CONSULTING Training Courses

CONSULTING Training Courses

2 EXPLOLABS TRAINING MAKES THE DIFFERENCE 1. GENERAL Why training by Explolabs Consulting? For training in the specialized, high-risk field of explosion protection, one needs a thorough understanding of the explosion protection concepts. Explolabs Consulting staff has expertise in all aspects of explosion protection, including design requirements, testing and certification of Ex apparatus, area classification and inspection of Ex apparatus. We stay abreast of developments in Ex technology by our association with a SANAS accredited test laboratory and being involved in national and international standard committees that compile Ex standards. Our staff are enthusiastic and have many years of experience in compiling and presenting Ex courses. Explolabs Consulting offer a range of training courses in the field of explosion protection. The courses are aimed at staff from plants and mines with hazardous locations, as well as at companies involved in the design, manufacture and repair of explosion-protected apparatus. Students receive up-to-date practical and theoretical information. Depending on the course, students need some technical background that may include formal training. Most courses allow students the opportunity to be assessed for having achieved the desired competence by means of a questionnaire and/or observation during lectures and practical sessions. COURSES ARE PRESENTED AT OUR PREMISES OR ON SITE. One of our strengths is that courses can be developed to suit specific company needs. 2. BEE STATUS Explolabs Consulting complies with the BEE requirements for small companies. Our most important contribution is empowerment through training. 3. CONTACT DETAILS For further information please contact: Johannes Auret Charlene Bosch Tel: +27 11 316 4601/3548 Tel: +27 11 316 4601/3548 Cell: +27 83 628 4862 Fax: +27 86 554 0865 / +27 11 316 5670 Fax: +27 11 316 5670 E-mail: johannesa@explolabs.co.za charlene@explolabs.co.za Website: www.explolabs.co.za

4. FEEDBACK FROM STUDENTS 3 Recent feedback includes: Course was excellent. We appreciate your time and knowledge sharing to make us better maintainers. Well done. The course was presented very well. The info I received will most certainly help me in the future. Well balanced, well paced course!!! Very informative and enlightening. Thank you; would love to do advanced course.

4 5. TRAINING COURSES SCHEDULE AND COSTS FOR 2014 No Title (see contents next pages) Standards covered 1 Costs (ex VAT) 2 Dates 2014 1 Design, Manufacture, Repair and Maintenance of Intrinsically Safe Apparatus (3 days) IEC/SANS 60079-0 IEC/SANS 60079-11 SANS 10086-1(2) SANS 10086-3 SANS 1/ARP R4250 including Only on request 2 Design and Installation of Intrinsically Safe Loops (3 days) 3 Manufacture, Repair and Inspection of Flameproof, Increased Safety, Type n, Pressurized and Dust Ignition Protected Electric Motors (3 days) If you are a manufacturer, repairer, national agent or major user of explosion protected motors, do not miss this course! 4 Manufacture, Repair and Inspection of Apparatus with Flameproof Boxes (3 days) 5 Manufacture, Repair and Inspection of Ex Electrical Apparatus, Assemblies and Machines (Powered by Electrical Mains or Batteries) (3 days) 6 Manufacture, Repair and Inspection of Ex Diesel Powered Engines and Machines (2 days) 7 Explosion Protection for Plant Staff (3 days plus now ADVANCED 2 days) 8 Classify with confidence Unlocking the key principles of area classification (2 days) 9 Introduction to Explosion Protection (1 day) SANS 10086-1(2) SANS 10086-3 SANS 1/ARP IEC/SANS 60079-0 IEC/SANS 60079-1 IEC/SANS 60079-7 IEC/SANS 60079-15 IEC/SANS 61241-1-1 IEC/SANS 61241-0,-1 SANS 10086-3 SANS 1/ARP SABS 314/970/969 IEC/SANS 60079-0 IEC/SANS 60079-1 SANS 10086-3 SANS 1/ARP IEC/SANS 60079-0 IEC/SANS 60079-1 IEC/SANS 60079-7 IEC/SANS 60079-11 IEC/SANS 60079-15 SANS 1654 SANS 10086-1,-2 SANS 1/ARP SANS 868 IEC/SANS 60079-1 SANS 1/ARP SANS 10086-1 SANS 10086-3 SANS 1/ARP IEC/SANS 60079-10 IP Code of Safe Practice Part 15 IEC/SANS 61241-10 SANS 1/ARP SANS 10086-1,-2 R4250 including R4250 including R4250 including R4250 including R3600 including R4250 including & R 5650.00 ADVANCED 2 days R3200 including R3200 including Only on request 19 21 May 2014 20 22 October 2014 19 21 May 2014 20 22 October 2014 14 16 April 2014 18 20 August 2014 Only on request 24 26 March 2014 09 13 June 2014 (plus ADVANCED 2 days) 15 17 September 2014 24 28 November 2014 (plus ADVANCED 2 days) Only on request Only on request

