator
7.4.3 Fans
7.4.4 Overloads
7.5 REPAIR
7.5.1 Enclosure repair
7.5.2 Winding replacement
7.5.3 Removal of windings
7.5.4 Repair of rotors
7.6 FINAL VERIFICATION
7.7 PACKAGING AND DESPATCH
7.8 REPORTING
SECTION 8 EX 'i' INSTRINSIC SAFETY
8.1 GENERAL
8.2 OWNER/OPERATOR RESPONSIBILITIES
8.3 INITIAL ASSESSMENT
8.4 OVERHAUL
8.4.1 General
8.4.2 Overhaul of intrinsically safe equipment
8.4.3 Overhaul of intrinsic safety associated equipment
8.5 PASS/FAIL CRITERIA FOR OVERHAULED EQUIPMENT
8.6 COMPONENTS FORMING PART OF INTRINSICALLY SAFE EQUIPMENT
8.6.1 Enclosures
8.6.2 Cable entries
8.6.3 Terminations
8.6.4 Soldered connections
8.6.5 Fuses
8.6.6 Relays
8.6.7 Shunt diode safety barriers
8.6.8 Printed circuit boards
8.6.9 Optocouplers and piezoelectric components
8.6.10 Electrical components
8.6.11 Batteries
8.6.12 Internal wiring
8.6.13 Transformers
8.6.14 Encapsulated components
8.6.15 Non-electrical parts
8.7 TESTING/ASSESSMENT
8.8 REPAIR
8.8.1 General
8.8.2 Repairs using soldering
8.9 RECLAMATION
8.10 TESTING
8.11 ALTERATIONS AND MODIFICATIONS
8.12 REPORTING
8.13 PACKAGING AND DESPATCH
SECTION 9 EX 'm' ENCAPSULATION
9.1 INTRODUCTION
9.2 REPAIR/OVERHAUL PROCEDURES
9.2.1 Removal of encapsulation material
9.2.2 Replacement of components
9.2.3 Preparation for replacing encapsulation
9.2.4 Encapsulating material
9.2.5 Pouring encapsulation material
9.2.6 Visual inspection
9.2.7 Reclamation
SECTION 10 EX 'n' NON-SPARKING
10.1 INTRODUCTION
10.1.1 General
10.1.2 Arcing or sparking parts
10.1.3 Insulation
10.1.4 Temperature
10.1.5 Terminals and terminations
10.2 INSPECTION AND OVERHAUL
10.2.1 General
10.2.2 Insulation material
10.2.3 Insulation clearances
10.2.4 Insulation creepage
10.2.5 Physical damage
10.2.6 Temperature-sensing devices
10.2.7 Terminals and terminations
10.2.8 Glands
10.2.9 Seals and IP rating
10.2.10 Rubber/Neoprene type seals
10.2.11 Shaft seals
10.2.12 Equi-potential (earth) bonding
10.3 ROTATING MACHINE SPECIFIC ISSUES
10.3.1 Rotor
10.3.2 Fans
10.4 REPAIR
10.4.1 Enclosure repair
10.4.2 Winding replacement
10.4.3 Repair of rotors
10.5 FINAL VERIFICATION
10.6 PACKAGING AND DESPATCH
10.7 REPORTING
SECTION 11 EX 'tD' (DIP)
11.1 INTRODUCTION
11.2 INSPECTION AND OVERHAUL
11.2.1 General
11.2.2 Gaskets
11.2.3 Motors
11.2.4 Temperature-sensing devices
11.2.5 Cables and conduit entries
11.2.6 Seals and IP rating
11.2.7 Repair
11.3 OVERHAUL
11.3.1 Motor windings
11.3.2 Repair of rotors
11.4 FINAL VERIFICATION AND TESTS
11.5 PACKAGING AND DESPATCH
11.6 REPORTING
SECTION 12 EX 'p' PRESSURISED
12.1 INTRODUCTION
12.1.1 General
12.1.2 Removal from service
12.2 INITIAL INSPECTION
12.3 ENCLOSURES
12.3.1 Materials
12.3.2 Gaskets and seals
