SACEA SAFETY WORKSHOP

SACEA SAFETY WORKSHOP

WILL FLAME PROOF REPAIRS BE RESPONSIBLE FOR THE

NEXT UNDERGROUND DISASTER IN THE COAL

MINING INDISTRY?

16 October 2014 Main Hall, Sasol Rec Club

Agenda

• Registration Tea & Coffee• Opening and Welcome• Typical deviation found• A Guideline for ex d equipment repairs as required by

ARP0108 and SANS 60079-19• Tea Break • Comparison of the IECEX services scheme vs. RSA mark

scheme requirements• SAFA responsibility of the repair facility • Legal Requirements and implications of non

conformance• Open Discussion• Acknowledgments• Meeting Closure• Lunch and Networking

AGENDA

REGISTRATION TEA & COFFEE08:00-08:30

OPENING AND WELCOME08:30 – 08:45

Louis BothaPresenting - SACEA

TYPICAL DEVIATION FOUND 08:45 – 09:15

Piet PrinslooPresenting - SASOL

better together ... we deliver

SACEASafety Workshop

16.10.2014

Presenter - Piet Prinsloo


SACEA Flame Proof Safety workshop

Deviations found during audits


Contend

Introduction

Process followed

Audit results/ Audit Findings

Post audit actions

Questions

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Introduction


Introduction

• Piet Prinsloo

• 35 Years service

• Qualified in ISO 9001, 14001, OHSAS 18001

• Head of SHEQ department at SMCW

• Function started after a major incident at Sasol

• Audited more than 100 companies

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Process followed


Process followed

Make an appointment

Explain purpose of audit

Quick tour of the facility

Request company to explain QA/QC process

Ask clarifying questions

Visit shop floor to verify explained QA/QC process (Audit against what I was told)

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Audit results/ Audit Findings


Audit results/ Audit Findings cont.

Manufactured and certified empty enclosure without any entries and windows.

Did not have M20, 25, 32, 40 Go/Not Go gauges to test gland entry threaded holes.

The flameproof test report do not indicate the following:• cylinder head and exhaust manifold temperature shut off sentinel

spec’s and its actual shut off test temperature • Pressure test values of scrubber box not indicated on test report

Findings raised by certification body has not been cleared and was raised again for the second time during an audit and action plan as requested by the certification body auditors was not submitted

The data pack of a completed machine lacked the test data for the engine safety shut off system at 60 seconds

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No proof that Jigs are inspected

No temperature gauge on the hot water testing facility

No indication of what the water temperature should be.

Could not find proof that the heating element was calibrated.

The procedure to do hydraulic pressure testing indicate a test pressure between 800 and 1000kpa, the gauge on the hydraulic tester was scaled to measure pressure in BAR, PSI and MPA

No documented proof could be supplied that any inspections or sizes of products were checked. The step was signed off on the final inspection document.

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Threaded holes on flame proof manifolds are not tested with Go, Not Go gauges. Never had any Go, Not Go gauges for 19 years.

When a product is received from the customer without the flame proof name plate indicating the equipment “D” number the name plate will not be replaced or the piece of equipment re-certified.

No IA on name plates

The final inspection document of a motor found to be not flame proof was checked and all items were marked as correct

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• A flame proof motor that was about 80% assembled was inspected and the following deviations were found:

• The flp face of the terminal box was damaged, pitted and not cleaned.

• An unpermitted modification was made to fit the terminal box to the motor by welding the mounting plate to the motor

• The connection hole between the barrel and the terminal box were not sealed off with a compound to prevent pressure piling.

• A threaded hole on the terminal box, to secure the cover, was found to be stripped.

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• The inspection sheet for the said motor was checked and the following deviations found:

• All threaded holes were marked off to comply.

• Sizes recorded when the barrel was measured were exactly the same, it appears that only one area was measured and the size then copied to the other areas.

