ELECTRICAL SAFETY MANUAL WHYALLA (Part 3) - … Safety Manual ... Job Safety Analysis (JSA) ... WI37.EIC.086 Procedure to Initiate and Control Excavation and Piling work

Electrical Safety Manual

Document: QM37.02 WHY-OST-ELEC-PRO-001- Version: 6.0

Authorised By: OneSteel Whyalla ESN Date Reviewed: 14/03/2017

OneSteel WHYALLA Intranet version is the only controlled version Page 1 of 42

ELECTRICAL SAFETY MANUAL

WHYALLA (Part 3)





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 ............................................................... 16

3.7.2 Training for Electrical Competency .................................................................................... 17 3.7.3 Supervision of Apprentices .................................................................................................. 18

3.8 Plumbing Installations ......................................................................................................... 19

3.9 ‘Certificate of Compliance’ and Testing results .................................................................. 20

3.10 SAFE SYSTEM OF WORK (SSoW) .................................................................................. 21

3.10.1 When a SAFE SYSTEM OF WORK (SSOW) is required ..................................................... 21

3.10.2 Emergencies ......................................................................................................................... 22

3.11 Electrical PPE ...................................................................................................................... 26

3.11.1 Whyalla Standard PPE / Dress for Electrical Work ............................................................ 27

3.12 Working Safetly Near Overhead Powerlines/collectors ...................................................... 29

3.13 Electrical Switchroom Entry Requirements......................................................................... 33

Appendix 1 - Job Safety Analysis (JSA) for testing and fault finding ...................................................... 34 Appendix 2 – Risk Assessment for testing and Fault Finding .................................................................. 37

Appendix 3 - Arrium switchroom audit .................................................................................................... 41

Appendix 4 - Guide for the minimum PPE requirements for arc fault protection while testing and fault

finding on energised LV electrical equipment……………………….………………………...42





1 REFER TO ELECTRICAL SAFETY MANUAL PT-1(OST-OHS-ELEC-PRO-

001)

2 REFER TO ELECTRICAL SAFETY MANUAL PT-2(OST-OHS-ELEC-PRO-

001)

3 PART 3 – SITE SPECIFIC – WHYALLA

3.1 ELECTRICAL SAFETY EQUIPMENT

Equipment Details Reference Supply

Barrier/ screen Use with open panels (refer 1.6.14.1 sketch 1) 1.6.14 Various

Breathing Apparatus Various to suit application 1.2.4 Various

Face Shield Replacement faceshield

Replacement bracket

Replacement chin guard

Storage bag

Order the components to build the face shield

1.6.3 55104163

55104164

55104165

55104166

Balaclava Arc fault rated 1.6.3 55087267

Forms Reporting shock to Office of Energy

COC Certificate of Compliance for Elect Work

1.2.5,

1.4.5

Electrical Inspector

SA Regulator

Gloves: Insulating and heat resisting

Ins- 4,000 V working (20,000v test) to AS2225

Ins- 1000 V working (2,500v test) to IEC 903, 21.6 cal/cm2

Size 7

Size 8

Size 9

Size 10

Size 11

Cotton Inner (absorbs perspiration) suit above

Leather outer over insulating

Size 8

Size 9

Size 10

Size 11

Lightweight leather gloves, for general elect use

Ansell powerflex, 12 cal/cm2 rated „Ninja‟

Size 8

Size 9

Size 10

Size 11

3.11.1 55046969

55120621

55120622

55120623

55120624

55120625

55050119

55086750

55086752

55086754

55086758

53155690

55080756

55078174

55078175

55078176

Helmet Light PRIMUS Focus+K2 LED Light Standard for electrical work 55066737

Labels RCD Protected stickers

Test Before You Touch stickers

1.8.3

1.5.8

Special order

Dtls QM37.01





Mats and Covers - Insulating

Ins Cover: 1500 x 1200 x 2mm to AS4204.

