Supplementary Presentation on Certification of Services – Regional

Experience from Malaysia

IECEx 2018 International Conference

Jakarta, Indonesia8th and 9th August 2018

• ARIZA MOHD YUSOF• Section Head• SIRIM QAS INTERNATIONAL

INTRODUCING

INSERT Company Logo here

Fire On board of Tanker- July 2012

Fire on two crude oil tanks- July 2018

Why Facilities/Plants Caught Fire

IECEx 03-2 – IECEx Certified Service Facilities Scheme –Part 2: Selection Of Ex Equipment And Design Of Ex Installations

IECEx 03-3 – IECEx Certified Service Facilities Scheme –Part 3: Ex Installation And Initial Inspection

IECEx 03-4 – IECEx Certified Service Facilities Scheme –Part 4: Ex Inspection And Maintenance

IECEx 03-5 – IECEx Certified Service Facilities Scheme –Part 5: Repair, overhaul and reclamation of Ex equipment

IECEx Service Facilities Schemes

Improved Safety – assures that equipment is repaired/ overhauled/installation carried out according to strict International Standards

One Standard, One Assessment, One Certification, Valid Worldwide

Cost savings – reduced need for additional testing and certification resulting in faster access to new markets.

Instant Verification – authenticity all issued IECEx Certificates can be conformed instantly

Certifications are delivered by an approved IECEx Certification Body (ExCB)

Why IECEx Certified Service Facilities

APPLICATION

ADEQUACY AUDIT

ON SITE ASSESSMENT(IEC60079 -14 &17 /19 + Scheme Requirements)

APPROVAL(FAR & CoC) issued)

SURVEILLANCE(every 12 months)

REASSESSMENT(every 3 years)

Steps to Certification

1.Quality System Procedures2.Quality Plan based on protection types

1.Repair work instruction – Ex d, etc.2.Test WI – e.g Overpressure, etc.

1.Inspection Report + Inspection Certificate2.Sub-contracting Agreement3. Others

Defines policies and rules related to standard and regulatory requirements

Standard and Scheme requirements

ISO 9001 + IECEx OD 314-4 or 314-5

IECEx Certified Service Facility shall demonstrate effective Quality Management System that includes Document and records controls Control of contract reviews. Control of services provision(repair/ overhaul/ reclamation/

inspection/ maintenance) Control of purchase materials and outsource process Calibration of measurement & test equipment Equipment and tool to service of Ex Equipment in scopes Human resources - Operatives & Responsible Persons Handling of customer complaint and satisfaction Handling of non-conforming product, corrective & preventive action Internal Audit and Management reviews

Standard and Scheme requirements

Assessment Process

Assesses organizations/workshops for the scope of services :-- OD 314-4 or OD 314-5 and 315-4 or 315-5- Ex Equipment repair, overhaul and reclamation (IEC 60079 – 19)- Ex Inspection and Maintenance (IEC 60079 – 14 and

IEC 60079 - 17

Ensures effective and efficientquality management system is inplaced and unique Ex safety/protection features are notcompromised and always intactduring service execution.

Assessment Process – Witness test

Assessment – Witness on site operation

Responsible Personnel and Operative to be assessed their competence covering the actual activities within the scope Ex Service Facility Certified IECEx CoPC of Unit Ex 004, 005, 007 and 008.

Other assessment and demonstration of Competencies based on IEC 60079-14 and IEC 60079-17, and IEC 60079-19

In-house rigorous training and qualification program

Assessment Process - Ex Competent Person

Ex Competent Person is not transferable between service facilities without assessment by an ExCB.

Marking shall be at visible place, legible and durable .Marking shall include– the relevant symbol– the standard number "IEC 60079-19" or national equivalent;– the name of the repairer or his registered trade mark and

workshop certification, if any;– the repairer's reference number relating to the repair;– the date of the repair/overhaul

Marking of Repaired/overhauled equipment

Example

R R

SIRIM QAS Certification Panel - to conduct Independent Review of new

recommendation (draft FAR)- members include at least one qualified IECEx

auditor or IECEx expert- does not include auditor who performed the

assessment

Independent review activities - report to SIRIM Certification Advisory Committee (CAC)Independent review process shall not be outsourced (ISO/IEC 17065)

Independent Review

Certification Agreement

ExCB and IECEx Certified Service Facility to sign a legally enforceable agreement for the certified scopeThe provision of the agreement to be in accordance with ISO/IEC 17065 that include responsibilities of the ExCB and Certified Service Facilities IECEx Certified Service Facility to always fulfil the certification requirements, including implementing appropriate changes as communicated by the ExCB

Schemes Certified SF Country/Region

IECEx 03-5

3 Malaysia2 Middle East1 Indonesia1 Vietnam

IECEx 03-4 1 Malaysia

IECEx Service Facilities

Schemes In Progress SF Country/Region

IECEx 03-5 3 Malaysia1 Kazakhstan

IECEx 03-42 Malaysia1 Kazakhstan1 Singapore

Validity and status of IECEx Service Facility Certificate of Conformity can be checked on-line at www.iecex.com or with the IECEx Mobile Device “App”