12.3.3 Fasteners
12.4 TEMPERATURE RATING
12.4.1 Lighting fittings
12.4.2 Heat-generating equipment
12.5 OVERHAUL AND REPAIR PROCEDURES FOR PRESSURISED EQUIPMENT
12.5.1 General
12.5.2 Routine tests
12.5.3 Marking
12.6 GROUP I EXPLOSION PROTECTED TRANSFORMERS
SECTION 13 EX 'o' OIL FILLED
13.1 INTRODUCTION
13.2 NON-SPARKING PROTECTION
13.3 OIL CONDITIONING
13.4 TESTING
SECTION 14 EX 'v' VENTILATED
SECTION 15 EX 's' SPECIAL PROTECTION
SECTION 16 GROUP I HAZARDOUS AREA REELING AND TRAILING CABLES
16.1 SCOPE
16.2 CABLE COMPONENTS
16.2.1 General
16.2.2 Conductors and conductor constructions
16.2.3 Insulation
16.2.4 Earthing and earthing conductors
16.2.5 Screens on the active cores
16.2.6 Semi-conductive elastomer
16.2.7 Central pilot
16.2.8 Sheath reinforcement
16.2.9 Sheath
16.2.10 Materials
16.3 GUIDANCE ON ASSESSING CABLE CONDITION
16.3.1 General
16.3.2 Initial test
16.3.3 Sheath test
16.3.4 Cable repairer
16.3.5 Final testing
16.4 EVALUATION BEFORE REPAIR AND HISTORY RECORD
16.4.1 History record
16.4.2 Cable construction
16.4.3 Terminations
16.4.4 Insulation Resistance test records
16.4.5 Symmetrical load test
16.4.6 Visual examination
16.4.7 Pre-repair tests
16.4.8 Practicability of repair
16.5 PROCEDURE FOR HARD SOLDERING REELING AND TRAILING CABLES
16.5.1 General soldering information
16.5.2 Procedure
SECTION 17 PRE-OVERHAUL INSPECTION (CODE C1) FOR GROUP I
17.1 PRE-OVERHAUL REQUIREMENTS
17.2 FLAMEPROOF
17.3 INCREASED SAFETY EQUIPMENT
17.4 PRESSURISED EQUIPMENT
SECTION 18 COMPLIANCE OF LEGACY PLANT
18.1 GENERAL
18.2 HISTORY
18.3 USING THE FACTS
18.4 ASSUMPTIONS
18.5 VERIFICATION DOSSIER
18.6 FACT GATHERING
18.6.1 General
18.6.2 Auditing
18.6.3 Missing information
18.6.4 Status
18.6.5 Summary
APPENDIX A - QUALITY MANAGEMENT SYSTEM COMPONENT
A1 GENERAL
A2 ROLES AND RESPONSIBILITIES OF SERVICE FACILITY
A3 QUALITY MANAGEMENT SYSTEM—RESOURCE MANAGEMENT
A3.1 General
A3.2 Technical library
A3.3 Training and competency
A4 QUALITY MANAGEMENT SYSTEM—REPORTS
A5 QUALITY MANAGEMENT SYSTEM—DIMENSIONAL CHECKS
A5.1 Dimensional measurements
A5.2 Measuring equipment
A6 QUALITY MANAGEMENT SYSTEM—WORK PROCEDURES
A7 QUALITY MANAGEMENT SYSTEM—CONDITIONS FOR EQUIPMENT RELEASE
A7.1 General
A7.2 Welding and brazing
A7.3 Non-conforming product
APPENDIX B - MEASUREMENT AND CALIBRATION IN Ex WORKSHOPS
B1 SUMMARY—ESSENTIAL WORKSHOP INFORMATION
B2 WORKSHOP MEASUREMENT MANAGEMENT
B3 CALIBRATION INTERVALS
B4 CONTEXT
B5 DEFINITIONS
B5.1 Calibration
B5.2 Traceability
B5.3 Verification
B6 SPECIFYING MEASUREMENTS
B6.1 General
B6.2 The metric system, calibration and traceability
B7 CALIBRATION PATHWAYS FOR TRACEABILITY
B7.1 General
B7.2 Pathway A
B7.3 Pathway B
