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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 ?
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
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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.
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
Ex system in Brunei – NOW
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
inspection division, MOD)
• Yet to – Establishment of the Brunei National Standards Act
Ex system in Brunei – NOW
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…
• Yet to – Establishment of the Brunei National Standards Act
Ex system in Brunei – NOW
Source: 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
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
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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)
Ex system in Brunei – Days Ahead
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
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
Ex system in Brunei – Days Ahead
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
inspection division, MOD)
• Implemented – Establishment of the Brunei National Standards Act
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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
Ex system in Brunei – Days Ahead
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)
Ex system in Brunei – Days Ahead
Finishing Question… Is adopting IEC(Ex) Brunei’s best solution ?
Ex system in Brunei – Days Ahead
Source: http://www.iecex.com/
MIPR: National Standards Centre Division
Source: 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