PETRONAS TECHNICAL STANDARDS

Ex Equipment Repair Requirement (Ex ERR)

PTS 13.40.02
November 2016

© 2016 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.

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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.

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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE .............................................................................................................................. 5
1.2 GLOSSARY OF TERM ........................................................................................................ 5
1.3 SUMMARY OF CHANGES ................................................................................................. 6
2.0 GENERAL REQUIREMENT ....................................................................................... 7
2.1 INSPECTION/DAMAGE ASSESSMENT .............................................................................. 7
2.2 REPAIR/REPLACEMENT OF DAMAGED COMPONENTS ................................................... 7
2.3 IN-HOUSE REPAIR ............................................................................................................ 8
2.4 REPAIR BY Ex SERVICE PROVIDER.................................................................................... 8
2.5 REPLACEMENT EQUIPEMENT – COMPLETE UNIT ........................................................... 9
2.6 ECONOMIC JUSTIFICATION ............................................................................................. 9
3.0 MARKING SYSTEM ............................................................................................... 10
3.1 SYMBOLS ....................................................................................................................... 10
4.0 BIBLIOGRAPHY .................................................................................................... 12
APPENDIX 1: Ex EQUIPMENT OVERHAUL/REPAIR FLOWCHART ....................................... 13

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1.0 INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the minimum technical requirements for
repair and overhaul of Ex certified equipment by Ex Service Providers.

This PTS adopts an International Standard IEC 60079-19 and IECEx OD13, 14, 15 as a
supplement based on PETRONAS lesson learnt and best practices.

1.1 SCOPE

This PTS specify requirements for repair and overhaul of all electrical equipment certified for
use in hazardous area and specify requirement for making appropriate decision on the repair
and overhaul of Ex certified equipment.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 Ex Service Provider An organization that has been certified by an

independent Ex Certification Body under IEC Ex
03 scheme or an OEM that has the required
service facilities including the appropriate
equipment, competent personnel and
procedures such that the repair, overhaul or
modification works complies with the relevant
Ex standards and requirements.

2 Hazardous Area An area in which an explosive gas atmosphere is

or may be expected to be present in quantities
such as to require special precautions for the
construction, installation and use of electrical
apparatus.
NOTE(S): This applies equally to hazardous dust atmospheres.

3 Modification Change to the design and construction of the

apparatus which affects material, fit, form or
function.

4 Overhaul Action to restore to a fully serviceable condition

an apparatus which has been in use or in storage
for a period of time but which is not faulty.

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No Term Definition

5 Reclamation Means of repair involving, for example, the

removal or addition of material to reclaim
component parts which have sustained damage,
in order to restore such parts to a serviceable
condition in accordance with the relevant
standard.

6 Repair Action to restore a faulty apparatus to its fully

serviceable condition and in compliance with
the relevant standard.
Table 1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 Ex Abbreviation which relate to equipment or

facility that is suitable to be used in hazardous
area.

2 OEM Original Equipment Manufacturer

Table 2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 13.40.02 (November 2016) replaces PTS 13.40.02 (September 2013).

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2.0 GENERAL REQUIREMENT

Three (3) options shall be considered for repair or replacement of Ex equipment, namely:

i. In-house Repair

ii. Repair by Ex Service Facility

iii. Replace Equipment (Complete Unit)

The Ex equipment overhaul/repair process flow is best depicted by the Flowchart given in
Appendix 1.

2.1 INSPECTION/DAMAGE ASSESSMENT

The condition of each Ex equipment that need to be repaired or overhauled shall be first
inspected and assessed for any damages upon delivery to the workshop.

2.1.1 Ex Motor

Ex Motor shall be dismantled for close inspection of its rotor, stator, end shield etc. Detail
findings shall be recorded in specific check sheet based on IECEx OD 15. When assessment is
carried out, the motor’s bearing fit (shaft and housing) and shaft straightness/run out shall be
checked against tolerance limits given by OEM or relevant standards.

2.1.2 Other Equipment

Other equipment shall be assessed based on the specific check sheet adapted IECEx OD 15
report form.

2.2 REPAIR/REPLACEMENT OF DAMAGED COMPONENTS

2.2.1 The damaged components of Ex equipment may be repaired (either in-house or by external
Ex Service Provider) or replaced with new identical parts from OEM to ensure the equipment
still comply with original certification including ingress protection and temperature
classification after repair or overhaul. The component parts made from glass, plastics or any
material that is not dimensionally stable as well as fasteners should not be repaired or
reclaimed.

2.2.2 No modification shall be made to the certified apparatus unless that modification is permitted
in the certificate or is approved in writing by the manufacturer. Subsequent clauses of this
standard give detailed instructions regarding modifications in the context of different types of
protection. Particular attention is drawn to the need for care on the following activities:

i. When adding a variable speed/frequency drive to an Ex-rotating machine. It shall

be ensured that this is only done when the intended combination of the drive and
rotating machine is specified in the certificate or in the rotating machine
manufacturer’s documentation.

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ii. When adding or replacing part(s) of a panel which has been certified as 'a
complete assembly' (for example, panel built for Zone 2 hazardous area, e.g. Ex
nA) that the make and model of the replacement shall be identical with the part
being replaced even though the replacement carries the same Ex Protection, Gas
Group and Temperature Class. In addition, care shall be taken when this involves
an active device (self or externally powered), where OEM may need to be
consulted to ensure the Ex certification of the entire system remains intact.