Ins Mat 915mm wide x 6mm AS2978 class A:

- 1m length

- 2m length

- 3m length

- 4m length

- 5m length

- 6m length

1.6.13

1.6.14

55047129

55048324

55048323

55048322

55048321

55048320

55048319

Lock, Personal Red 1.5.1 54001609

Multimeter All new multimeters purchased from July 2015 shall be Cat IV at 600V minimum

1.7.2 Current electrical supplier

Rescue kit In switchrooms 1.6.5 54033863

Signs, Safety Safety signs, (Prohibition, Mandatory, Warning, Danger, Emergency information and Fire signs)

1.11.3 Special order

Tape, Barricade Black/Yellow Warning/Caution

Red/White Danger

Blue/Yellow Commissioning

51683176

51683140

51683164

Tape, U/ground Orange “Caution Cable Below” 150mm x 360m 1.6.2 51683206

Test tags Refer to Work Instruction WI37.EIC.084 1.7.5 WI37.06.001

Warning Tags Black/yellow 55032365

Welding VRD‟s Limits open circuit voltage from welding m/c 1.14 Order or Hire





3.2 ACCIDENTS & EMERGENCIES (WHYALLA)

#1 Raise the alarm and contact emergency personnel. Do not hang up but remain calm and give all details.

4000 on internal or 8640 4000 on external / mobile phones #2 Keep well clear of live conductors to avoid risk of electric shock form „step‟ or

„touch‟ potential..

DO NOT BECOME THE NEXT VICTIM #3 Switch off power supply where practical.

If power cannot be immediately isolated and victim is unconscious or unable to move, assess the accident site for hazards, take precautions against becoming a victim yourself and:

High Voltage, or if not sure: Do not rescue until voltage source has been isolated and verified.

Low Voltage, eg 240/415 volts: Move victim from danger using insulated rescue crook or dry non conductor eg clothing, wood, clean rope or sheet. Do not touch the victim‟s skin or use anything metallic or moist.

#4 Resuscitate unconscious electric shock victim. (Refer 1.2.6)

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. Delayed effects of electrical shock can be severe, including internal organ damage from inhaling hot arc products. Common direct and indirect effects are muscle pain, burns, eye damage from arc flash or injuries from a fall.

Make safe the installation causing the electric shock but do not interfere with it unnecessarily as to prevent a proper investigation of the accident. Report electric shock as soon as practical to OneSteel and the Technical Regulator.

#5 Stay in the machine (vehicle, excavator, crane, etc) if it contacts live conductors to avoid risk of electric shock. Move machine clear if possible, to break contact with the live conductor. 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.





#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. Keep others clear until trained and authorised personnel arrive. Do not fight fires on HV equipment. Report the fire and wait. 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.

3.2.1 Reporting Incidents / Accidents

Report all electric shock and incidents to your supervisor immediately. The supervisor shall report the shock/incident to the OneSteel Electrical Inspector as soon as possible or, in his absence or outside normal hours the Electrical Flying Squad who will assist as required to conduct the incident investigation as per WI37-CEN-009 Report to the Technical Regulator, to be completed by the Electrical Inspector Immediately by phone for accidents involving death. Within one working day when the victim requires medical assistance. Within 10 working days for other cases. Report to Safework SA It is the Plant Managers responsibility to communicate with the SafeWork SA office in case of electric shocks or significant electrical incident.





3.3 POLICIES, QUALITY PROCEDURES, WORK INSTRUCTIONS & REFERENCE LISTS

OneSteel 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.

Note that all applicable standards are not necessarily listed.

OneSteel WHYALLA

MM - Management Manuals

MM31.01 Site Contract Management Manual

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

WI31.119 Safe system of work process

WI37.IEC.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

WI37.07.004 Demolition of Electrical Equipment





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)

Other Standards, Regulations and Publications

AS2225 Insulating gloves for electrical purposes

SA Work Health and Safety) Act 2012 & Regulations 2012

Safe Work Australia Managing Electrical Risks in the Workplace, Code of Practice

SA Electricity Act 1996 and Regulations under the Act 2012

SA Plumbers, Gasfitters and Electricians Act 1995 and Regulations

SA Electrical Products Act 2000 and Regulations





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.

