Beruflich Dokumente
Kultur Dokumente
MANUAL
WHYALLA (Part 3)
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Contents
1 Refer to Electrical Safety Manual Pt-1(OST-OHS-ELEC-pro-001) ..................................... 3
2 Refer to Electrical Safety Manual Pt-2(OST-OHS-ELEC-pro-001) ..................................... 3
3 PART 3 – SITE SPECIFIC – WHYALLA............................................................................ 3
3.1 Electrical Safety Equipment .................................................................................................. 3
3.2 Accidents & Emergencies (WHYALLA) .............................................................................. 5
3.2.1 Reporting Incidents / Accidents ............................................................................................. 6
3.3 Policies, Quality Procedures, Work Instructions & Reference Lists ..................................... 7
3.4 RISK ASSESSMENT – Working on or near LV conductors................................................ 9
3.5 WORKING ON OR NEAR ELECT. EQUIP. & SERVICES ............................................. 12
3.6 Construction site electrical equipment ................................................................................. 13
3.7 SA Regulations Requirements regarding Electrical Apprentices & Cadets Work .............. 14
3.7.1 Qualified but inexperienced Electrical Personnel ............................................................... 14
3.7.2 Training for Electrical Competency .................................................................................... 14
3.7.3 Supervision of Apprentices .................................................................................................. 14
3.8 Plumbing Installations ......................................................................................................... 15
3.9 ‘Certificate of Compliance’ and Testing results .................................................................. 16
3.10 SAFE SYSTEM OF WORK (SSoW) .................................................................................. 17
3.10.1 When a SAFE SYSTEM OF WORK (SSOW) is required ..................................................... 17
3.10.2 Emergencies ......................................................................................................................... 17
3.11 Electrical PPE ...................................................................................................................... 20
3.11.1 Whyalla Standard PPE / Dress for Electrical Work ............................................................ 20
3.12 Working Safetly Near Overhead Powerlines/collectors ...................................................... 23
3.13 Electrical Switchroom Entry Requirements......................................................................... 27
Appendix 1 - Job Safety Analysis (JSA) for testing and fault finding ...................................................... 28
Appendix 2 – Risk Assessment for testing and Fault Finding .................................................................. 31
Appendix 3 – SIMEC Mining/Liberty OneSteel Whyalla switchroom audit ............................................ 35
Appendix 4 - Guide for the minimum PPE requirements for arc fault protection while testing and fault
finding on energised LV electrical equipment……………………….………………………...36
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1 REFER TO ELECTRICAL SAFETY MANUAL PT-1(OST-OHS-ELEC-PRO-
001)
Helmet Light PRIMUS Focus+K2 LED Light Standard for electrical work 55066737
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Equipment Details Reference Supply
Mats and Covers - Ins Cover: 1500 x 1200 x 2mm to AS4204. 1.6.13 55047129
Insulating Ins Mat 915mm wide x 6mm AS2978 class A: 1.6.14
- 1m length 55048324
- 2m length 55048323
- 3m length 55048322
- 4m length 55048321
- 5m length 55048320
- 6m length 55048319
Lock, Personal Red 1.5.1 54001609
Multimeter All new multimeters purchased from July 2015 shall be Cat 1.7.2 Current electrical
IV at 600V minimum supplier
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3.2 ACCIDENTS & EMERGENCIES (WHYALLA)
#1 Raise the alarm and contact emergency personnel. Do not hang up but
remain calm and give all details.
Transport all persons who have had an electric shock by Ambulance to the
hospital without delay. Advise Medical Staff of the shock details to enable
them to determine the path of electrical current through the body.
Severity of shock depends on magnitude, duration and path of current flow and
health of the victim.
Make safe the installation causing the electric shock but do not interfere with it
unnecessarily as to prevent a proper investigation of the accident.
If necessary to leave the machine, eg, fire, jump clear, landing with feet
together and do not touch the machine.
To leave a hazard site jump or take short ‘shuffle’ steps.
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#6 Fight Low Voltage electric fires in the early stage with hand extinguishers if
practical and safe to do so.
Carbon Dioxide for small electrical or Dry Chemical powder for larger fires.
Otherwise keep well clear of the fire in electrical switchrooms or substations to
avoid hazard from burning oil, inhalation of toxic fumes from burning cables and
electric shock.
Do not enter a switchroom if the alarm from automatic fire protection systems
is activated until the All Clear is given by Emergency Services.
Audible and visual evacuation alarms are activated prior to discharge. Contact
the Emergency Personnel with details unless you know they have been
contacted.