2.2.3 For any proposed modification which would result in the apparatus not conforming to the
certification documents and the relevant type of protection standard, the Owner shall be
informed in writing that the apparatus will no longer be suitable for use in a hazardous area.
The modification shall be subject to the approval in writing from the Owner.
NOTE(S):
1. Detailed repair requirements for specific Ex protection type shall comply with IEC 60079-19.
2. The documentation and reporting for Ex equipment repair preferably be in line with IECEx OD 13, 14, and 15.

2.3 IN-HOUSE REPAIR

2.3.1 In-house repair of Ex equipment shall normally be limited to part replacement (with new
identical parts from OEM) and cleaning which will not impair the explosion-protection
integrity of the machine.

2.3.2 No modification shall be made to the certified equipment unless such modification is
permitted in the Ex certificate or in compliance with the standard. Otherwise the OEM shall
be consulted on the necessary modification.

2.4 REPAIR BY Ex SERVICE PROVIDER

2.4.1 Ex equipment which could not be fully repaired in-house (as specified in section 2.3 above) or
the validity of its Ex certificate is uncertain after the repair shall be sent to external Ex Service
Provider for necessary repair.

2.4.2 Ex Service Provider shall assess the damage, identify necessary repair work and propose work
scope for the service subject to Owner’s approval.

2.4.3 Reclamation work may result in dimensions which are different from the original stated in
relevant certification documents and affecting explosion-protection integrity of an Ex
equipment. Hence, any permitted reclamation work for all types of Ex equipment shall only
be carried out by Ex Service Provider to ensure the equipment still comply with its original
certification.

2.4.4 In case of motor, damaged stator/rotor laminations or cores normally should not be machined
or skimmed to remove surface irregularities as the maximum permissible air gap may be
exceeded. If necessary, surface skimming of stator or rotor laminations shall only be
performed by Ex Service Provider.

2.4.5 Rewinding of all Ex motors shall only be carried by Ex Service Provider to ensure that the
temperature classification of the machines are not affected.

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2.5 REPLACEMENT EQUIPEMENT – COMPLETE UNIT

2.5.1 Ex equipment which is damaged beyond economical repair or is not able to comply with
original certification after repair shall be replaced with a new unit of appropriate or equivalent
Ex certification unless appropriate repair or modification has been agreed by B-TA. The
replacement equipment should be identical with the original unit to avoid any unnecessary
retrofitting works on site.

2.5.2 In the event that the damaged equipment is obsolete and identical Ex certified replacement
equipment is no longer available from OEM, then equivalent equipment with appropriate Ex
certification may be sourced from OEM or other manufacturers/vendors for retrofitting.
Inputs from OEM may be required for sourcing the replacement equipment with the best fit
(physical dimensions, mounting/foundation requirements, electrical characteristics, etc.) and
least modification on the necessary retrofitting work.

2.6 ECONOMIC JUSTIFICATION

2.6.1 The Life Cycle Cost analysis should be performed for economic justification of any major work
required for repair of damaged Ex equipment.

2.6.2 If the total repair cost (including part replacement) is more than 50% of the cost of a new
equipment, the damaged Ex equipment should be replaced with a new unit. However, other
factors like delivery period for the new equipment, etc. should also be considered before
deciding to go for the replacement option.

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3.0 MARKING SYSTEM

Repairs not affecting the integrity of the explosion features should not be marked.

All other repaired and overhauled apparatus should be marked on the main part in a visible
place.

This marking should be legible and durable taking into account possible chemical corrosion.

The marking should include:

i. The relevant symbol (see 3.1 below);

ii. The standard number “IEC 79-19” or national equivalent;

iii. The name of the repairer or his registered trade mark;

iv. The repairer’s reference number relating to the repair;

v. The date of the overhaul/repair

The marking may be on a plate permanently attached to the repaired apparatus.

In the event of subsequent repairs, the earlier plate may be removed, a record being made of
all the markings on it.

3.1 SYMBOLS

3.1.1 Full Compliance

This mark shall be used when the apparatus is in full compliance with the standard and
certificate.

3.1.2 Compliance with the standard

This mark shall be used when apparatus is in compliance with the standard but not in
compliance with the certificate.

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3.1.3 Non-Compliance

This mark shall be used when apparatus is not in compliance with the standard and the
certificate.

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4.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each Standards/Publications shall be used, together
with any supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Index to Standard Drawings PTS 00.11.01
Field Commissioning and Maintenance of Electrical Installations PTS 13.02.01
and Equipment
SI Quantities and Units PTS 16.00.01

OTHERS STANDARDS
PETRONAS Technical Standards Management Procedure Version 3.0

INTERNATIONAL STANDARDS

Electrical Apparatus for Potentially Explosive Atmospheres. IEC 60079 – 19

IECEx Operations Manual-Assessment and Certification of IECEx OD13

Ex Repair and Overhaul Service Facilities Assessment
procedures to be followed by ExCBs for issuing and
maintaining of IECEx Certificates of Conformity for Service
Facilities conducting repair, overhaul or modifications of Ex
equipment seeking to be known as an IECEx Certified
Service Facility.

Quality Management System Requirements and IECEx OD14

Assessment of, for IECEx Service Facilities involved in repair,
overhaul and modification of Ex equipment.

IEC 60079: Electrical apparatus for explosive gas IECEx OD15

atmospheres
Part 19: Repair and overhaul for apparatus used in
explosive atmospheres (other than mines or explosives)

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APPENDIX 1: Ex EQUIPMENT OVERHAUL/REPAIR FLOWCHART

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