Does the electrical equipment

need to be isolated to perform the work

safely?

Can the work be rescheduled so

that it may then be isolated?

Can barriers be installed satisfactorily?

Can the risk be controlled by the

use of safety equipment , PPE or a safety observer

?

Can it be isolated

safely at this time?

Work cannot be carried out energised

Risk assessment determines the need

for risk control Work request

Implement safe working procedures for the work being

carried out

Reschedule work

Carry out work

2

5

6 Isolate and make safe

1

3

4

7

8

9 10

Clauses refer to AS4836 . Margin

numbers are referenced in the

check list following this chart.

Yes No





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.

* Check list item number plus chart pg 1 margin reference number.

Ref* Hazards check Item

- or ? Action/procedure to control risk

1. No High Voltage is present. If refer work to HV group. (HV Safety

Manual QM37.03).

2. No work on overhead power lines is involved. If refer work to HV group (HV Safety

Manual QM37.03).

3. All planned changes have been approved. QP02.05. Use Modification control procedure.

4. Dept. hazard prompts, safety analysis etc have been done & considered in the Safe Work Procedure. Electrical Safety Manual

5. 1,2 Isolation & Test before touch principles are key considerations in the Safe Work Procedure..

6. 1,2 Stored energy (capacitors etc) & dual supplies are considered..

7. 1,9 Tools, swarf etc cannot slip or fall & cause an arc between parts at different potential. active-active, active-

neutral or active-earth.

8. 1,4,9 Only conductors at the same voltage are worked on at one time. AS4836.

9. 1,4,9 No live exposed conductors within 500mm of workers. If use insulating barriers, mats, covers, gloves or

tools.

10. 1,4,9 No live conductors in adjoining compartments. If

isolate adjoining compartments or ensure that the work will not contact them or cause other contact.

11. 1,4,9 No live exposed conductors with potential dangerous arc fault within work area. If use, in addition to above,

determine arc fault risk and apply appropriate PPE.

12. 1,4,9 No live conductors with potential dangerous arc fault in adjoining compartments. If isolate adjoining

compartments or ensure that penetrations, swarf or movement will not cause an arcing fault in them.

13. 7 No work done on live conductors, insulating tools are not needed AS4836.

OR if insulating tools are needed/used they have been maintained and tested. AS4836.

14. 7,9 Standard PPE, body, head, eye protection, is used during work. AS4836.

15. 7,9 Class O insulating gloves are used for shock risk.

16. 7,9 Non-flammable gloves are used for arc risk





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 (OneSteel 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:

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________





3.5 WORKING ON OR NEAR ELECT. EQUIP. & SERVICES

This Authority is only valid when completed, signed and dated. Attach risk assessment*, hazard prompts and other relevant records. (based on AS4836). Application date Work to be done date Plant Substation/ switchroom Circuit Reason why plant/ equipment cannot be isolated:

In the attached risk assessment, you MUST be able to answer „go‟ () to all the questions and possible hazards referenced if permission is to be obtained for live electrical work on Low Voltage. If „no go‟ () appears, preventative or contingent actions must be put in place.

Persons to be involved in risk assessment:

Name Signature Date

Persons undertaking live electrical work: I have participated in the risk assessment and agree to implement the required hazard controls.

Name Signature Date

Person/s undertaking observer role: I have participated in the risk assessment and agree to implement the required hazards controls.

Name Signature Date

Authority to work on live Low Voltage conductors: I am satisfied that the above live work is necessary and approve the hazard controls to be used.

Plant Elect Supervisor: print ........................................ sign ..................................... date ..........................

Electrical Inspector: print ........................................ sign ..................................... date ..........................

Plant: Manager/ Deputy: print ........................................ sign ..................................... date ..........................





3.6 CONSTRUCTION SITE ELECTRICAL EQUIPMENT

Regulatory requirements:

Typical Construction site electrical equipment requirements: 1. Supply from permanent power or from Portable generator to AS2790 & AS3010.1.

