370. or 00 fat f21 020 electrical safety procedure

Oman Rolling Mill Project No.: OR-00-FAT-F21-020

Contract for Rolling Mill Plant in Sohar Rev: 00

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Electrical Safety Procedure Date: 01/11/2011

OR-00-FAT-F21-020

ELECTRICAL SAFETY PROCEDURE

00 01/11/2011 K. Lamb M.J. Dunn K. Feldmann First issue

Rev. Date Prepared Checked Approved Description



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Table of Contents

1.0 Purpose

2.0 Scope

3.0 Responsibilities

3.1 Site Manager

3.2 Appointed Person (Electrician)

3.3 Vendors/Subcontractors

3.4 Site HSE Manager

3.5 Employees

4.0 Electrical Systems

4.1 Testing of Temporary Electrical Installations

4.2 Use of Reduced Voltage Electrical Tools and Equipment

4.3 Security of Electrical Installations

4.4 Protection of Electrical Cable

4.5 Electrical Connections

5.0 Inspections

5.1 Testing

5.2 Portable Electrical Hand Tools

6.0 Safe Working Methods

6.1 Lockout and Tagout

6.2 Permit to Work

7.0 Working Near Overhead Power Lines

8.0 Underground Services

8.1 Use of Cable and Pipe Locators

8.2 Sweeping

8.3 Digging Mechanical or manual

8.4 Exposure and Protection

8.5 Reporting Damage

9.0 Working In Confined Spaces

9.1 Use of Low Voltage Electrical Equipment

9.2 Grounding/Earthing Requirements

10.0 Forms/Reports

11.0 Records



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1.0 PURPOSE

To ensure that a standard approach is taken in the control and management of the temporary electrical systems used on the project by FATA Gulf.

2.0 SCOPE

This section covers the safety of temporary electrical installations on the project as well as the use of electrical tools and equipment. FATA Gulf is responsible for ensuring the safety of all temporary electrical installations and for ensuring the risks associated with using electrical tools and equipment is kept as low as possible. This procedure is mandatory and applies to all construction projects being undertaken by FATA Gulf.

3.0 RESPONSIBILITIES

3.1 Site Manager

The Site Manager shall ensure that all electrical systems at the work site are managed in a safe manner. In order to ensure that this procedure is followed he shall appoint competent Electricians to carryout work on electrical systems.

3.2 Appointed Person (Electrician)

The appointed person (Electrician) shall be responsible for the application of this procedure and ensuring that all electrical systems are inspected periodically and all electrical systems are maintained in good working order. All persons employed as electricians must be competent and be in the possession of a recognised electrical qualification. FATA Gulf will ensure that any persons working on electrical installations including temporary electrics are competent.

3.3 Vendors/Subcontractors

Vendors/Subcontractors shall be responsible for implementing this procedure and ensuring that all necessary steps are taken to protect the workforce and other person(s) who may be working in the vicinity.

3.4 Site HSE Manager

The Site HSE Manager shall assist the Site Manager in the implementation of this procedure and provide the necessary Health & Safety advice to ensure compliance. 3.5 Employees

Use portable electrical equipment only for the purpose it has been provided and in accordance with any information, instruction or training received. Carry out pre-use visual checks of portable electrical equipment (including when issued new equipment) as outlined in 5.2.1. Immediately report to their Supervisor/Foreman any fault or defect to portable electrical equipment or if they notice that a test record (label) is out-of date. [Note: If there is safety concerns cease use and immediately disconnect the equipment from the power source.]



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4.0 ELECTRICAL SYSTEMS

4.1 Testing of Temporary Electrical Installations

Vendors/Subcontractors will ensure that all temporary electrical installations are tested by a competent electrician and that a certificate is issued for each distribution board. A copy of the certificate shall be held in a plastic wallet and fixed to the distribution board so that it is easily available for inspection. All temporary electrical installations must be earthed and the resistance of the earthing must be checked to ensure it meets the level required under electrical safety guidelines from the generator manufacturer or local mains supplier in the case of mains supply. In the absence of any guidance from the generator manufacturer the earth rod shall be driven to a depth so that it penetrates the summer water table by 2 metres and the resistance of any point in the earth continuity system does not exceed 0.5 ohms.