NOTES 1. SANS standards for training can be obtained at a discount rate through us. 2. Companies with 4 or more students may negotiate a special discount. 3. These costs apply to courses presented at our premises. 5 6. CONTENTS OF COURSES 1. Design, Manufacture, Repair and Maintenance of Intrinsically Safe Apparatus Target group Technicians and engineers working for manufacturers and suppliers involved in the design, certification and repair of intrinsically safe electronic equipment. Instrumentation technicians and engineers in petrochemical, chemical, steel, alloy, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Mine technicians and engineers. Subjects covered Overview of area classification and explosion protection techniques Standards for IS apparatus Typical circuits IS loops and installation requirements Earthing Repair and maintenance. Applying the intrinsically safe (Ex i) concept to the design of electronic apparatus (instruments, power supplies, barriers). The inspection of newly manufactured and repaired Ex i apparatus. An understanding of legal requirements and the responsibility of the manufacturer or repairer. Understanding the certification process and requirements for Ex apparatus. Understanding the quality management required for the manufacture or repair of Ex i apparatus. 2. Design and Installation of Intrinsically Safe Loops Target group Suppliers of intrinsically safe electronic equipment and mining machines. Buyers and instrumentation technicians and engineers in petrochemical, chemical, steel, alloy, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Mine technicians and engineers. Subjects covered Overview of area classification and explosion protection techniques IS loops and installation requirements Design and evaluation of simple to complex IS loops and installations Earthing requirements in installations Preparation of loops for certification. Technical requirements for Ex i apparatus and systems. Legal requirements and the designer s responsibility. The certification process for Ex i systems. Pre-submission evaluation of Ex i systems. Preparing document packs for certification of Ex i systems. The validity of certification when new installations are to be made, including the use of (a) upgraded models and (b) new apparatus.

6 3. Manufacture, Repair and Inspection of Flameproof, Increased Safety, Type n, Pressurized and Dust Ignition Protected Electric Motors Target group Technicians and engineers working for manufacturers, suppliers and repairers of explosion protected motors. Electrical technicians and engineers in petrochemical, chemical, steel, alloy and light metal, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Mine technicians and engineers. Subjects covered Introduction to explosion protection: Terminology, hazardous locations, types of protection. Legal requirements in terms of the certification, use, manufacture, repair and conversion of explosion protected motors. Who has to hold certificates. Which certificates are required when batch testing versus when operating under a Product Certification Scheme. Which certificates/copies are to be supplied to clients. Validity of certificates in terms of age, standard changes, modifications. Validity of SABS 970, SABS 969, SABS 314-1 etc certificates. How to upgrade certification easily and cost-effectively. Certification of motors converted to Type n or DIP by a repairer. Marking: National, international, ATEX. New motors, repaired motors, converted motors. Flameproof (Ex d) motors: Protection concept, standards, certification requirements including prototype preparation and type testing, electrical design (no restrictions), mechanical design including flameproof joints and sealing requirements, inspection and testing, repair, operational requirements (cable connection, overload protection, VSDs, zones for which suitable, special conditions of use). Increased safety (Ex e) motors: Protection concept, standards, certification requirements including prototype preparation and type testing, electrical design (only induction motors, de-ration), mechanical design (sealing requirements), inspection and testing, repair, operational requirements (cable connection, zones for which suitable, use of Ex e overload in Zone 1, VSDs, special conditions of use). Non-sparking (Ex na) motors: Protection concept, standards, certification requirements including prototype preparation and type testing, electrical design (only induction motors, de-ration), mechanical design (sealing requirements), conversion of standard motors including determination of temperature class, repair, operational requirements (cable connection, overload protection, VSDs, zones for which suitable, special conditions of use including dilution ventilation during startup of large machines). Pressurized (Ex p) motors: Protection concept, standards, certification requirements including prototype preparation and type testing, electrical design (no restrictions), mechanical design including pressurization system, inspection and testing, repair, operational requirements (cable connection, pressure monitoring system, VSDs, zones for which suitable, special conditions of use). Included upon request. Dust ignition protected motors: Protection concept, standards including the new SANS 61241-0 and -1 for Ex td motors, certification requirements including prototype preparation and type testing, electrical design (no restrictions), mechanical design including sealing of enclosure, conversion of standard motors including determination of temperature class, inspection and testing, repair, operational requirements (cable connection, overload protection, VSDs, zones for which suitable, special conditions of use). Quality management requirements and Product Certification (Mark) Schemes. How to introduce modifications safely and cost-effectively under a Mark Scheme. How to expand your product range. Practical sessions. Applying the flameproof (Ex d), increased safety (Ex e), Type n (eg non-sparking Ex na), pressurization (Ex p) and dust-ignition-protection (DIP) concepts to motors. The inspection of newly manufactured and repaired explosion protected motors. An understanding of legal requirements and an inspector s responsibility.