2. Construction wiring installed/removed by registered electrical worker.

3. Power and lighting from circuit with overload and max 30mA RCD protection. 4. Regularly test equipment including wiring, boards, RCD‟s. 5. Extension cords heavy duty, limited length, protected against damage. 6. Portable multi outlet boxes (AS3439.4). 7. Multiphase outlets connected so that all have the same phase sequence. 8. Dist switchboard for Construction Site (AS3012, AS3439.4):

Robust, corrosion resistant construction to suit site and minimum IP43 rated. Securely attached to pole, post or wall or of stable, freestanding design.

Boards, if more than one on site, should be distinguished by numbers/letters.

Provide means for anchoring cords. Labels as specified.

PROTECTED

RCD

Label: “Anchor cables on bar before plugging into sockets”

Guide for suitable arrangement of power dist. for Construction sites AS3439

Overload and RCD protection

Power outlets

Cable anchoring bar

Front view Section view

Cords supported over walkways etc.

Cords protected from damage.

Cable anchoring bar

O/l protection

Power outlets

Single phase 800 Three phase 950

Inner tube 25x25x2 RHS sliding in outer tube

32x32x2 RHS for height adjustment as required.

Braces 30x30x5 angle iron

RCD

Label: “Remove all leads prior to resetting RCD”

75

0

65

0

35

0

Label: “Keep closed Run all leads through

bottom”

„Feet‟ 40x40x5

angle iron





3.7 SA REGULATIONS REQUIREMENTS REGARDING ELECTRICAL APPRENTICES & CADETS WORK

Guide: First / Second Year Electrical Apprentices First year electrical apprentices will undertake basic trade skill training outside of OneSteel in the practical, theoretical and safety aspects of the electrical trade. A first or second year electrical apprentice may be engaged with direct supervision (for definition refer to 3.8.3), provided the Electrical Supervisor considers them to be competent in the work to be done, including knowledge of the hazards, safety procedures and use of appropriate safeguards.

1) Use of test equipment for proving low voltage electrical equipment de-energised.

2) Maintenance and testing after equipment is isolated and appropriately safeguarded from all energy sources.

3) Access to and work on moving equipment such as overhead travelling cranes and crane runways, furnace chargers, coke ovens machines, etc.

4) Maintenance on High Voltage electrical equipment only in accordance with business units High Voltage Rules requirements.

5) Any other task for which they are considered competent, e.g. testing and repair of lighting circuits.

Guide: Third Year Electrical Apprentices A Third year electrical apprentice may be engaged as follows with direct or general supervision (for definition refer to 3.8.3), providing the Electrical Supervisor considers them to be competence in the work to be done, including the knowledge of the hazards, safety procedures and the use of appropriate safeguards.

1) As permitted for a first and second year apprentice.

2) Any other task for which they are considered competent.

Guide: Forth Year Electrical Apprentices





A Fourth year electrical apprentice may be engaged as follows with general supervision (for definition refer to 3.8.3), providing the Electrical Supervisor considers them to be competent in the work to be done, including the knowledge of the hazards, safety procedures and the use of appropriate safeguards.

1) As permitted for a third year apprentice.

2) Any other task for which they are considered competent.





Apprentices working on Moving Equipment

An apprentice may be permitted to work on moving equipment for example, overhead travelling cranes and crane runways, furnace chargers, coke ovens machines or rolling mills tilting tables provided that access to the moving equipment, use of test equipment for proving low voltage electrical equipment de-energised and maintenance and testing shall be carried out under:

1) Direct supervision; or

2) General supervision if the Apprentice has reached the final year of an apprenticeship, and is considered competent by the electrical supervisor for the work to be performed.

3.7.1 Qualified but inexperienced Electrical Personnel

Inexperienced electrical personnel such as Engineering vocational students, new Cadets and some recently graduated Engineers shall be inducted and trained before allocation to a OneSteel department. Any work involving High Voltage shall be as specified by business unit‟s High Voltage Rules. The supervisor should be aware they are inexperienced, despite academic qualifications. Their industrial experience may be less that that of a first year Electrical Apprentice:

They shall notify the area Electrical Supervisor of their presence on the plant and the activity they intend to undertake. If not, the assignment shall be terminated.