The reason for non complying threaded holes on pump panels was over tightening of bolts ( later acknowledged that panels was not checked, only certified, production pressure)

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Post audit actions


Post audit actions

A written report is discussed with the company

Some instances business was suspended or terminated

All companies acknowledged that audit was value adding

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Questions ?

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Confidential Document


A GUIDELINE FOR EX D EQUIPMENT REPAIRS AS REQUIRED BY ARP0108

AND SANS 60079-19

09:15 – 09:45

David MareePresenting - EXPLOLABS

Presented by : David Maree

A guideline for Ex ‘d’ equipment repairs in accordance with SANS

60079-19 and ARP0108

Introduction

Original Equipment Manufacturer

End User Repair Facility

The repair facility

Repair Facility

ISO 9001 Quality Management System +

Certified by approved mark scheme or batch testing by an ATL

Personnel competency as per Annex B of SANS 60079-19

Adequate facilities

Meet Eddy…the fall guy..

http://www.google.co.za/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.sodahead.com/united-states/is-it-ok-to-publicly-accuse-someone-of-lying-while-not-providing-evidence-of-intent-to-deceive/question-1331331/&ei=ly0-VPGmBY3Xav2MgvgE&bvm=bv.77412846,d.ZGU&psig=AFQjCNHxJfB9j6_kOgYJiUa1jt2n0TMUtg&ust=1413447429538664

Documentation

SANS 60079-19 Clause 4.4.1.5.1

“The repair facility should seek to obtain all necessary information/data from the manufacturer or user for the repair and/or overhaul of the equipment.”

• What basic data is required?

• Difficulty in obtaining the data/information

Technical specifications

Flameproof Drawings

Operating & Installation instructions

The IA Certificate

• Documentation after the repair has been completed

Job card

Maintain records

Repair without documentation

MODIFICATIONS DURING REPAIR

No unauthorized modifications

Examples:

Additional entries

Adding or removing compartments

Major dimensional changes

Changes in the connection facilities

In some cases end users use the repair process as an opportunity to modify the product to suit their current needs. However, if the certification documents and manufacturers design drawings don’t make provision for the modification, it is unauthorized and therefore not certified.

http://www.google.co.za/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://techxb.com/social-media-gone-badly-wrong-2&ei=yU8-VIWUBNPsaMGSgOAG&bvm=bv.77412846,d.ZGU&psig=AFQjCNGo483KQfIw1SVBv1fUsVLYnug8nQ&ust=1413456189629879

SUMMARY

• Lack of proper documentation = substandard repairs and result in product failures or not operating as they are expected, or in worst case scenario’s compromise the flameproof properties of the equipment.

• Manufacturers can’t be held responsible for unauthorized modifications or changes to the original product design during the repair process.

• What happened to the fall guy Eddie

Thank you!

TEA BREAK

10:00 -10:15

COMPARISON OF THE IECEX SERVICES SCHEME VS. RSA MARK SCHEME

REQUIREMENTS

10:15 – 10:45

Roelof Viljoen Presenting - MASC

Repair Markschemes in RSAIECEx services scheme

vs.

RSA requirements / Issues

Presenter: R. ViljoenMining And Surface Certification

(MASC)

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Standards and rules:

• Manufacturing of new product:

• IECEx: IEC/ISO 80079-34………………RSA Markscheme: No formal indication / standard

• Repairs:

• IECEx: OD0013/14/15………………RSA Markscheme: No formal indication / standard

• Rules:

• RSA one of the front runners for Ex quality systems worldwide.• And now?

• MP87 (Aus) / IECEx rules (IECEx 01… IECEx 03-5 repairs)• MASC proposed a “rule book” for Ex in RSA be compiled. (Extension of ARP0108?)

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How does IECEx

and RSA Markscheme

Requirements differ in practice?

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OD015 helpful templates

Flameproof enclosures

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OD015 helpful templates

Flameproof – equipment installed inside enclosures

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Some specific issues / questions

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1. How does the culture of compliance in RSA compare with other countries?

• Quality system comparison• Technical manufacturing comparison.