4.2 Use of Reduced Voltage Electrical Tools and Equipment

Vendors/Subcontractor will ensure that all electrical hand tools and machinery such as circular saws operate at 110v through a step down transformer. All 110v leads connected to the transformer and run across site are to be Yellow in colour. The only exception allowed will be where certain tools or machinery are not available in the reduced voltage. In this case where 230v or greater are used a Residual Current Device (RCD) must be fitted with a 30mA trip. The requirement for the use of 110v shall also extend to temporary lighting.

4.3 Security of Electrical Installations

Vendors/Subcontractor will ensure that all electrical installations are secured. Distribution boards must be locked shut and under no circumstances shall live conductors be exposed where workers could accidentally come into contact with them. Clear warning signage must be displayed on all electrical installations and only competent electricians are to have access to distribution boards.

4.4 Protection of Electrical Cable

Vendors/Subcontractor will ensure that all electrical cables running from a generator to the distribution board are mechanically protected. The preferred method will be the use of steel wire armoured (SWA) cable to ensure that the risk of electric shock from cable damage is greatly reduced. All connections in cables are to be made by a competent electrician and with proprietary connectors under no circumstances are joints to be made using solely electrical tape. Cords, leads and hoses shall be kept at least 2.0 meters off the ground or whatever height is necessary to be protected from traffic and prevent tripping hazards. Electrical power and extension cords and welding cables/leads and hoses shall not be coiled while in use.

4.5 Electrical Connections

Vendors/Subcontractor will ensure that all electrical connections are made using plugs and sockets that meet the requirements of BS4343. These connections should be either the waterproof or splash proof design under no circumstances are domestic 2 or 3 pin plugs or sockets to be used. It is strictly prohibited for bare electrical cable ends to be pushed into electrical sockets in order to make a circuit.

5.0 INSPECTIONS

5.1 Testing

Every installation should be tested in accordance with the IET Regulations at three-monthly intervals or shorter periods if necessary by an electrician. The record of any testing and inspections should be made by a responsible person on the appropriate certificates Testing and inspections must include:

a visual inspection

the continuity of final circuit conductors

the continuity of protective conductors



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the earth electrode resistance

the insulation resistance

polarity

the earth fault loop impedance

the correct operation of residual current

devices and fault voltage operated

protective devices

Weekly inspections should be made of the whole system, including all portable electric tools. Records should also be kept of all these inspections.

5.2 Portable Electrical Hand Tools

An appropriate maintenance system should be established for all portable electrical equipment and should include user checks, regular visual inspections and combined inspection and electrical testing as necessary. It is recommended that all portable and handheld tools should have the following inspection and testing facilities.

User check before use

Visual Weekly Inspection recorded

Combined inspection and test before first use and thereafter three-monthly recorded and colour coded.

5.2.1 Visual Inspection Guidance

Visual inspections are usually the most important components of a portable electrical equipment maintenance regime. The majority of potentially dangerous faults can be picked up by such inspections, which are normally carried out by users themselves and/or periodically by a competent person.

Any visual inspection should critically examine the equipment to check that it appears to be in sound condition and should include any extension leads and associated plugs and sockets. User visual inspections should not include taking any equipment apart. When carrying out a visual inspection ensure the electrical equipment is turned off and check for:

Damage to plugs (e.g. cracked casing or bent pins)

Damage to the external cover/casing of the equipment, loose parts or loose/missing screws

Damage to outer coverings/insulation to leads, wires or cables (apart from light scuffing).

Cable located where it might be subject to damage or forced into a tight bend as it exits equipment.