✖ They are not permitted to independently undertake work on live plant electrical circuits. This shall only be undertaken by a plant electrician or under direct supervision of experienced Electrical Engineer or unrestricted licensed Electrician.

✖ If an area Electrical Supervisor is uncomfortable with assignment, permission should not be given and the matter referred to relevant Engineering Manager or Superintendent who shall assign an experienced Electrical Engineer or Electrical Supervisor to evaluate work performance and methods. Regular contact with this Supervisor is required to identify any further training requirements or discipline needed to ensure the safety of the worker.





3.7.2 Training for Electrical Competency

OneSteel is committed to achieving the highest performance in Workplace Health and Safety by achieving the maintaining a high level of basic competency, and the highest level of electrical safety awareness of people working in the Electrical Craft.





3.7.3 Supervision of Apprentices

The degree of supervision requires continual assessment of the apprentices experience and competence and nature of the task. Supervision can vary from direct to general.

Direct Supervision: The personal supervision of a worker, at all times, on a direct and constant basis, within visual contact and/or earshot.

General Supervision: Does not require constant attendance of supervisor, but requires the personal contact with a registered electrical worker on at least a daily basis when working on electrical equipment.

Conditions for the employer of apprentices.

Ensure that supervision is by a person registered to carry out the work in question without supervision.

Consider the kind of electrical work, especially with regard to whether live parts are worked on or are in the vicinity of the work.

Have regard to the level of competence of the person to be supervised; and

Ensure that where apprentices are working in vicinity of live parts, a registered electrical worker is close, in sight of and can communicate directly with apprentice.





3.8 PLUMBING INSTALLATIONS

Dangerous situations can be created if plumbing equipment is rewired incorrectly. Some OneSteel installations have complex circuits.

The disconnection and reconnection of electrical components and any re-wiring of plumbing installations with fixed wiring on OneSteel site shall only be done by a suitably qualified Electrician and not a worker with a restricted Electrical Licence. Those working on plumbing installations shall comply with the work scope, the issued ATW and OneSteel electrical work requirements. General plumbing work: Workers can be at risk of electric shock during routine work such as cutting water pipes if there is a faulty installation. Pipes should be bridged across with cable connected insulated clamps such as „jumper leads‟ before cutting. OneSteel site installation with fixed wiring: The isolation and electrical work shall be arranged through the Electrical Supervisor who shall ensure that a suitably qualified Electrician does the electrical work. Plumbers with restricted Electrical Licenses are not permitted to disconnect / reconnect the electrical components or do any wiring changes. Outside OneSteel site (e.g. OneSteel 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 OneSteel 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. Plumbing installations supplied with 240 volt socket outlet: A plumber with a restricted Electrical License may switch off and remove plug from outlet and then undertake repairs on the unit. The unit shall be inspected / tested / tagged by an Electrician before it may be re-installed by the Plumber.





3.9 „CERTIFICATE OF COMPLIANCE‟ AND TESTING RESULTS

For all electrical work requiring inspecting / testing a Certificate of Compliance form shall be accurately completed. This includes the disconnection or reconnection of fixed wiring. Information to include measured test required by AS3000 and the measured results, e.g. earthing resistance, insulation resistance and fault loop impedance, signed by the appropriate licenced electrical worker. The tradeperson completing the Certificate of Compliance shall ensure that;

Section “A” contains an accurate description of the work that has been completed.

Section “B” is the defect list of non-compliant issues that have been identified but were not part of the tradeperson‟s work. It is mandatory to fill in this section. If no defects have been observed than simply write “No Defects Observed”.