B7.4 Pathway C
B7.5 Implementation of pathways
B8 PERFORMANCE BREAKDOWN AND RE-CALIBRATION
B9 CALIBRATION OF COMMONLY USED EQUIPMENT
B9.1 General
B9.2 Specifications for calibration
B9.3 Considerations in purchasing calibration services
B9.4 Outsourcing of verification activities
B10 EFFECTS OF UNCERTAINTY ON CONFORMITY DECISIONS
B10.1 General
B10.2 Assumptions
B11 MEASUREMENT CONSIDERATIONS
B11.1 General
B11.2 Analysis of measurement tasks
B11.3 Considerations
B11.4 Selection of measuring equipment
B11.5 Use of user-adjustable equipment (zero and span)
B11.6 Application of correction factors
B11.7 Environmental influences
B11.8 Environmental monitoring equipment
B11.9 Use of hired equipment
B11.10 Determination of calibration intervals
B12 EQUIPMENT ASSURANCE PROGRAMS
B12.1 General
B12.2 Suspending calibration or checks
B12.3 Integration of calibration activities with workshop measurement
B13 COMMENTARY ON MEASUREMENT TASKS
B13.1 General
B13.2 Length
B13.3 Surface roughness
B13.4 Thread gauges
B13.5 Torque
B13.6 Electrical
B13.7 Temperature
B13.8 Balancing
B13.9 Pressure testing
B14 COMMENTARY UPON MP 87-2
B15 EQUIPMENT RECORD KEEPING
B16 REFERENCES
APPENDIX C - SAMPLE CERTIFICATES AND FORMS
APPENDIX D - HISTORICAL INFORMATION RELATING TO EQUIPMENT APPROVAL SCHEMES
D1 GENERAL
D2 STATE AUTHORITY APPROVALS
D2.1 History
D2.2 Overview
D2.3 Handling changes
D3 P/3 APPROVALS COMMITTEE (1960–1987)
D3.1 History
D3.2 Overview
D4 P/3 AUSEx SCHEME (1987–1993)
D5 AUSEx SCHEME 1993–2003
D5.1 History and overview
D5.2 Documentation
D6 ANZEx SCHEME 2001
D7 HANDLING CHANGES
D8 RELEVANT INTERNATIONAL SCHEMES
D8.1 UK
D8.2 IECEx
APPENDIX E - HISTORICAL INFORMATION RELATING TO SERVICE FACILITY APPROVAL SCHEMES
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References
Electrical equipment for explosive atmospheres - Selection, installation and maintenance - Flameproof enclosure 'd'
Explosive atmospheres - Part 18: Equipment protection by encapsulation ‘m’
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HB 239:2011 GUIDANCE ON THE REPAIR AND OVERHAUL OF ELECTRICAL EQUIPMENT FOR EXPLOSIVE ATMOSPHERES
PREFACE
CONTENTS
SECTION 1 GENERAL
1.1 SCOPE
1.2 REFERENCED DOCUMENTS
SECTION 2 DEFINITIONS
2.1 GENERAL
2.2 ADDITIONAL DEFINITIONS
2.2.1 Verification Dossier
2.2.2 Metal spray (also known as thermal spray)
2.2.3 Laser welding
2.2.4 Solder
2.2.5 Controlled temperature burn-out
2.2.6 Final inspection
2.2.7 Competent person
2.2.8 Special processes
SECTION 3 TECHNICAL PRINCIPLES AND PROCESSES
3.1 INTRODUCTION
3.2 BACKGROUND
3.3 COMPETENCIES
3.4 SERVICE FACILITY RELATIONSHIPS WITH THE EXPLOSION-PROTECTED EQUIPMENT OWNER/OPERATOR
