2014 CTL PTP WORKSHOP

1. 2014 CTL PTP WORKSHOP Ingrid Flemming IFM Quality Services Pty Ltd

2. Today: • The official agenda: • Outcomes and summary from recent PTPs • Touch Current • Heating transformers • Heating switches • Cables, conductor resistance and insulation thickness • A walk down the road……… • Learning from Histories • The guilty and the innocent • Effectiveness testing

3. Today: • The unofficial (but actual) agenda • Starting fires • Fighting fires • Resolving risk

4. Raise hands • Who attended the 2013 CTL PTP Workshop? • Who took something of benefit home with them? • Who shared the workshop content with their co-workers? • Whose laboratories changed ANY procedure as a result of attending the workshop? • How will we get MORE from attending the workshop?

5. September 2013, was NSW’s hottest and driest September since the beginning of weather record keeping.In October 2013, NSW was on fire.

8. 2 people lost their lives The damage costs were enormous. Many insurance policies will not pay.

9. Then... In the face of devastation • Starts the “BLAME GAME”. • The green (political) party is at fault because back burning was legislated out • The government has done nothing to mitigate climate change • Local authorities (that approve building work) allowed us to build here • The parents of those naughty children that started fires should have minded their kids.

10. We were not told how to prepare our house • The staff did not know how to perform the test • We didn’t know how to use the fire equipment • The staff was not trained to use the equipment • We didn’t know there was a ban on lighting fires outside at this time • We didn’t know we should apply the standard

13. Conformity and non-conformity • We all understand conformity • Do we all understand non-conformity? • We all know there is a COST of Conformance • What about cost of non-conformance? • We are coming back to this...........

14. 13E36 - Touch Current

19. M=0.48, 77 outliers, sinusoidal M=0.3, 139 outliers non-sinusoidal M=7.5, 64 reported low results, sinusoidal M=0, 82 “outliers”, sinusoidal M=3.5, 73 outliers, wave form mixed reply

20. Small resistors • Point 3 was expected to yield a very high result (7.5 mA, 240 V input) • 64 laboratories reported a measurement less than 3.5 mA, including >20 “0” results. • An additional 24 laboratories reported the words “pass” as the result. • 88 laboratories would have passed an unsafe sample.

22. Point 4 was not connected to any part of the circuit. (A rivet attached to the plastic box.) • 193 laboratories reported a measurement greater than zero, up to 0.05 mA. • 24 laboratories reported greater than 0.05 mA. • 8 laboratories reported greater than 3.5 mA.

24. The forest has burned • It is too late to call the fire brigade • There is no-one else left to blame

25. It is time for renewal

26. Discussion point: What kind of renewal is needed for our laboratories?

27. Outcomes: renewal discussion

28. Bringing renewal about • From where does change need to originate? • Technical staff? • Supervisors? • Lab managers? • Company heads? • ISO/IEC 17025 4.2.3 Top management shall provide evidence of commitment to the development and implementation of the management system and to continually improving its effectiveness.

32. Equipment • 30-40% additional labs are required to perform follow up activities if equipment audits occurred. • The audits issued by IFM receive “outliers” ONLY when the reported measurement is contrary to the requirements in the standard. • Test staff perform the audit, but nobody seems to CHECK the audit results – EXCEPT IFM. • Why do labs wait for IFM to tell them to comply with the standard?

33. The IFM equipment audits relating to PTP are NOT comprehensive. • Equipment performance needs to be verified and/or validated – IFM cannot “audit” this • Items such as steadiness of power supply, also need to be checked. Who does this? • Who will believe the lab checks equipment performance if the PTP audits show labs do not get the basic equipment questions right?

34. ISO/IEC 17025 5.5 • 5.5.2 Equipment and its software shall be capable of meeting the accuracy required and shall comply with specifications...... Before being placed into service, equipment shall be calibrated or checked to see it .... complies with the relevant standard specifications. ... It shall be checked and/or calibrated before use.

35. 5.5.3 Equipment shall be operated by authorised personnel • 5.5.5c records shall be maintained of .... Checks that equipment complies with the specification

36. 5.2 Personnel • 5.2.1 the laboratory management shall ensure the COMPETENCE of all who (perform tasks). ...Personnel performing specific tasks shall be qualified on the basis of appropriate education, training, experience and/or demonstrated skills.... • 5.2.2 ...... The laboratory shall have a policy for identifying needs and providing training..... THE EFFECTIVENESS OF TRAINING ACTIONS SHALL BE EVALUATED.

37. Discussion: What does it mean to train someone? • General education on concepts • Pass on skill and knowledge • Make information easily available and keep it up to date • Scope of training to be defined (depth of understanding vs monkey-work) • Mentorship • Explanation of procedure • Demonstration/observation • Works under supervision • Effectiveness of training assessment, discussion and demonstration • Approval for testing • Still OK after time? • Provide info for the trainee to absorb • More intensive obtaining of info, not to forget • Assessment of both knowledge and skills • Behaviour of the trainee – observation

38. Temperature Rise in Switches 13e33

39. 13e33 Test method • Attach conductors between switch and power source • Attach thermocouples to specified part of switch • Mount the switch on wooden surface • Apply suitable specified current. • Monitor until steady state has been reached (as stated in ALL standards quoted) • Determine the temperature rise • Variation – on one of the samples, perform additional actuations while “live”. This was only to demonstrate whether initial actuations were adequate to clear manufacturing residues from switch.

40. Questions relating to 13e33 • I would like to ask more detail with the testing method of DC supply, we have no DC power source with high power like 12A and we just only have 3A with low voltage. So can we skip the part of the DC measurement and providing with AC? • Answer: it is specified in instructions only to apply tests in scope

41. So Which program (part01 or part 02) should I enter the result at online system ? • Answer: Instructions contain information about part01 and part02

42. 17025 section 4.4 • Review of requests, tenders and contracts... • 4.4.1.a ensure that the customer’s requirements are understood, including methods to be used • Concept: In PTP – the provider is the customer

43. I setup my test circuit today with the test switches installed. Something is wrong. Neither one of the switches are working. They do not allow current to pass. I checked the switches when we received them by performing 20 mechanical operations and they were fine. The test results are due in 17 days. • Answer: run current through the switch according to the instructions, not across the insulation.

44. OUTCOMES 13e33

45. 13e33 Temperature Rise - Switches

46. Group Exercise • Identify the aspects of training that would be required for staff to set up a heating test in switches • How will effectiveness of training be determined? • How will the performance of all staff doing this test be monitored?

47. Training? • Standard • Procedure • Thermocouples: preparation, selection, fixing, attachment, positioning • Load • Connection • Control of environmental conditions • Power supply • Installation • Time • Equip specification • Calibration • Using equip • Personal safety

48. Ishikawa Materials Methods Equipment Problem Measurement Environment People

49. Materials Methods Equipment Problem Measurement Environment People