For OneSteel departments where supervision exists, a SAP notification shall be raised to include the defects requiring to be repaired. Consideration should be given for the larger type issues whether they should also be entered into the departmental Hazard Register. The tradesperson should consult his/her supervisor. Retention period for Certificates of Compliance shall be 5 years for contractors and OneSteel departments. The Electrical Supervisor shall ensure that the earthing system resistance value is maintained over time. Distribution of Certificate of Compliance copies shall be as follows:

Owner‟s or Occupiers copy Electrical Inspectrate

Network Operators copy Plant owner or electrical supervisor

Contractors copy Kept in the electricians book





3.10 SAFE SYSTEM OF WORK (SSOW)

At OneSteel Whyalla all work undertaken by maintenance personnel shall be conducted in accordance with the hazard identification and control requirements detailed in QP29.13 Safety Risk Management. QP29.13 details how the three methods of risk management, mental take 2, hazard prompt and SSOW, are to be used. Training in the usage of QP29.13 is available and every new starter in maintenance and engineering organisations at 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 OneSteel Whyalla intranet Occupational Heath & Safety website and download QP29.13 attachment 4.5 or 4.6.

3.10.1 Minimum SAFE SYSTEM OF WORK Requirements

Electrical function Take 2, Written Hazard Prompt or

SSOW from QP29.13

Faultfinding - Investigation (refer definition) Hazard Prompt

Faultfinding - Electrical Testing (refer definition)

SSOW

Electrical Work (refer definition) SSOW

Isolating (open panels) Hazard Prompt

Isolating (enclosed panels) Take 2

Isolation verification via contact testing SSOW

When within 500mm of live open panels SSOW





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





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





EXAMPLE ONLY

Example of Whyalla’s SSoW, QP29.13

(side 2) REFER TO QP29.13

ATTACHMENT 4.6





3.11 ELECTRICAL PPE

Standard Electrical PPE

Indura Ultra Soft shirt and trouser. ATPV (cal/ cm2) rating of 8.7 for the shirt and ATPV (cal/ cm2) rati ng of 8.7 for the trousers, This PPE is suitable for arc fault protection during general electrical work.

Alternate Standa rd Electrical PPE

Indura Ultra Soft overalls. ATPV (cal/cm2) rating of 12.4. This PPE is suitable for arc fault protection duri ng general electrical work.

Switching PPE

Indura Ultra Soft Switching Coat over either of the combinations above plus Indur a Ultra Soft balaclava, arc flash rated face shield and HV gloves. Total ATPV (cal/cm2) rating of 51.5. This PPE is suitable for most high energy switching operations.

One Steel Whyalla

Arc Flash rated PPE for

Electrical Workers

A recent arc flash incident at Steelmaking and incidents outside of OneSteel have highlighted that cotton drill PPE is not an effective barrier under arc fault conditions.

To ensure the safety of our Electrical workers the Indura Ultra Soft range of arc fault rated clothing is available from the PPE. catalog

A full hood is required for HV switching





3.11.1 Whyalla Standard PPE / Dress for Electrical Work

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. Minimum PPE / Dress for Electrical Work The standard described below is to be implemented in OneSteel Whyalla by August 2010. 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.

High-risk electrical work For HV work and work with a high risk of arc-fault a switching coat made from Indura Ultra material shall be worn (refer to table in this section). The switching coat when worn over the minimum electrical PPE attire will offer a combined APTV of 51.5cal/cm2. The coat shall be worn with the approved electrical full-face shield and approved electrical balaklava. Note that a full hood is required for HV switching operations.





PPE for tasks with increased risk of shock or arcing Some electrical tasks at OneSteel sites have an increased risk due to the nature and age of the plant and the presence of some uninsulated equipment.

Task example and PPE additional to minimum

Insu

latin

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Non

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at

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Full

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ield

5

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itch

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d 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

1. To minimise non-electrical personnel need to enter electrical switchrooms isolation boards should be located outside the switchrooms where practical.

2. Non-electrical worker not permitted to work at rear of open panel, unless authorised by Electrical Supervisor.

3. Insulating gloves to AS2225 or IEC903. Minimum rating – Class O (1000V working) and ATPV 21.6 cal/cm2, . Leather over glove to be used when the insulated glove may be damaged by the task

4. Insulating mat (personal) for additional risk control for electric shock. To AS2798 or AS4202.

5. Approved full-face shield with balaclava: (face shield is to have no metal rim for control of arc risk and shall be OneSteel standard Uvex arc rated faceshield). A full hood is required for HV switching

6. Switching coat shall be Indura Ultra Soft type and when worn over the standard electrical PPE give a minimum APTV rating of 51.5cal/cm2.