3.5 CONSULTATION WITH OTHER PARTIES: MANUFACTURERS AND REGULATORS
3.6 DOCUMENTATION—VERIFICATION DOSSIER
3.7 TRANSITION OF STANDARDS
3.8 SELECTION OF SERVICE FACILITY
3.9 SERVICE FACILITY CAPABILITIES
3.10 WORK FLOW
3.10.1 Overview
3.10.2 Initial inspection
3.10.3 Failure analysis
3.10.4 Determination of conformity
3.10.5 Determination of pass/fail criteria
3.10.6 Exceptional circumstances
3.10.7 Resolution of Scope of Works
3.10.8 Changes to equipment
3.10.9 Repair
3.10.10 Verification of repair
3.10.11 Justification for the omission of verification tests
3.10.12 Final inspection
3.10.13 Equipment compliance reporting
3.10.14 Equipment compliance labelling
3.10.15 Pre-delivery inspection
3.11 COMMENTARY ON MATERIALS
3.11.1 Introduction
3.11.2 Aluminium and light alloys
3.11.3 Cast irons
3.11.4 Corrosion inhibitors (‘grease’) and their application
3.11.5 Insulation materials
3.11.6 Plastics and rubber
3.12 COMMENTARY ON INSPECTION TECHNIQUES
3.12.1 General
3.12.2 Mechanical inspection techniques and equipment
3.12.3 Electronic inspection techniques
3.13 MECHANICAL REPAIR PROCESSES
3.13.1 General
3.13.2 Welding
3.13.3 Metal spraying
3.13.4 Sleeving
3.13.5 Thread repair
3.13.6 Bolt fit—Fixing bolts, studs and nuts
3.13.7 Distortion repair
SECTION 4 GENERIC TESTING PROCESSES FOR VERIFICATION OF EXPLOSION-PROTECTION TECHNIQUES
4.1 NON-DESTRUCTIVE TEST (NDT)
4.2 DIELECTRIC WITHSTAND (HIGH POTENTIAL OR HI-POT) TESTING
4.2.1 General
4.2.2 Hi-pot (high voltage, line frequency or Dielectric Withstand) test
4.3 INSULATION RESISTANCE
4.4 COMPONENT TESTING
4.4.1 Circuit breakers
4.4.2 Overloads
4.4.3 Current transformers
4.5 TEMPERATURE MEASUREMENT
SECTION 5 OVERHAUL OF ROTATING MACHINES
5.1 GENERAL
5.2 REPAIR/OVERHAUL
5.3 OWNER/OPERATOR RESPONSIBILITIES
5.4 QUALITY-MANAGED ASSESSMENT STRATEGIES
5.5 EVALUATION PROCEDURES FOR ROTATING MACHINES
5.5.1 General
5.5.2 Before power shutdown (typically for large machines only, i.e. ≥1 MW
5.5.3 After shutdown
5.5.4 Before dismantling
5.5.5 Rewinding
5.5.6 Removal of windings
5.5.7 Before winding
5.6 ADDITIONAL NOTES FOR COPY WINDING
5.7 AFTER WINDING
5.8 REPAIR OF ROTORS
5.9 TEMPERATURE SENSORS
5.10 ENCLOSURES
5.11 SPECIFIC TESTS APPLICABLE TO ROTATING MACHINES
5.11.1 General
5.11.2 Core loss testing
5.12 SPECIFIC REQUIREMENTS FOR REPORTING ON ROTATING MACHINES
5.13 SPECIFIC REQUIREMENTS FOR PACKAGING AND DESPATCH OF ROTATING MACHINES
5.14 REINSTALLATION RECOMMENDATIONS FOR ROTATING MACHINES
SECTION 6 EX 'd' FLAMEPROOF EQUIPMENT
6.1 INTRODUCTION
6.1.1 General
6.1.2 Without suffering damage
6.1.3 Without causing ignition
6.1.4 Overhaul pre-requisites
6.1.5 Initial inspection
6.2 OVERHAUL
6.3 REPAIR
6.4 RECLAMATION
6.5 CATEGORIES OF REPAIR
