Upcoming changes to AS/NZS2290.1, AS/NZS3800 and HB239

1. Upcoming Changes to
AS/NZS2290.1,
AS/NZS3800 & HB239
Tim Webster
Chair EL23-04

2. Introduction
• AS/NZS2290.1, AS/NZS3800 and HB239 are currently under review
by EL23-04
• The intent was to:
• Fix technical errors
• Make the suit of documents cohesive and aligned
• Align the documents with the next edition of IEC60079.19

3. AS/NZS2290.1
Changes made so far:
• Definition for “Readily accessible component” changed from
A component nominated as accessible as identified by risk assessment,
refer to clause 2.4.2
to:
A component that is capable of being reached quickly for operation,
renewal or inspections, without requiring to climb over or remove
fixed/permanent obstacles.
Refer to Clause 2.4.2.
Note: Components that are mounted behind swinging guards or covers
that can be easily moved are classed as readily accessible for short
interval inspections.

4. Clause 2.2.2 Verification Dossier has been amended to include
the following additional requirements:
(h) Information related to the selection and management of
non-intrinsically safe cables
(p) Copies of previous inspection records.
(q) Reports from previous repairs (temporary or other)
(r) Risk management information/documentation
(s) Functional safety proof tests and validation records
(t) Software version history.
AS/NZS2290.1

5. • Clause 2.3.1 Competency has been revised to allow IEC Ex units
of competency as an alternative to AS/NZS4761
• Clause 2.3.2 Electrical Engineering Manager has been deleted
• Clause 2.4.2
• Current revision states tables 1 to 4 are recommended but a risk
assessment approach should be used to determine what the users
site specific requirements are
• The new revision states tables 1 to 4 are mandatory, however,
allows the user to deviate from these where supported by a risk
assessment process.
AS/NZS2290.1

6. • Clause 2.5 Initial Inspection Requirements has been cleaned up and
streamlined to remove duplication. The following text has been added:
• Where equipment has been in storage prior to installation, its current condition shall be assessed.
Assessment shall include verification of storage and maintenance records to demonstrate
suitability. The justification to extend the overhaul period must be able to demonstrate that the Ex
technique has been adequately maintained and not compromised in any way. For the purpose of
overhaul, the start date for the equipment lifecycle shall be implemented from the in-service date
or manufacture date, dependent on this assessment.
NOTE: Consideration should be given to marking/labelling an in-service date, beyond the
manufacture date, for equipment that has been appropriately maintained whilst in clean storage as
the shelf life time will be a contributing factor of the lifecycle period for the overhaul
requirements.
The following documentation shall be obtained where equipment has been kept in storage prior to
going in to service:
• Maintenance history / reports
• Maintenance undertaken
• Maintenance frequency
• Continual periodic inspections or overhaul
Statements of storage conditions are not sufficient unless supported by the above documentation.
Once started, the lifecycle period cannot be stopped or suspended i.e. equipment that has been in
service and then /stored or parked up.
AS/NZS2290.1

7. • Clause 2.6.6.1 Pre-Overhaul Audit Requirements has been cleaned up
and streamlined to remove duplication. The following text has been
added:
• Where it is determined not to utilise the pre-overhaul inspection regime, the overhaul
requirements of tables 1 to 4 shall apply with no deviation permitted.
• Where a pre-overhaul audit is required, the initial pre-overhaul audit shall be carried out
12 months before the overhaul is due. Where an end user considers extending the overhaul
period, a second pre-overhaul audit shall then be carried out at the time of the
recommended overhaul. The results of these two pre-overhaul audits can then be
compared to determine if the condition of explosion-protected features has deteriorated.
Subject to the above results, a decision to overhaul or extend service life of the equipment
can be made. A third pre-overhaul audit shall then be completed within 12 months of the
second audit to determine if the overhaul period can be extended by 12 months a second
and final time.
• Where a piece of Ex rated equipment goes out of code and is moved to a non hazardous
area with no intention of being re-coded, the certification nameplate should be removed
and an assessment completed to verify the appropriate IP rating is still achieved. Suitable
marking of the achieved IP rating shall be attached to the equipment.
AS/NZS2290.1