Not all automatic systems report to Security. To avoid false alarms when doing
maintenance work in protected switchrooms, contact emergency services
before starting work and again on completion so that the system can be
isolated.
Report to Safework SA
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3.3 POLICIES, QUALITY PROCEDURES, WORK INSTRUCTIONS & REFERENCE
LISTS
GFG Alliance (SIMEC Mining/Liberty OneSteel Whyalla) policies detailed in this document
and other Procedures, Manuals or Work Instructions shall be followed where applicable to
the work being carried out. The policies commonly used are listed below along with
Australian Standards and Regulations referenced in this document.
Management Procedures
SA31.245 SIMEC Mining / Liberty OneSteel Whyalla Site Conditions
https://www.libertyonesteel.com/OneSteel_whyalla/default.htm
QM - Quality Manuals
QM37.01 Electrical equipment and Installation Tender Manual
QM37.03 High Voltage Safety Manual
QM37.04 Electrical Technical Handbook
QP29.24 Radiation Safety Manual
QP - Quality Procedures
QP02.05 Modification Control and Trial Process
QP29.01 Manual handling risk management
QP29.06 Incident Investigation and Reporting
QP29.13 Safety Risk Management
QP29.18 Working in Confined Space
QP29.20 Isolation for personal protection
QP29.21 Warning Tag regulations
QP30.17 Access to Switchroom and Switchyard
WI - Work Instructions
WI29.251 Hot work
WI29.600 Safe system of work process
WI37.EIC.084 In-Service Safety Inspection & Testing of Elect. Equipment
WI37.EIC.086 Procedure to Initiate and Control Excavation and Piling work.
WI37.INF.040 HV Distribution Committee
WI37.07.001 Working on or in the vicinity of Elect. Trays or Ladders
WI37.EIC.091 Penetrating Surfaces and Structures
WI37.EIC.135 Demolition of Electrical Equipment
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HB Handbooks Produced by Standards Australia but not an AS standard
HB13 Handbook on hazardous areas and equipment
HB94 Electrical safety in the workplace (is now dated due to the change from OHS to WHS
in 2012)
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3.4 RISK ASSESSMENT – WORKING ON OR NEAR LV CONDUCTORS
Risk Control Procedures Flow Chart (from AS4836)
For electrical work ON live exposed LV conductors this Risk Assessment, or equivalent, shall be used
and attached to the Authority to work on live conductors application.
For work NEAR live exposed LV conductors this Risk Assessment should also be used.
Prepare a Safe Work Procedure using the chart below and the checklists, which follow, in conjunction with
department Hazard Prompts, Safety Analysis etc.
Yes No
Does the
electrical equipment
1 need to be isolated to
perform the work
safely?
Can
it be isolated 2
safely at this time?
Can the
work be rescheduled so
3
that it may then be
isolated?
Can barriers
4 Reschedule work 5
be installed satisfactorily?
Work cannot be
8 carried out energised
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Risk Assessment Check List
Estimated date of work:__________________________________Plant: ___________________
Substation, Switchroom or Area: ___________________________________________________
Circuit: _______________________________________________________________________
Participants in Risk Assessment: ______________________ _______________________
_______________________ _______________________
The following check list includes items from this manual and standard AS4836. It is recommended that each
department and contractor have access to the standard AS4836, in addition to the Electrical Safety Manual OST-
ELECT-PRO-001. For additional information see the references given.
Column 3 should be marked with - or ? for every check item. If or ? then the last column should show the action
or procedure to control that risk.
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Ref* Hazards check Item - or ? Action/procedure to control risk
17. 7,9 Full-face shield, without metal frame, is used for arc
risk. AS4836.
18. Workers are trained in rescue & resuscitation
19. 7,9 Safety observer is not needed,
OR if needed, Safety observer is trained. AS4836.
20. 9 Safety/ rescue and communication equip will be
available for emergency use.
21. 9 All workers are competent in the work to be done.
QM37.01; AS4836.
22. 9 Conductive tools & equip. will not be used near live
exposed conductors; AS4836.
23. 9 Neutral conductors will remain connected during
work. QM37.01; AS4836.
24. 9 All parts normally earthed will remain earthed during
work. AS4836.
25. 9 Work platform is stable. AS4836.
26. 10 If work is left unfinished equip/ work site will be left in
safe state. QM37.01; AS4836.
27. 10 Before power restored work site search for misplaced
tools, swarf etc which could cause arc fault. Clean up/
vacuum.