6.6 CHECKS AND REPORTING
6.6.1 General
6.6.2 Flameproof motors
6.6.3 Maximum surface temperature
6.6.4 Fixing bolts, studs and nuts
6.6.5 Breathing devices
6.6.6 Flamepaths
6.7 IN-SITU TEMPORARY REPAIR FOR HOLE OR THREAD
6.8 HYDROSTATIC PRESSURE TESTS
6.8.1 General
6.8.2 Testing personnel
6.8.3 Test procedure
6.8.4 Reporting of results
6.8.5 Interpretation of results
6.9 FINAL VERIFICATION
6.10 PACKAGING AND DESPATCH
SECTION 7 EX 'e' INCREASED SAFETY
7.1 INTRODUCTION
7.1.1 General
7.1.2 Arcing or sparking parts
7.1.3 Insulation
7.1.4 Temperature
7.1.5 Terminals and terminations
7.2 OWNER/OPERATOR
7.3 INSPECTION/OVERHAUL
7.3.1 Insulation material
7.3.2 Insulation clearances
7.3.3 Insulation creepage
7.3.4 Physical damage
7.3.5 Temperature sensing devices
7.3.6 Terminals and terminations
7.3.7 Glands
7.3.8 Seals and IP rating
7.4 SPECIFIC ISSUES FOR ROTATING MACHINES
7.4.1 Rotor
7.4.2 Stator
7.4.3 Fans
7.4.4 Overloads
7.5 REPAIR
7.5.1 Enclosure repair
7.5.2 Winding replacement
7.5.3 Removal of windings
7.5.4 Repair of rotors
7.6 FINAL VERIFICATION
7.7 PACKAGING AND DESPATCH
7.8 REPORTING
SECTION 8 EX 'i' INSTRINSIC SAFETY
8.1 GENERAL
8.2 OWNER/OPERATOR RESPONSIBILITIES
8.3 INITIAL ASSESSMENT
8.4 OVERHAUL
8.4.1 General
8.4.2 Overhaul of intrinsically safe equipment
8.4.3 Overhaul of intrinsic safety associated equipment
8.5 PASS/FAIL CRITERIA FOR OVERHAULED EQUIPMENT
8.6 COMPONENTS FORMING PART OF INTRINSICALLY SAFE EQUIPMENT
8.6.1 Enclosures
8.6.2 Cable entries
8.6.3 Terminations
8.6.4 Soldered connections
8.6.5 Fuses
8.6.6 Relays
8.6.7 Shunt diode safety barriers
8.6.8 Printed circuit boards
8.6.9 Optocouplers and piezoelectric components
8.6.10 Electrical components
8.6.11 Batteries
8.6.12 Internal wiring
8.6.13 Transformers
8.6.14 Encapsulated components
8.6.15 Non-electrical parts
8.7 TESTING/ASSESSMENT
8.8 REPAIR
8.8.1 General
8.8.2 Repairs using soldering
8.9 RECLAMATION
8.10 TESTING
8.11 ALTERATIONS AND MODIFICATIONS
8.12 REPORTING
8.13 PACKAGING AND DESPATCH
SECTION 9 EX 'm' ENCAPSULATION
9.1 INTRODUCTION
9.2 REPAIR/OVERHAUL PROCEDURES
9.2.1 Removal of encapsulation material
9.2.2 Replacement of components
9.2.3 Preparation for replacing encapsulation
9.2.4 Encapsulating material
9.2.5 Pouring encapsulation material
9.2.6 Visual inspection
9.2.7 Reclamation
SECTION 10 EX 'n' NON-SPARKING
10.1 INTRODUCTION
10.1.1 General
10.1.2 Arcing or sparking parts
10.1.3 Insulation
10.1.4 Temperature
10.1.5 Terminals and terminations
10.2 INSPECTION AND OVERHAUL
10.2.1 General
10.2.2 Insulation material
10.2.3 Insulation clearances
10.2.4 Insulation creepage
10.2.5 Physical damage
10.2.6 Temperature-sensing devices
10.2.7 Terminals and terminations