8. • Clause 2.6.7 Examinations has been amended to allow the
utilization of the IEC Ex scheme rules for competency and
recognized service facilities.
• Clause 2.6.7 Examinations has also been amended as follows:
The competent person shall document the actual inspection results.
A report on the condition of the equipment and any recommended
future actions shall be supplied to the owner. The owner shall
determine any future actions.
• Clause 2.6.8. We have added in a provision for equipment with non-
permanent repairs to be excluded from pre-overhaul audits.
• Clause 2.7.1 has been amended to clearly detail that modifications
outside the boundaries of the certification are not permitted.
AS/NZS2290.1

9. • Clause 2.7.3 has been amended to read as follows:
Where repairs that affect the explosion-protection technique of the equipment need to be
carried out whilst the equipment is in service, any repair procedure or method used including
any test or assessment that assures the equipment is safe to use shall be documented and
carried out by persons with recognized competencies to AS/NZS 4761 or equivalent and
authorized by the electrical engineering manager.
Care shall be exercised to ensure that a repair completed in service—
(a) does not increase risk, or introduce an uncontrolled ignition source into the hazardous
area;
(b) At the next overhaul, the service facility performing that overhaul shall be informed
of any temporary repair(s).
(c) Where a non-permanent repair is completed outside of the certification
documentation but using a recognised practice, risk management techniques shall be employed
to determine when then equipment needs to be permanently repaired in line with the
certification documentation
(d) The repair should be monitored for continued effectiveness during periodic
inspections until the equipment is overhauled and permanently repaired.
NOTE: The method for in service repair of a damaged hole or thread in a flameproof enclosure
shown in Appendix C is an example of this.
AS/NZS2290.1

10. • Clause 3.2.2 External periodic inspections has been amended as follows:
The inspection shall include, but not be limited to, the following checks on all accessible parts as
defined in clause 1.3.21:
(a) Flameproof gaps are within acceptable tolerance as defined in the certificate of
conformity.
(b) The enclosure, including any windows/lenses, and its attachments are free of any
physical damage, corrosion or build-up of fines, slurry and contaminants that may impair the
explosion-protected properties.
(c) The equipment, mechanical interlocks, all actuators and locking facilities are operational
and not damaged.
AS/NZS2290.1

11. • Clause 3.2.3 Internal periodic inspections has been amended as follows:
The inspection shall include, but not be limited to, the following checks:
(a) Cables glands and any blanking elements for unused entries are fitted and secure.
(b) Correct mounting and termination of electrical components.
(c) Insulation testing is carried out on:
(i) all electrical circuits, low voltage and above.
(ii) All circuits which go external to Ex rated enclosures
NOTE: Consideration may be given to the exclusion of insulation testing for control circuits due to possible damage to electronics and sensors.
(d) All electrical equipment associated with Ex ‘d’ enclosures is tested and inspected, as follows:
(i) All electrical components are checked for correct mounting.
(ii) All cables are checked for damage, including all machine cables and their associated cable protection hoses, etc.
(iii) All connections are checked for signs of corrosion or heating.
(iv) All protection devices are checked for correct settings, and where test facilities are incorporated within the machine, correct operation shall also
be verified.
(v) The integrity of all earth connections is tested, including the connections from apparatus to main supply earth connection and the main supply
earth connection to the frame.
(vi) Insulation resistance of transformers, operating at low voltage and above, are checked between primary and secondary windings and windings to
frame and core.
(vii) All contactor mechanical interlocks are checked for correct operation.
(viii) All insulation is checked to ensure it is clean and sound and no signs of overheating or cracking are evident.
(ix) All insulation is checked for appropriateness, ensuring no polycarbonates are within the vicinity of potential points of arcing.
(e) The integrity of earth bonds.
(f) Component operation is appropriate; wear and adjustment are within specification.
(g) Protection devices are installed correctly, set to site specifications, and tested to ensure that they are functional.
(h) Certificate and component labelling of internally installed components are legible and securely fitted.
(i) Flamepath surfaces are undamaged and a corrosion inhibitor, where required, has been applied.
(j) Cooling systems are operating within limits.
(k) Visual inspection of bolt holes and threads.
(l) Check the enclosure is clean and dry inside with no evidence of moisture or dirt.
(m) Plugs, adaptors, receptacles and back-to-back couplers are uncoupled and inspected for cracked insulators, discolouring due to excessive
temperatures and signs of arcing. Ensure the earthing is correct, the integrity of moisture and dust barriers intact, phase barriers in place, flamepath condition
satisfactory and locking pins and fasteners are functional and secure.
AS/NZS2290.1