Understanding the certification process and requirements for Ex apparatus. Understanding the quality management required for the manufacture or repair of explosion protected motors. 7 HIGHLY ACCLAIMED BY STUDENTS. THE MOST COMPREHENSIVE COURSE AND HANDS-ON COURSE AVAILABLE IN SOUTH AFRICA! CPD registration no. SAFA-0002-06. 4. Manufacture, Repair and Inspection of Apparatus with Flameproof Boxes Target group Technicians and engineers working for manufacturers (including manufacturers of mining machines), suppliers and repairers of explosion protected panels. Electrical technicians and engineers in petrochemical, chemical, steel, alloy and light metal, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Mine technicians and engineers. Subjects covered Introduction to explosion protection: Terminology, hazardous locations, types of protection Marking: National, international, ATEX Product certification schemes Flameproof boxes and panels: Construction and performance requirements, electrical design, mechanical design, routine tests in IEC/SANS 60079-0 and IEC/SANS 60079-1, inspection and quality control Intrinsically safe instrumentation and equipment loops supplied from flameproof boxes Repair of flameproof boxes Practical session. Applying the flameproof (Ex d) concept to panels. The inspection of newly manufactured and repaired Ex d enclosures. The inspection Ex d assemblies including intrinsically safe (Ex i) associated apparatus. An understanding of legal requirements and an inspector s responsibility. Understanding the certification process and requirements for Ex apparatus. Understanding the quality management required for the manufacture or repair of Ex d panels. CPD registration no. SAFA-0002-06.

8 5. Manufacture, Repair and Inspection of Ex Electrical Apparatus, Assemblies and Machines (Powered by Electrical Mains or Batteries) Target group Designers and Manufacturers of Ex Apparatus and Machines. Quality inspectors operating under an approved national Product Certification Scheme. Inspection and maintenance staff on mines, chemical and petrochemical plants. Subjects covered Introduction to explosion protection: Hazardous locations, types of protection Terminology Legal requirements Explosive gases, vapours and dusts Classification of hazardous locations Description of explosion protection techniques, typical equipment and level of protection Marking systems Certification of Ex apparatus and assemblies including machines Product Certification Schemes Flameproof, Increased Safety, Type n, Intrinsically Safe Apparatus: definition, definition explained, product standards, construction and performance requirements, specific types of apparatus Ex machines (assemblies) Practical session. Understanding the explosion prevention concept and terminology. Applying the flameproof (Ex d), increased safety (Ex e), Type n (eg non-sparking Ex na), and intrinsic safety (Ex i) concepts to apparatus such as motors, panels, lights, solenoids, plugs and sockets and sensors. The inspection of explosion protected apparatus and machines (for example Ex d assembled panels including intrinsically safe (Ex i) associated apparatus) during the machine manufacturing or repair process. Marking of explosion protected apparatus and machines. An understanding of legal requirements and an inspector s responsibility. Understanding the certification process and requirements for explosion protected apparatus, including modified apparatus. CPD registration no. SAFA-0002-06.