10.2.8 Glands
10.2.9 Seals and IP rating
10.2.10 Rubber/Neoprene type seals
10.2.11 Shaft seals
10.2.12 Equi-potential (earth) bonding
10.3 ROTATING MACHINE SPECIFIC ISSUES
10.3.1 Rotor
10.3.2 Fans
10.4 REPAIR
10.4.1 Enclosure repair
10.4.2 Winding replacement
10.4.3 Repair of rotors
10.5 FINAL VERIFICATION
10.6 PACKAGING AND DESPATCH
10.7 REPORTING
SECTION 11 EX 'tD' (DIP)
11.1 INTRODUCTION
11.2 INSPECTION AND OVERHAUL
11.2.1 General
11.2.2 Gaskets
11.2.3 Motors
11.2.4 Temperature-sensing devices
11.2.5 Cables and conduit entries
11.2.6 Seals and IP rating
11.2.7 Repair
11.3 OVERHAUL
11.3.1 Motor windings
11.3.2 Repair of rotors
11.4 FINAL VERIFICATION AND TESTS
11.5 PACKAGING AND DESPATCH
11.6 REPORTING
SECTION 12 EX 'p' PRESSURISED
12.1 INTRODUCTION
12.1.1 General
12.1.2 Removal from service
12.2 INITIAL INSPECTION
12.3 ENCLOSURES
12.3.1 Materials
12.3.2 Gaskets and seals
12.3.3 Fasteners
12.4 TEMPERATURE RATING
12.4.1 Lighting fittings
12.4.2 Heat-generating equipment
12.5 OVERHAUL AND REPAIR PROCEDURES FOR PRESSURISED EQUIPMENT
12.5.1 General
12.5.2 Routine tests
12.5.3 Marking
12.6 GROUP I EXPLOSION PROTECTED TRANSFORMERS
SECTION 13 EX 'o' OIL FILLED
13.1 INTRODUCTION
13.2 NON-SPARKING PROTECTION
13.3 OIL CONDITIONING
13.4 TESTING
SECTION 14 EX 'v' VENTILATED
SECTION 15 EX 's' SPECIAL PROTECTION
SECTION 16 GROUP I HAZARDOUS AREA REELING AND TRAILING CABLES
16.1 SCOPE
16.2 CABLE COMPONENTS
16.2.1 General
16.2.2 Conductors and conductor constructions
16.2.3 Insulation
16.2.4 Earthing and earthing conductors
16.2.5 Screens on the active cores
16.2.6 Semi-conductive elastomer
16.2.7 Central pilot
16.2.8 Sheath reinforcement
16.2.9 Sheath
16.2.10 Materials
16.3 GUIDANCE ON ASSESSING CABLE CONDITION
16.3.1 General
16.3.2 Initial test
16.3.3 Sheath test
16.3.4 Cable repairer
16.3.5 Final testing
16.4 EVALUATION BEFORE REPAIR AND HISTORY RECORD
16.4.1 History record
16.4.2 Cable construction
16.4.3 Terminations
16.4.4 Insulation Resistance test records
16.4.5 Symmetrical load test
16.4.6 Visual examination
16.4.7 Pre-repair tests
16.4.8 Practicability of repair
16.5 PROCEDURE FOR HARD SOLDERING REELING AND TRAILING CABLES
16.5.1 General soldering information
16.5.2 Procedure
SECTION 17 PRE-OVERHAUL INSPECTION (CODE C1) FOR GROUP I
17.1 PRE-OVERHAUL REQUIREMENTS
17.2 FLAMEPROOF
17.3 INCREASED SAFETY EQUIPMENT
17.4 PRESSURISED EQUIPMENT
SECTION 18 COMPLIANCE OF LEGACY PLANT
18.1 GENERAL
18.2 HISTORY
18.3 USING THE FACTS
18.4 ASSUMPTIONS
18.5 VERIFICATION DOSSIER
18.6 FACT GATHERING
18.6.1 General
18.6.2 Auditing
18.6.3 Missing information
18.6.4 Status
18.6.5 Summary
APPENDIX A - QUALITY MANAGEMENT SYSTEM COMPONENT
A1 GENERAL