12. • Table 1 has been amended as follows:
AS/NZS2290.1

13. • Clause 3.2.4 Pre-Overhaul Audit has been modified by adding the
following text:
• Where equipment has multiple occurrences of an Ex certified assembly, the initial pre-
overhaul audit shall inspect 100% of all readily accessible assemblies. Subsequent pre-
overhaul audits may use sampling methods, however a minimum of 25% shall be assessed
and measured. This must include the worst case from the initial pre-overhaul audit.
• (b) Bolt holes which form part of a flameproof joint or those whose integrity is in doubt
are examined for hole depth, thread depth and condition along with the correct amount
of material around and behind blind holes, as specified by the certificate drawings.
Where shrouds are fitted, check condition.
• (ix) During the first pre-overhaul audit, all push button/switch operators shall be
assessed for corrosion and securing method verified. They shall also be measured for fit.
subsequent pre-overhaul audits may use sampling methods, however a minimum of 25%
shall be assessed and measured. This must include the worst case from the initial pre-
overhaul audit.
• Part ( c) has been deleted
AS/NZS2290.1

14. • Table 2 has been amended as follows:
AS/NZS2290.1

15. • Clause 3.4.15 has been added to cover the Prevention of Resistive
Faults as follows:
Fires can occur in certified intrinsically safe power circuits. The heat generated from a series
resistive fault has been shown, under certain conditions, to ignite flammable materials.
To prevent resistive ignitions from occurring, the following steps should be taken:
(a) Verify the electrical protection systems that are in place for intrinsically safe electrical
circuits are functional as per the original design intent. These may include earth fault monitoring
or overload protection requiring manual reset.
(b) Confirm the mechanical protection system for intrinsically safe circuits is in place and
effective.
(c) Verify that the areas around intrinsically safe cables and devices are free from
flammable materials such as coal dust or hydraulic fluid/hydrocarbons
(d) Ensure that all personnel are made aware of potential hazards in relation to
intrinsically safe electrical circuits and that appropriate care and management is taken in
relation to these installations.
AS/NZS2290.1

16. • Table 3 has been amended as follows:
AS/NZS2290.1

17. • Table 4 has been amended as follows:
AS/NZS2290.1

18. • Appendix B for Corrosion or Surface Indentation Tolerances has been
amended to include the following text:
• Where the maximum permissible gap is known, the tolerance for damage to flame paths
can be up to 100% of the maximum permissible gap as per certification. Where the
maximum permissible gap as certified is not known, then the following diagram and graph
applies
• Appendixes D through K and M have been deleted.
AS/NZS2290.1

19. Standards Australia Approved a project to revise AS/NZS3800 to fix
technical issues and bring alignment with IEC 60079-19
Unfortunately copyright issues have prevented the written draft from
progressing without major changes
After much debate with Standards Australia a decision has been made to revise
change AS/NZS3800 to be an adoption of IEC 60079-19:2010 with national
differences
Rather than take their normal approach of making these national differences an
Annex ZZ at the back of the standard, they have agreed to grant an exemption
to their drafting rules and present the national differences underneath the
effected clause as follows
AS/NZS 3800 & IEC 60079.19

20. AS/NZS 3800 & IEC 60079.19

21. Next Steps
• All drafting/editing work has been completed
• Expected to send the draft for public comment within the next few months
• The revision is expected to be published within the first half of 2019
AS/NZS 3800 & IEC 60079.19

22. Drafted changes reflect changes made in the next revision of IEC
60079-19 AND the technical changes we wanted to make to AS/NZS
3800. These include:
• Changing “repairer” to “repair facility” throughout the document
• Adding in the requirement to comply with AS/NZS 60079.14 in regards to
installations, cables and glands etc.
• Updating and redefining what types of documentation are required to be
given to the repair facility and to be generated by the repair facility in
line with changes being made to IEC 60079.19 Ed4.
• Additional information added in regards to the treatment of certification
nameplates during overhauls by third parties
AS/NZS 3800