• Auditor culture / integrity• Auditee culture / integrity

2. How does RSA companies with existing MARK Schemes compare under IECEx scrutiny?

• Manufacturing audits on companies under IECEx.

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3. Is SANAS accreditation required for RSA CB’s?

• DMR/DOL approval• Testing ISO 17025 (Test labs)• Certification under SANAS ISO17065…

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4. Is repair included when a company has a manufacturing markscheme?

• Industry perception• Legal status • Quality system requirements• Competence• Label requirements• Markscheme Permit number• Etc.

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5. What is a product list (RSA)

• IECEx certificates are web based and linked to their QAR.• End users do not know about product lists.• Permit incomplete without product list• Is a product list required for repairs mark holder? • Can a flameproof repairer repair any flameproof equipment?

6. Can a markscheme incorporate certificates from different EXTL’s?

• Product list with different certf numbers.• Does a Markscheme indicate that all products on a product

list is correctly certified?• What is the auditing function?

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7. Golden thread of Ex Auditing

• Manufacture / repair to standard?

• Certification drawings… system… product• Vs• Standard / Certification Drawings… system… product

• Quality of drawings / available drawings• Modifications to standard?

• IEC/SANS 60079-19… E.g. Annex C for Flamepaths.

• Intrinsic safety repairs without information?

8. Repair process

• WHAT activities will be undertaken? Decision making by mark holder on each repair…..

• Competence (RSA… two inspectors required)

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9. Is a COC from a markholder issued with equipment (new or repaired) sufficient?

• Some manufacturer’s state that an IA certificate is confidential and their COC is sufficient.

• Permit / product list required with equipment?• IA certificate number is added on COC.• OD015 COC

10. Empty enclosure sales by Markholders.

• Sale of empty enclosures by markholders • Certf number…. X• Certf does not indicate internal content.

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11. “I will have my equipment certified by a markholder”

• Perception in industry.• Ex n Motors• Markholders “certifying” machines

Questions???

Contacts:Roelof Viljoen083 235 5256

[email protected](012) 653 7594

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mailto:[email protected]

SAFA RESPONSIBILITY OF THE REPAIR FACILITY

10:45 – 11:15

Paul MeanwellPresenting - SAFA

South African Flameproof Association

FlameproofRepairs

Maintenanceand Standards


Training and competence

We’ve all seen this…. Is it safe?

I don’t know! Not legal!Flange thicknessDepth of threadFlame path lengthFree internal volumePressure piling


Question is……….. Will it get fixed, and when?


When does safe become unsafe?


Who will stop a machine for this?


In my opinion, not many, but why not?

Production pressure, bonus, knowledge

Does that CH4 monitor ensure safety?

Lets look at the knowledge factor


Available trainingPlenty to choose from, good and badHow do you choose? How long does it take?What does it cost?How long is it valid?What value does the trainee put on it?How long is the training remembered?What is the value to the employer?What about SANS 10086-2?


CompetencyCompetency is not the same is trainingTraining without experience does not result in

competencyExperience without training does not result in

competenceIn the workplace, peer and production

pressures will normally take precedence over formal training (on the job training)

The DRC experience…..


Can we change things?Culture change required – takes time!

YOU – the end user hold all the aces!Downstream – actively support your ethicsUpstream – Demand that your suppliers do

the right thing. Audit them yourselves. Set your own standards! It’s competitive out there!


Resistance to ChangeADKAR – A 5 step model

AWARENESSDESIREKNOWLEDGEABILITYREINFORCEMENT


You rely on certificates……..But you don’t read them!


Almost all of you will have this report

Estimated 500+ issued to industry!

So what about special conditions of use?What about the “U” suffix?


Lets look at “the System”

ILAC

SANAS

Global

CB’s & TL’s

National - STC

National


Lets look at “the System” cont…….

Mnfr

Repairer

Needs Mnfr Licence

Pirate

May need a licence

Use at own risk!


So, how can we improve things?

Take ownership of your FLP products, relying solely on the certificate is not always good enough.