6. Manufacture, Repair and Inspection of Ex Diesel Powered Engines and Machines 9 Target group Technicians and engineers working for manufacturers (including manufacturers of mining machines), suppliers and repairers of explosion protected motors. Electrical technicians and engineers in petrochemical, chemical, steel, alloy and light metal, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Mine technicians and engineers. Subjects covered Introduction to explosion protection: Terminology, hazardous locations, types of protection Marking: National, international, ATEX Product certification schemes Flameproof diesel engines: Construction and performance requirements, certification, inspection, maintenance, repair Explosion protected diesel-powered engines: Construction and performance requirements, certification, inspection, maintenance, repair, electrical equipment, intrinsically safe instrumentation and instrumentation loops Practical session. Applying the flameproof (Ex d) concept to panels. The inspection of newly manufactured and repaired Ex d enclosures. The inspection Ex d assemblies including intrinsically safe (Ex i) associated apparatus. An understanding of legal requirements and an inspector s responsibility. Understanding the certification process and requirements for Ex apparatus. Understanding the quality management required for the manufacture or repair of Ex d panels.

10 7. Explosion Protection for Plant Staff This highly acclaimed course is a must for a wide range of plant staff. It is packaged in a format that has been developed by experience over several years, namely a) An Overview that presents the latest developments in an understandable way. Most students find the 3-day period ideal. b) This is followed by a 2-day Advanced phase, which allows for a field assignment in the interim period. The Advanced phase is strongly focused on practical issues. c) A Refresher 1-day course enhances and updates knowledge from the Overview and Advanced stages every 2 years. 7.1 OVERVIEW TRAINING (3 DAYS) Target group E&I Maintenance and Project engineers, supervisors, electricians, instrumentation technicians and mechanicians, trainees, charge hands, contractors. Mechanical staff. Production staff. Buyers/Procurement staff. Safety/SHEQ staff. Applicable industries - Petrochemical, chemical, steel, alloy and light metal, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain plants and factories. Entry requirement Staff being trained for first time or after significant period. Background on explosion prevention required, or basis for advanced competence training. Course content THEORY What is explosion protection? Legislation Classification of hazardous locations Ignition properties of flammable/combustible materials Overview of explosion protection techniques Selection of explosion protected apparatus Installation Inspection Maintenance Repair. PRACTICAL Electrical apparatus including motors, lights, switches Instrumentation including sensors, Ex p panels, analysers Inspection practice Inspection checklists Marking Tests/measurements Cables, conduit and glands. The basic concepts of explosion prevention as applied to hazardous locations. Area classification and the ignition of explosive atmospheres. Explosion protection techniques used on electrical apparatus and instrumentation (mechanical apparatus). The certification process and requirements for Ex apparatus. Installation rules for hazardous locations. Practical inspection skills in terms of explosion protected apparatus and installations. Safe maintenance practices for explosion protected apparatus and installations. An understanding of legal requirements and a technical person s responsibility. Good practice in terms of the managing of hazardous plants. Skills programme registration no. SP/583/0081. CPD registration no. SAFA-0002-06.