23. • Welding techniques permitted changed from a defined list to instead
refer to techniques permitted by ISO 4063.
• Threaded holes for fasteners…
• Changed to be read as follows:
Threads that have been damaged beyond an acceptable extent, as defined in the certification
documentation, may be reclaimed, depending upon the type of protection, by the following means:
a) Oversize drilling and re-tapping.
b) Oversize drilling, re-tapping and the fitting of a proprietary thread insert.
c) Oversize drilling & tapping, insert solid threaded plug, re-machine (as req’d).
d) Plugging, re-drilling and tapping elsewhere.
e) Plug-welding, re-drilling and tapping.
Plugs shall be securely retained.
The effectiveness of the repair shall be verified by an appropriate test which confirms Ex protection
features are maintained and continued compliance with certification.
Note: The pull test defined in Appendix L may be used or as an alternative, an overpressure test may be
conducted.
As per clause 4.4.1.1, justification for the test method should be recorded and provided to the end user
in the job report.
AS/NZS 3800

24. • Following note added to “4.4.3.1. Alterations”
Note: The principle role of a repair facility is to maintain, or return
equipment to, its originally certified condition. A repair facility cannot
assume the role of a manufacturer and assemble new equipment. In this
context, a repair facility cannot, for example, populate an empty
enclosure to produce a new piece of equipment, without that equipment
first being returned to the original equipment manufacturer for quality
verification and conformity assessment. An original equipment
manufacturer cannot delegate quality verification and conformity
assessment of new equipment to a repair facility. Furthermore, the
original equipment manufacturer can only sub-contract assembly work to
a repair facility when the original equipment manufacturer’s quality
documentation, and the equipment’s certification documentation, allow.
AS/NZS 3800

25. • 4.4.4. Temporary repairs changed to be as follows:
A temporary repair, such as per AS/NZS 2290.1 for underground coal
mining applications, intended to achieve continued short-term operation
of the equipment shall only be carried out if retention of explosion-
protection aspects is ensured or other appropriate measures are taken
until the equipment is fully restored. Certain temporary repair
procedures may therefore not be allowed. Any temporary repair shall be
brought up to full repair standards as soon as reasonably practicable.
Temporary repairs shall follow good engineering practice and shall only
be completed on site and in consultation with either the manufacturer or
repair facility.
Temporary repairs are a possible source of significant failure and
therefore are to be approved by the end user, fully documented and
added to the verification dossier and in the equipment repair record.
Risk review strategies in Appendix K should be considered.
AS/NZS 3800

26. Pressure testing…
• The drafted changes to the pressure testing section are extensive.
• These are intended to:
• Clarify the requirements of when to perform a pressure test.
• Clarify the pass/fail criteria
• Cover pressure relieving
• Details that need to be in the test report
• Testing required for water jackets
• Permit the use of mediums other than water
Appendices
• Only the relevant appendices from AS/NZS3800 are being incorporated
into this revision. All other s are being removed for inclusion in
AS/NZS60079.19:SUPP
AS/NZS 3800

27. Update…
• IEC have been working on the draft for the next edition of 60079.19
(Edition 4).
• All proposed changes for AS/NZS 3800 were passed to IEC for inclusion in
their draft
• All changes were accepted apart from the overhaul of Ex m equipment
and our changes to pressure testing.
• These were shelved pending further discussion and evidence for possible
inclusion in edition 5
• The current draft has now progressed to FDIS and is expected to be
published at the end of this year/early next year
IEC 60079.19

28. Original Plan…
• Amend the HB to reflect the changes made to AS/NZS 3800,
AS/NZS2290.1 and IEC 60079.1
New Plan…
• A hand book is an informative guide and therefore cannot contain any
mandatory requirements i.e. must not include the word “shall”
anywhere, even when referring to legislation
• When edition 4 of IEC 60079.19 is published at the end of this year, we
will go for a direct text adoption i.e. no changes, with a supplementary
standard
• The supplementary standard can be both Normative and Informative but
must be released within 12 months of the standard
• EL14 and EL23 will work on turning HB239 into AS/NZS60079.19:SUPP.
HB239

29. AS/NZS60079.19:SUPP …
• Will need to incorporate all appendices from AS/NZS 3800
• Will need to ensure we have captured the overhaul requirements for Ex
m products
• Will need to detail the “national differences” between what part
60079.19 and what the Australian requirements will be. These should be
relatively minor
• Will need to include as much relevant information as possible from
HB239
HB239