28. 10 Before power restored all work done will be tested.
AS4836.
29. 10 When work is finished equipment will be returned to
service in safe state. QM37.01; AS4836.
30. Cert. of Compliance will be completed.
31. No mechanical hazards which could cause injury
Rotating or moving equipment? Burn hazard? Other mechanical
hazard?
32. Climate hazards are controlled
Wet weather? Lightning? Other weather hazard?
33. Tools right for job and correct use is understood
Cutting/stabbing hazard?
34. Use of special PPE for specific risk has been
considered
Harness for working at height etc?
35. Site hazards are controlled:
Height, scaffolds? Confined space? Harmful atmosphere (Liberty
OneSteel Whyalla hazard zones)? Explosive atmosphere
(AS2430)? Access: exits, barriers, vehicle movement? Ergonomic:
manual handling? Environment: ventilation, noise, lighting,
temperature?
Other site hazard?
36. Emergency services are effective
Emergency lighting? Fire? Communication, evacuation? Other
emergency service, which could be needed?
Additional comments for Hazards:
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
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3.5 WORKING ON OR NEAR ELECT. EQUIP. & SERVICES
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3.6 CONSTRUCTION SITE ELECTRICAL EQUIPMENT
Regulatory requirements:
Label: “Keep
350
Cords protected
from damage.
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3.7 REQUIREMENTS REGARDING ELECTRICAL APPRENTICES & CADETS
WORK
REFER TO OST-OHS-PRO-001 SECTION 2.3 FOR DETAILS
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3.8 PLUMBING INSTALLATIONS
Those working on plumbing installations shall comply with the work scope,
the issued ATW and SIMEC Mining / Liberty OneSteel Whyalla electrical work
requirements.
Outside SIMEC Mining / Liberty OneSteel Whyalla site (e.g. SIMEC Mining /
Liberty OneSteel Whyalla houses): A plumber with a restricted Electrical
License may work within its constraints. Where wiring, re-connection, circuit
modifications or component replacements are done a copy of the COC shall
be forwarded to SIMEC Mining / Liberty OneSteel Whyalla Electrical
Inspection Officer who will review and may verify the tests. The Contract
Control Officer shall supply the Electrical Inspection Officer with details of
plumbers likely to do such work.
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3.9 ‘CERTIFICATE OF COMPLIANCE’ AND TESTING RESULTS
The Electrical Supervisor shall ensure that the earthing system resistance
value is maintained over time.
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3.10 SAFE SYSTEM OF WORK (SSOW)
Training in the usage of QP29.13 is available and every new starter in maintenance and
engineering organisations at SIMEC Mining / Liberty OneSteel Whyalla is required to
undertake this training, they are also required to fully participate in the execution of risk
management documentation for all work undertaken.
The following example of a SSOW should not be used as a proforma, the reader is
directed to obtain the latest version of SSOW by visiting the SIMEC Mining / Liberty
OneSteel Whyalla Intranet Occupational Heath & Safety website and download
QP29.13 attachment 4.5 or 4.6.
3.10.2 Emergencies
If a situation arises that involves;
a threat to the wellbeing of a person or group of persons, and/or
the potential for loss of critical process control or stability or the risk of a
significant loss of operational security or critical plant
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then a ‘Take 2’ shall be used. Should the Take 2 indicate it is unsafe to proceed, a formal SSOW must be utilised.
EXAMPLE ONLY
Example of Whyalla’s SSoW, QP29.13
(side 1)
REFER TO QP29.13
ATTACHMENT 4.6
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EXAMPLE ONLY
Example of Whyalla’s SSoW, QP29.13
(side 2)
REFER TO QP29.13
ATTACHMENT 4.6
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3.11 ELECTRICAL PPE
Switching PPE
Indura Ultra Soft Switching Coat over either
of the combinations above plus Indura Ultra
Soft balaclava, arc flash rated face shield
and HV gloves. Total ATPV (cal/cm2)
rating of 51.5. This PPE is suitablefor most
high energy switching operations.
A full hood is required for HV switching
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PPE / Dress for Electrical Work, General
PPE (Personal Protective Equipment) shall be used when the risk cannot be
completely eliminated or controlled by Engineering and Administrative controls.
Shall be as follows:
Safety glasses with side shields
Lightweight leather gloves (gauntlet type to protect the wrist) wherever
practical.
Safety footwear with rubber soles.
Safety hat, hearing and / or hand protection where required by the nature or
location of the work site or as indicated by local safety signs.