• Fairuz Yahaya• Director• EXS Synergy Sdn Bhd

(IECEx Certified Service Facility for Ex Inspection and Maintenance IECEx 03-4)

INTRODUCING

Performance Delivered, Safety Assured

Certified Service Facilities (IECEx 03-4) -Malaysian Experience

Malaysia is currently moving forward in ensuring safe working environment through adoption of IECEx System

• Currently implementation is merely user-driven, absence of regulations and limited certified service providers; however situation is improving

• Direction from PETRONAS – revised PETRONAS Technical Standards (PTS) in late 2016 requiring the use of Certified Service Facility under the IECEx scheme

• Growing awareness of Ex as part of Safety Critical Element• Competition with non-certified service providers• Potential for global expansions

Steps in Executing an Inspection Campaign

Contract Review - Identify Scope, Manpower, Client

Document and Deliverables- Ex Verification Dossier Guideline

- Ex Integrity Assurance Plan- IEC 60079 series

- Client Technical Standards/ Spec

Identify Qualified Personnel

1. Project Manager2. Project Engineer / Inspection

Coordinator3. Ex Responsible Person (Ex-RP)

4. Ex Inspector / Operative (Ex-OP)5. Ex Technician (if required)

Kick-Off Meeting with Client

- Finalize team (safety training, BOSIET etc)

- Project duration- Reporting Requirement

- Meeting Frequency- Deliverables

Mobilization and Execution

- Perform work as per Ex Inspection and Maintenance Guideline

- Ex Register- Ex-ITR

Monitor Progress and Issues

- Regular meetings with Client- Report submission

- Identify issues and way forward

Completion of Inspection Campaign

- Submit Findings- Discuss closure of findings

- Discuss Rectification requirements

- Issue Certificate of Completion- Lessons Learnt

Typical Documents for Submission to Client

Ex Verification Dossier

Ex Register

Ex Inspection Test Record (Ex-ITR)

Findings List

Work Completion Report

Maintaining Personnel Competency

Perform knowledge, practical and oral assessment based on IECEx references and internal

question bank

Perform Gap Analysis –identify limitation in terms of

protection types, product types, groups, voltages etc

Determine training requirements

On multiple campaigns, mix and match inspector teams

Rotate personnel to ensure everyone gain experience

Identify CoPC validity

Review Personnel experience and qualifications

References: IECEx OD 314-4; IECEx OD 502; IECEx OD 503; IECEx OD 504; IEC 60079-14, 17

Examples of Common Findings – High RiskCondition of transmitter enclosure are not satisfactory. Enclosure broken and totally damaged.

Weather seal damaged. Seal failure around the outer cable sheath

Earthing cable not installed from equipment to earth boss

Cable braid exposed

Examples of Common Findings – High Risk

Non certified Ex cable gland

Cable armour exposed

Improper glanding

Missing IP washer

Benefits of Using IECEx 03-4 Certified Service Facilities

1. Compliance to a global standards2. A more systematic approach to Ex verification and compliance process

(inspection, maintenance, rectification)3. Provides peace of mind to USERS as services are provided by IECEx-

certified facility, not individuals (typical manpower supply arrangement)4. Independent verification giving higher degree of assurance to USERS5. Reduce risk of injury/ fatality to personnel and environment impacts6. Scheduled Monitoring leading to Predictive Maintenance

Our Clients

Certified Service Facilities – Challenges

1. Lack of awareness on IECEx requirements among O&G industry players (asset owners and operators)

• Malaysia has over 400 offshore facilities and over 30 onshore facilities, however less number of long term contracts were tendered out in past 3 years.

• Personnel performing inspection tasks does not have right qualification• Currently no category for Ex Inspection and Maintenance in O&G license system

2. Cost perception• Greater focus on cost optimization following energy crisis, putting Ex compliance

in back seat• Ex compliance seen as new/ additional requirement• Wait and See approach

3. Other challenges• Competitive tendering cannot be done with a single player environment• Common question from potential clients – why do they need to spend extra on Ex

inspection and rectification when there is no enforcement?

Certified Service Facilities – Going Forward

1. Awareness among stakeholders is paramount2. Emphasis on cost of incident prevention3. Mandatory compliance via by-laws, parliamentary act4. Ex compliance is a Safety Critical Element, with potential

impact on personnel injury, loss of life, property and environment impacts

5. Move towards predictive maintenance

Regulation together with awareness among industry’s stakeholders are crucial in ensuring safe

and conducive working environment

Thank you

Fairuz YahayaDirector EXS Synergy Sdn Bhdfairuzyahaya@exssynergy.com Performance Delivered, Safety Assured

ARIZA MOHD YUSOFSection HeadSIRIM QAS INTERNATIONALarizamy@sirim.my