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.

















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. Preference is that only electrical personnel enter switchrooms. Electrical personnel have been issued with special clothing to limit their expose to electrical energy in the form of arc flash. Entry into switchrooms to undertake lock-out.

It is highly preferred that lock-out for non-electrical work is undertaken at plant based local field isolator/s. If this is not suitable for the proposed task, lockout should be undertaken on a lock-out board located outside the electrical switchroom

Isolation of switchroom isolator/s should be undertaken by electrical personnel, even for simple isolation/s.

Only non-electrical personnel who have been trained, assessed competent and approved to undertake isolation and verification within a switchroom by their Plant Manager can undertake plant isolation within switchrooms.





Appendix 1 - Job Safety Analysis (JSA) for testing and fault finding

Department / Location Whyalla Steelworks

Job Description: Risk assessment & JSA

Low voltage electrical testing and fault finding

Required PPE: In accordance with the minimum electrical PPE clothing requirements outlined in the OneSteel Electrical Safety Manual OST-OHS-ELEC-PRO-001 Gloves – Class 0 insulated 21.5 cal/cm2 arc fault rated minimum

Special Equipment / Tools / Materials (including Chemicals):

Multi-meters, Electronic test equipment and test leads of appropriate Category Rating, minimum Cat III at the voltage in question.

JSA Developed by: Scott Fisher, Peter Engelke, Whyalla ESN

Signature: Date:

JSA Authorised by: Peter Rostig Signature: Date:





Step No

Description of Job Step

Potential Hazards

Risks Effective Control Measures

1 Preparation and accessing the work area

Unknown Environment

Complete a Safe System of Work for Electrical Workers to identify hazards/risk and implement control measures

2

Carry out electrical work:

- Fault Finding

- Testing

Electricity (LV)

Faulty Test Equipment

Electric shock

Arc fault injuries

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.

Check correct electrical PPE is worn in accordance with Electrical PPE Standard.

Check that NO conductive jewellery is worn as per QP29.29

At all times personnel must not allow any portion of their body or any movable object to come within 500mm of the exposed conductors unless expressly for the purpose of placing the test probes.

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.

Task to be completed / System to be in place: Task Supervisor

Workers are authorised to use contact test equipment on energised LV. (Licensed Electrician or authorised Apprentice‟s only)

Workers are trained and competent to do this task

Observers have completed CPR & LV Rescue training within the last year

Workers have completed the required local safety inductions, and their induction status is current





Supervisor: Name: Signature: Date:

Other Permits / Clearances / Documents: (e.g. Isolations, MSDS‟, etc.)

The undersigned have read, understood and agree to abide by this JSEA/Risk Assessment

Name

Sign

Date

Name

Sign

Date





Appendix 2 – Risk Assessment for testing and Fault Finding

Department / Location Whyalla Steelworks

Job Description: Risk assessment

Low voltage electrical testing and fault finding

Required PPE: In accordance with the minimum electrical PPE clothing requirements outlined in the OneSteel Electrical Safety Manual OST-OHS-ELEC-PRO-001 Gloves – Class 0 insulated 21.5 cal/cm2 arc fault rated minimum

Special Equipment / Tools / Materials (including Chemicals):

Multi-meters, Electronic test equipment and test leads of appropriate Category Rating, minimum Cat III at the voltage in question.