Long sleeves and collard shirt fastened at the wrist,
made of Indura Ultra Soft with minimum ATPV rating of 8.7cal/cm2
with sleeve cuff openings that are designed to make it difficult to roll
sleeve up
with sleeve placket openings sewn up or gusseted or fastened to
prevent exposure to bare wrist
and
Long trousers that cover the ankles, made of Indura Ultra Soft with a
minimum ATPV rating of 8.7cal/cm2
or
Overalls made from Indura Ultra Soft with minimum APTV rating of
12.4cal/cm2.
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PPE for tasks with increased risk of shock or arcing
Some electrical tasks at SIMEC Mining / Liberty OneSteel Whyalla sites have an
increased risk due to the nature and age of the plant and the presence of some
uninsulated equipment.
Insulating Gloves 3
Switching coat
with hood 6
Switching LV knife or open switch <100A M - - M -
Switching LV knife or open switch >100A M - - M RA
Switching LV enclosed switch >100 A - M - - -
Switching HV at breaker see 1.9 M - - - M
Aerial switching: reclosers, air breaks, links and fuses M - - M -
Lockout on live open panels 1 M - - - -
Work at rear of live open panel 2 M - RA M -
Electrical testing LV control circuits M - RA RA -
Electrical testing high energy LV circuits M - RA - M
Energised cables on tray M - RA - -
Resetting open panel overload M - - RA RA
Non electrical work, e.g. cleaning switchrooms 2 Subject to risk assessment
RA = Risk assess M = Mandatory - = not required
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3.12 WORKING SAFETLY NEAR OVERHEAD POWERLINES/COLLECTORS
Find below safety guideline from the Office of Technical Regulator regarding working safely near
overhead powerlines. We have extended this requirement to plant collector rails as well.
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2 Working safely near overhead powerlines
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s
3 Working safely near overhead powerlines
Table1: Clearance distances from powerlines – to be taken from the position of the closest conductor
Cranes Machinery
Electricity Act/Regulations Buildings and Structures,
AS 2550.1 Crane Code. Safe Approach Limits
Schedule 6 – Distance to including Scaffolds
(Approved Code of Practice) Electricity Regulations 23A(3)
operation of machinery, vehicles Electricity Regulations Schedule
Earthmoving machinery and Safe Approach Limits
or vessel with elevating 2, Table 1
Elevating Work Platforms
component or shear legs
Equipment
Power
Voltage (in Spotter Risk assessment and and manually Horizontal Vertical
No Spotter operated
volts) required spotter required operated direction direction
tools
tools
240 6.4m 3.0m 1.0m 1.0m 3.0m 1.5m 3.7m
415 6.4m 3.0m 1.0m 1.0m 3.0m 1.5m 3.7m
7,600 6.4m 3.0m 1.5m 2.0m 3.0m 3.1m 5.5m
11,000 6.4m 3.0m 1.5m 2.0m 3.0m 3.1m 5.5m
19,000 6.4m 3.0m 1.5m 3.0m 3.0m 3.1m 5.5m
33,000 6.4m 3.0m 1.5m 3.0m 3.0m 3.1m 5.5m
66,000 6.4m 3.0m 3.0m 4.0m 4.0m 5.5m 6.7m
132,000 pole 6.4m 3.0m 3.0m 5.0m 5.0m 15.0m NA
132,000 tower 10.0m 8.0m 3.0m 5.0m 5.0m 20.0m NA
275,000 10.0m 8.0m 4.0m 6.0m 6.0m 25.0m NA
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4 Working safely near overhead powerlines
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3.13 ELECTRICAL SWITCHROOM ENTRY REQUIREMENTS
Switchrooms can pose a threat to the safety of personnel who enter them; hence
a switchroom is not a place to loiter and a specific purpose is required before
entry.
All who enter electrical switchrooms are required to have successfully completed;
Switchroom Fundamental (Part I) training (theory)
and
Switchroom Fundamental (Part II) training (practical, consisting of plant tour
of electrical switchrooms and assessment).
Entry into switchrooms by those who have not completed Switchroom Fundamental
training and assessment (part I & II) is allowed only under supervision of a trained and
assessed person.
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Appendix 1 - Job Safety Analysis (JSA) for testing and fault finding
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Step Description of Job
Potential Hazards Risks Effective Control Measures
No Step
Preparation and
Complete a Safe System of Work for Electrical Workers to identify hazards/risk and implement control
1 accessing the work Unknown Environment
measures
area
A person intending to carry out electrical testing and fault-finding is entitled and, indeed, obliged to
determine the need for a safety observer. A safety observer must have current LV rescue and resuscitation
accreditation (12 monthly)
If unsure of test procedure STOP and discuss with team leader or supervisor.