11 7.2 ADVANCED TRAINING (2 DAYS) Background Students that work in hands-on capacity with or are directly responsible for with new Ex installations and inspections and maintenance of existing Ex installations may enter for an additional, advanced two-day course. This advanced course covers the practical aspects of new installations, inspection of existing installations, hot work etc. Target group 1. E&I electricians, instrumentation technicians and mechanicians (full-time and contracted) that work in hands-on capacity with new Ex installations and inspections and maintenance of existing Ex installations ( Operatives in terms of SANS 60079-17). 2. Management staff such as Project Managers, Maintenance Managers, Supervisors ( Responsible Persons in terms of SANS 60079-17). Entry requirement Overview Training successfully completed (for example within preceding 2 years). Course content Day 1 Gas Testing Permit. Hot Work Permit. Electrical Permit. Preparation for Practical sessions (permits). Inspection Sheets. Management System for Hazardous Areas (Responsible Persons only) Day 2 Inspection of Ex d, Ex e and Ex na Systems. Preparation & Installation of Ex d, Ex e and Ex na Systems. Inspection of Ex i and Ex nl Systems. Preparation & Installation of Ex i and Ex nl Systems. (2 groups of x8 persons maximum each; run two sessions in parallel.) NOTE A distinction can be made for which Ex techniques a person is qualified based on operational/development requirements and existing knowledge, for example only for Ex i systems. Installation rules for hazardous locations. Practical inspection skills in terms of explosion protected apparatus and installations. Safe maintenance practices for explosion protected apparatus and installations. Good practice in terms of the managing of hazardous plants. 7.3 REFRESHER TRAINING (1 DAY) The Refresher Course enhances and updates knowledge from the Overview and Advanced stages every 2 years. It involves a training session and an evaluation.

12 8. Classify with confidence Unlocking the key principles of area classification Target group Technical staff on plants that are directly involved in the classification of hazardous plant (permanent or ad hoc). Plant management (legal responsibility and authority). Technical staff of consulting engineering firms. Subjects covered Why classify? Terminology Classification standards Legal requirements Basic principles Ignition properties of flammable materials Classification of gas/vapour locations by Direct Example. Classification of gas/vapour locations by Point Source Classification of gas/vapour locations by First Principles Classification of dusty locations Functions of the area classification Working Group Demarcation of hazardous locations. Standards and legal requirements covered The latest editions of relevant standards and legal requirements: SANS 1 IEC/SANS 60079-10 IP Code of Safe Practice Part 15 IEC/SANS 61241-10 Electrical Machinery Regulation 8 of the OHS Act, Act 85 of 1993 and Regulations. Mine Health and Safety Act, Act 29 of 1996 and Regulations. Format Theoretical and practical training. Duration 2-3 days. Course outcomes At the conclusion of the course students should have: a clear understanding of the reasons for and goals of area classification. a clear understanding of the classification concept. developed the basic skills required to participate in a classification study. a clear understanding of their role and responsibility (in technical and legal terms).

9. Introduction to explosion protection 13 Target group Managers, service staff and the sales force working for manufacturers, repairers and suppliers of explosion protected apparatus. Managers, supervisors, quality controllers and inspectors, buyers and technical staff not directly involved in explosion protection, on plants and factories in the petrochemical, chemical, steel, alloy and light metal, beverage and liquor, pharmaceutical, sugar, wood products, ink, paint and printing, tobacco, and grain industries. Engineering consultants and consulting firms. Subjects covered What is a hazardous location and explosion protection? Legislation Classification of hazardous locations Selection of explosion protected apparatus Installation Inspection Maintenance Repair The management of plants with hazardous locations. Course outcomes The course promotes understanding in the following areas: Explosion hazards caused by flammable materials. How to identify explosion hazards in a plant. How such explosions can be prevented. The legal requirements concerning hazardous locations. The properties of flammable materials. Explosion protection techniques applied to electrical apparatus, instrumentation and mechanical apparatus, and how such apparatus is certified and marked. The installation rules applicable to explosion protected apparatus. the requirements concerning the inspection, maintenance and repair of explosion protected installations. 10. Other available courses include Increased Safety Battery Packs.

14 7. COURSE APPLICATION CONSULTING APPLICATION TO ATTEND AN Ex COURSE PLEASE COMPLETE THIS FORM AND FAX/E-MAIL TO: 086 554 0865 charlene@explolabs.co.za Attention: Charlene Bosch Your Company Details Company Name Invoice Address Order Number (attach copy) Details of Person(s) Attending the Course Surname, Initials ID Number Course No (1-9). Indicate (F)ull/ (R)efresher Potential Dates VENUE: EXPLOLABS, No 7 Spanner Road, Olifantsfontein Please arrange your own accommodation. To cover costs a cancellation fee of 50% will be charged unless we are notified more than 5 working days in advance, in writing. I hereby accept the cost and conditions for the attendance of the people listed above. Signed: Print name: Date: