Repairing ATEX motors
There are many motor users in hazardous environments who are unaware of recent changes to the ATEX regulations and to the standard that covers the repair of rotating equipment. There have been two recent legislative changes that have important implications for users of motors in ATEX-zoned environments. Keith Hargreaves explains
The legislative change, which followed the full adoption of ATEX legislation in July 2006, stipulates that new zones have been defined as zones 20 to 22 to cover environments where dust may be present in such concentrations as to constitute an explosion risk.
This means that many more manufacturing processes, such as the milling of flour and the processing of paper, are now likely to fall within the scope of the ATEX 137 Directive 1999/92/EC guidance section 4.6 maintenance, which is defined as repair, servicing and inspection of explosion equipment. Companies operating in industries, such as petrochemicals, where the hazardous areas have always been an issue will cope with the changes easily, but companies that are affected for the first time by the ATEX legislation are likely to need additional guidance and support.
The second and more recent change is that IEC 60079-19, the international standard that applies to the repair of electrical equipment for use in hazardous environments, has been updated from the original 1993 edition to a new 2006 edition. The new standard incorporates many changes, such as alterations in the recovery methods allowed for flame paths, and the verification of the recovery processes. Skill tests for the persons carrying out these processes are also included for the first time.
There are even changes to the scope of the standard, which now covers ‘equipment’ and not simply ‘electrical apparatus’. There are new definitions for ‘repair to certification’ that include full repair and re-certification and ‘repair to standard’. The latter covers only a basic repair to ensure that the requirements of the original equipment certified design are met. When this is not available, the applicable manufacturing standard should be maintained.
Probably the most significant change, however, is that the new standard places far more onus on end users of repaired equipment to ensure that it is fit for purpose and that it meets all of the requirements of the relevant sections of the regulations. Users may sub-contract Ex repairs but they are still responsible for ensuring that Ex equipment is safe to use and that the service centre is used to, and competent to repair Explosion Atmosphere Equipment.
Indeed, the standard includes a section that deals exclusively with the competence of operatives and responsible persons who make decisions about the status of ATEX-certified equipment. It requires that these persons should be able to demonstrate their competency in making these decisions, and that they should be able to provide evidence of attaining the necessary knowledge and skills.
In many cases, the responsible person will be someone working for the organisation that carries out the repair but, if this person cannot be shown to be competent, the legal responsibility for the consequences of any shortcomings falls directly back to the end user of the equipment. Few end users, especially those in smaller companies, would claim to have the competence in house to decide whether repaired equipment for use in hazardous areas met the appropriate standards. The solution, therefore, is to use a repair organisation that can take on this responsibility.
It is unsurprising that there are many repairers that are not in this position, as the training required for their employees is extensive. Prior to the introduction of the changes to the standard, training typically took the form of a seminar to give an appreciation of the tasks and risks involved.
Now, the training is a five-day course, during which the trainees must demonstrate their practical skills, followed by an examination. To pass this examination, the trainees must have a thorough knowledge of electrical and mechanical standards, and the principles behind the techniques that are used to ensure the safe operation of equipment in hazardous areas. Furthermore, they have to demonstrate on-going involvement in the repair process [of the equipment] to maintain their accreditation and submit their repair activity to assessment by an independent body.
The training organisation chosen by Eriks UK, to ensure that its staff is fully competent, is assessed and certified by a notified body. The expanded scope of the ATEX regulations and the changed emphasis on responsibilities means that end users should, in all cases authorise and approve modifications, repairs and reclamation of equipment. As we’ve seen, however, many lack the necessary skills and competencies to undertake these duties.
For them, by far the most satisfactory option is to give their consent for a qualified repair organisation to take over their responsibilities. In doing so, however, they must be absolutely certain that the repair organisation that they select is itself properly qualified and certified. Should they fail to do so, they run a very real risk that, in the event of problems, the responsibilities they sought to delegate will land right back on their own doorstep.
Footnote
Keith Hargreaves is regional director of Eriks Electro-Mechanical Services.
As of 2nd April 2008 Eriks UK became the new name for what was formerly known as Wyko Industrial Services in the UK. This name change is part of a major re-branding campaign that the company has undertaken since the £139 million acquisition of Wyko by Eriks nv in November 2006.
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