A2 ROLES AND RESPONSIBILITIES OF SERVICE FACILITY
A3 QUALITY MANAGEMENT SYSTEM—RESOURCE MANAGEMENT
A3.1 General
A3.2 Technical library
A3.3 Training and competency
A4 QUALITY MANAGEMENT SYSTEM—REPORTS
A5 QUALITY MANAGEMENT SYSTEM—DIMENSIONAL CHECKS
A5.1 Dimensional measurements
A5.2 Measuring equipment
A6 QUALITY MANAGEMENT SYSTEM—WORK PROCEDURES
A7 QUALITY MANAGEMENT SYSTEM—CONDITIONS FOR EQUIPMENT RELEASE
A7.1 General
A7.2 Welding and brazing
A7.3 Non-conforming product
APPENDIX B - MEASUREMENT AND CALIBRATION IN Ex WORKSHOPS
B1 SUMMARY—ESSENTIAL WORKSHOP INFORMATION
B2 WORKSHOP MEASUREMENT MANAGEMENT
B3 CALIBRATION INTERVALS
B4 CONTEXT
B5 DEFINITIONS
B5.1 Calibration
B5.2 Traceability
B5.3 Verification
B6 SPECIFYING MEASUREMENTS
B6.1 General
B6.2 The metric system, calibration and traceability
B7 CALIBRATION PATHWAYS FOR TRACEABILITY
B7.1 General
B7.2 Pathway A
B7.3 Pathway B
B7.4 Pathway C
B7.5 Implementation of pathways
B8 PERFORMANCE BREAKDOWN AND RE-CALIBRATION
B9 CALIBRATION OF COMMONLY USED EQUIPMENT
B9.1 General
B9.2 Specifications for calibration
B9.3 Considerations in purchasing calibration services
B9.4 Outsourcing of verification activities
B10 EFFECTS OF UNCERTAINTY ON CONFORMITY DECISIONS
B10.1 General
B10.2 Assumptions
B11 MEASUREMENT CONSIDERATIONS
B11.1 General
B11.2 Analysis of measurement tasks
B11.3 Considerations
B11.4 Selection of measuring equipment
B11.5 Use of user-adjustable equipment (zero and span)
B11.6 Application of correction factors
B11.7 Environmental influences
B11.8 Environmental monitoring equipment
B11.9 Use of hired equipment
B11.10 Determination of calibration intervals
B12 EQUIPMENT ASSURANCE PROGRAMS
B12.1 General
B12.2 Suspending calibration or checks
B12.3 Integration of calibration activities with workshop measurement
B13 COMMENTARY ON MEASUREMENT TASKS
B13.1 General
B13.2 Length
B13.3 Surface roughness
B13.4 Thread gauges
B13.5 Torque
B13.6 Electrical
B13.7 Temperature
B13.8 Balancing
B13.9 Pressure testing
B14 COMMENTARY UPON MP 87-2
B15 EQUIPMENT RECORD KEEPING
B16 REFERENCES
APPENDIX C - SAMPLE CERTIFICATES AND FORMS
APPENDIX D - HISTORICAL INFORMATION RELATING TO EQUIPMENT APPROVAL SCHEMES
D1 GENERAL
D2 STATE AUTHORITY APPROVALS
D2.1 History
D2.2 Overview
D2.3 Handling changes
D3 P/3 APPROVALS COMMITTEE (1960–1987)
D3.1 History
D3.2 Overview
D4 P/3 AUSEx SCHEME (1987–1993)
D5 AUSEx SCHEME 1993–2003
D5.1 History and overview
D5.2 Documentation
D6 ANZEx SCHEME 2001
D7 HANDLING CHANGES
D8 RELEVANT INTERNATIONAL SCHEMES
D8.1 UK
D8.2 IECEx
APPENDIX E - HISTORICAL INFORMATION RELATING TO SERVICE FACILITY APPROVAL SCHEMES
HB 239:2011
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