Check against drawings. Check that you are working on the correct panel / equipment and that you are
familiar with the circuit operation.
Carry out electrical Check correct electrical PPE is worn in accordance with Electrical PPE Standard.
work: Electric shock Check that NO conductive jewellery is worn as per QP29.29
Electricity (LV)
2 - Fault Finding Arc fault injuries At all times personnel must not allow any portion of their body or any movable object to come within
Faulty Test Equipment 500mm of the exposed conductors unless expressly for the purpose of placing the test probes.
- Testing
Use only the correct Category (Cat) rated test equipment (Cat III minimum), ensure the test equipment is in
good condition and the correct range is selected.
Test the function of the test equipment before and immediately after use.
Check that correctly rated test leads are firmly attached to test equipment and are in good condition.
Check for both AC and DC voltages.
If neutral conductors are involved in the work, ensure you retest after any disconnection.
Task to stop if new uncontrolled risk is identified.
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Supervisor: Name: Signature: Date:
The undersigned have read, understood and agree to abide by this JSEA/Risk Assessment
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Appendix 2 – Risk Assessment for testing and Fault Finding
Risk
Job Description: Low voltage electrical testing and fault finding
assessment
In accordance with the minimum electrical PPE clothing requirements outlined in the SIMEC Mining / Liberty OneSteel
Required PPE: Whyalla Electrical Safety Manual OST-OHS-ELEC-PRO-001
Gloves – Class 0 insulated 21.5 cal/cm2 arc fault rated minimum
Multi-meters, Electronic test equipment and test leads of appropriate Category Rating, minimum Cat III at the voltage in
Special Equipment / Tools / Materials
question.
(including Chemicals):
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Low voltage electrical testing for testing and fault finding risk assessment
Risk assessment Risk Assessment
Applicable Current controls Future controls Overall
Hazard Description Current Controls/Comments Proposed Control measures
Ranking
Yes No C L R C L R
Improved PPE, specifically
gloves (arc fault rated)
Confirm compliance to site
PPE, equipment design, site
safety policies and procedures
Arc fault risk from IP0X electrical safety policies and procedures,
equipment Yes trained and competent electrical 3 2 5 Confirm training and 3 1 4 4
competency
workers
Confirm correct test equip
Testing & fault finding JSEA
Safety observer
Improved PPE, specifically
gloves (arc fault rated)
Confirm compliance to site
PPE, equipment design, site safety policies and procedures
Arc fault risk from IP2X electrical safety policies and procedures, Confirm training and
equipment Yes trained and competent electrical 3 2 5 competency 3 1 4 4
workers Confirm correct test equip
Testing & fault finding JSEA
Safety observer dependant on
SSOW
Improved PPE, insulated
gloves
Confirm compliance to site
safety policies and procedures,
PPE, equipment design, site specifically the “no electrical
Exposed (not IP2X) energised
safety policies and procedures, work within 500mm of exposed
electrical equipment resulting in Yes trained and competent electrical 2 1 3 live electrical equipment “rule. 2 1 3 3
electric shock
workers Confirm training and
competency
Confirm correct test equip
Testing & fault finding JSEA
Safety observer
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Low voltage electrical testing for testing and fault finding risk assessment
Risk assessment Risk Assessment
Applicable Current controls Future controls Overall
Hazard Description Current Controls/Comments Proposed Control measures
Ranking
Yes No C L R C L R
Isolate motions, or
Safety observer in constant
equipment design, site safety contact with worker and
Moving machinery or equipment
(cranes) Yes policies and procedures, trained 2 2 4 operator and no “line of fire” 2 1 3 3
and competent electrical workers hazards
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References
Facilitator: Daniel Schmidt Occupation: Manager Safety Whyalla Steelworks Signature: Date:
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Appendix 3 – SIMEC Mining / Liberty OneSteel Whyalla switchroom audit
See Document WHY.OST.ELEC.PRO.001 Append 3 in the document control system (Intelex) under Engineering/Electrical Services/Manuals
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Appendix 4 - Guide for the minimum PPE requirements for arc fault protection while testing and fault finding on energised LV electrical equipment
Area 5- DB's
PPE level 3
Area 6- Control panels
PPE level 3
For definitions see the Electrical Safety Manual Area 1 – 400V distribution Area 2 - Crane SWRM Area 3 - Open MCC
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