Low voltage electrical testing for testing and fault finding risk assessment

Hazard Description Applicable

Current Controls/Comments

Risk assessment Current controls Proposed Control measures

Risk Assessment Future controls Overall

Ranking Yes No C L R C L R

Arc fault risk from IP0X electrical equipment Yes

PPE, equipment design, site safety policies and procedures, trained and competent electrical workers

3 2 5

Improved PPE, specifically gloves (arc fault rated) Confirm compliance to site safety policies and procedures Confirm training and competency Confirm correct test equip Testing & fault finding JSEA Safety observer

3 1 4 4

Arc fault risk from IP2X electrical equipment Yes


3 2 5

Improved PPE, specifically gloves (arc fault rated) Confirm compliance to site safety policies and procedures Confirm training and competency Confirm correct test equip Testing & fault finding JSEA Safety observer dependant on SSOW

3 1 4 4

Exposed (not IP2X) energised electrical equipment resulting in electric shock

Yes


2 1 3

Improved PPE, insulated gloves Confirm compliance to site safety policies and procedures, specifically the “no electrical work within 500mm of exposed live electrical equipment “rule. Confirm training and competency Confirm correct test equip Testing & fault finding JSEA Safety observer

2 1 3 3





Low voltage electrical testing for testing and fault finding risk assessment

Hazard Description Applicable

Current Controls/Comments

Risk assessment Current controls Proposed Control measures

Risk Assessment Future controls Overall

Ranking Yes No C L R C L R

Moving machinery or equipment (cranes) Yes

equipment design, site safety policies and procedures, trained and competent electrical workers

2 2 4

Isolate motions, or Safety observer in constant contact with worker and operator and no “line of fire” hazards

2 1 3 3

Wet environment Yes


2 2 4

RCD protection, or Safety observer

2 1 3 3

Responsible person not notified of the work in progress Yes

site safety policies and procedures, trained and competent electrical workers

2 2 4

Responsible person notified, procedure in place to constantly monitor the worker or a safety observer

2 1 3 3

No insulated mat to work from Yes equipment design, site safety policies and procedures 2 2 4

Install insulated mat Safety observer dependant on SSOW

2 1 3 3

Obstructions and limited access to the work area Yes

equipment design, site safety policies and procedures 2 2 4

Safety observer 2 1 3 3

Limited ability to isolate equipment in an emergency Yes equipment design 2 2 4

Safety observer 2 1 3 3





References

SA Work, Health and Safety Regulations 2012

Approved Code of Practice for Managing Electrical Risks in the Workplace

Summary: Testing and fault finding on live LV electrical equipment, which is of IP2X or better construction, in a low risk environment, poses a low risk to the person performing the work and should be conducted using this JSEA.

Testing and fault finding on live LV electrical equipment, which is of IP1X or lower construction as well as being in an environment that is not low risk, poses a risk to the person performing the work. Further risk assessments, hazard controls, safe systems of work and a safety observer are needed.

Risk Assessment Team Team Leader: Peter Rostig

Occupation: Manager Engineering

Signature:

Date:

Facilitator: Daniel Schmidt

Occupation: Manager Safety Whyalla Steelworks

Signature:

Date:

Name: Eric Vines

Occupation: Electrical maintenance leader

Signature:

Date:

Name: Carlos Bravo

Occupation: Electrician

Signature:

Date:

Name: Peter Engelke

Occupation: Electrical inspection officer

Signature:

Date:

Plant owner:

Business Unit Manager:

Assessment period:





Appendix 3 - Arrium switchroom audit

See Document WHY.OST.ELEC.PRO.001 Append 3 in the document control system (Intelex) under Engineering/Electrical Services/Manuals





Appendix 4 - Guide for the minimum PPE requirements for arc fault protection while testing and fault finding on energised LV electrical equipment

For definitions see the Electrical Safety Manual Area 1 – 400V distribution Area 2 - Crane SWRM Area 3 - Open MCC

Area 4 - Enclosed M Area 5 - Distribution board Area 6 - Control panels

Area 1- 400V Distribution

PPE level 1

Area 2 - Crane SWRM

PPE level 2

Area 3- open MCC

PPE level 2

Area 4- Enclosed MCC

PPE level 3

Area 5- DB's

PPE level 3

Area 6- Control panels

PPE level 3

PPE Level PPE

L1 Switching coat + hood + insulated gloves

L2 Standard electrical PPE + insulated gloves + face shield & balaclava

L3 Standard electrical PPE + insulated gloves