Employ or train an expert – give that position the authority to keep order, develop in implement policies and procedures


Audit your choice of CB and TL

Audit your suppliers, whether manufacturers, repairers, or suppliers

Audit your own operations!

COMPLAIN! about sub standard service


Finally, when everything is in place,

ENFORCE your plan, your policy, and your procedures.

It can be done – If you plan ahead


Thank You

www.flp.co.za

LEGAL REQUIREMENTS AND IMPLICATIONS OF NON

CONFORMANCE

11:15- 12:00

Ntabiseng MphahlelePresenting - DMR

Manufacturers’ Legal Obligations in Terms of the Mine Health and Safety Act

Mine Health and Safety Act (Act 29 of 1996)

Regarding Hazardous Locations

AA COUTINHODirector Mine Safety

Hazardous Locations

• The employer must take reasonably practicable measures to prevent persons from being injured in any hazardous location as a result of fire, explosion or the ignition of gas, dust, mist or vapour.

• Such measures must ensure that:a) All hazardous locations are identified, clearly marked and recorded on a plan or a

register, which must be kept updated and readily available at the mine;b) Only explosion protected apparatus and systems certified for use in a hazardous

location in accordance with the South African National Standard ARP 0108: 2005, “Regulatory requirements for explosion protected apparatus”, are used in any hazardous location;

c) The selection of explosion protected apparatus used in any hazardous location is done in accordance with SANS 10108: 2005, “The classification of hazardous locations and the selection of apparatus for the use in such locations”. The normative references as listed in SANS 10108 are not applicable to the employer;

Hazardous Locations … continue

d) The installation, inspection and maintenance of explosion protected apparatus used in a hazardous location is carried out in accordance with SANS 10086-1 2005, “The installation, inspection and maintenance of equipment used in explosive atmospheres Part 1: Installations including surface installations on mines” and SANS 10086-2 2004, “The installation, inspection and maintenance of equipment used in explosive atmospheres Part 2: Electrical equipment installed underground in mines” as appropriate;

e) Any repair, overhaul or modification to any explosion protected apparatus used in any hazardous location does not alter its design characteristics and is carries out in accordance with SANS 10086-3 2005; “The installation, inspection and maintenance of equipment used in explosive atmospheres Part 3: Repair and overhaul of apparatus used in explosive atmospheres”;

f) Explosion protected apparatus used in any hazardous location is installed, maintained, repaired, overhauled, inspected and tested by a competent person;

Section 21 (of the Act)Manufacturer's and Supplier's duty for Health and Safety

21. (l) Any person who –

Designs, manufactures, repairs, imports or supplies any article for use at a mine must ensure, as far as reasonably practicable -

(i) that the article is safe and without risk to health and safety when used properly; and (ii) that it complies with all the requirements in terms of this Act;

Repairs to be carried out according to SANS 10086-3

• “The installation, inspection and maintenance of equipment used in explosive atmospheres Part 3: Repair and overhaul of apparatus used in explosive atmospheres”;

Repair company responsibilities and mark holders

• Compliance that have

– A quality system

– Ensure compliance with SANS 10086-3

– Are regularly audited to ensure compliance

Manager responsibilities

• Ensure that the equipment that has to be repaired is sent to a mark holder.

• Check that the repairer has a quality system

• Has the equipment to repair hazardous location equipment

• The repair equipment complies to the relevant standard

Closing Summary / Key Points

• Consumer Protection Act Implications

• Manufacturer’s compliance with MHSA

• Product Risk Assessment / repaired equipment

T h a n k y o u f o r l i s t e n i n g

Questions

OPEN DISCUSSION12:00-12:30

ACKNOWLEDGEMENTS

12:30- 12:55

Acknowledgements

• Sasol Club

• Presenters

• Attendees

• Simon Orchardson

• Leoni / Lynette

MEETING CLOSURE12:55-13:00

LUNCH & NETWORKING

13:00

SACEA SAFETY WORKSHOP

Documents

Transcript of SACEA SAFETY WORKSHOP