Inadequate joints, including taped joints in the cable

Burn marks, staining or discoloration that may suggest overheating

Whether the equipment has been subjected to conditions for which it is not suitable, e.g. spillage of fluids or solids, overly dirty or dusty, or excessively contaminated in some other way.

The absence of inappropriate pieces of equipment or foreign objects on or inside the equipment

The formal inspection by a competent electrician (not the user) may also include checking the plug by removing the plug cover, particularly if there are any concerns (not applicable for moulded plugs, where only the fuse can be checked). This would only involve checking the correct fuse for the equipment is in use, the cord grip is effective, the cable terminations are secure and correct (including an earth where appropriate), and that there are no signs of internal damage, overheating or entry of liquid or foreign matter. Further guidance is given in the table and diagram below. Should a visual inspection indicate equipment to be unsafe for use (or reveal the lack of a valid PAT test where required) it should be reported to management and immediately taken out of use (disconnect from the power source and, if necessary, label as faulty and/or disable by removing the plug). This action should be noted on the register and arrangements made for any necessary repair or replacement.



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5.2.2 Inspection & Test Frequencies

Equipment/Application Voltage User Check

Formal Visual Inspection

Combined Inspection &

Test

Battery-operated power tools and torches

Less than 25 volts

No No No

25V Portable hand lamps (confined for damp conditions)

25 volt Secondary winding from transformer

No No No

50V Portable hand lamps Secondary winding centre tapped to earth (25 volt)

No No Yearly

110V Portable and hand-held tools, extension leads, site lighting, moveable wiring systems and associated switchgear

Secondary winding centre tapped to earth (55 volt)

Weekly Monthly Before first use on site, then every 3 months

230V Portable and hand-held tools, extension leads and portable floodlighting

230 volt mains supply through 30mA RCD

Daily/every shift

Weekly Before first use on site and then monthly

230V Equipment such as lifts, hoists and fixed floodlighting

230V Supply fuses or MCBs

Weekly Monthly Before first use on site, then every 3 months

RCDs Fixed** Daily/every shift

Weekly *Before first use on site, then every 3 months

Equipment in Site Offices 230 volt Office Equipment

Monthly 6 Monthly Before first use on site and then yearly

* Note: RCDs need a different range of tests to other portable equipment, and equipment designed to carry out appropriate tests on RCDs will need to be used.

** It is recommended that portable RCDs are tested monthly



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6.0 SAFE WOKING METHODS

6.1 Lockout and Tagout (OR-00-FAT-F21-014)

FATA GULF will ensure that all workers are trained in the correct isolation procedures, including Lockout/Tagout, identification of isolation points using plant drawings, Owners safety requirements and emergency procedures. The safety measures to be implemented for this procedure are:

Identify all energy sources connected with the work.

Disable, redirect, or stop all energy from doing what it normally does.

Confirm that youve reached a zero energy state.

Apply restraint devices to keep the system from starting up while you work on it.

Gravity may cause a mechanical device to drop even though all energy sources have been

disconnected, physically blocking the equipment may be necessary to prevent injury.

Check with staff at industrial sites regarding the necessity of obtaining lock out permits and follow

the plant procedure.

Restraint devices, (chains, locks, scissors, blocking), on mechanical, electrical, and physical

energy sources must be tagged.

Tags indicate who you are, who you work for, what equipment is locked out and when it was

locked out, as well as who to contact in case of emergency.

Construction sites must have formal lockout procedures and permits to identify all energy sources

- trace wiring,

- piping, and

- all lines in and out of the equipment or area.

Refer to drawings, specifications operating manuals etc.

Once each energy source has been identified and de-energized, testing must be performed to

verify a zero energy state.

Lockout can be simple locking out an electrical panel box while installing a stringer of temporary

lighting.

6.2 Permit To Work (OR-00-FAT-F21-012)

Permit To Work systems are essential to ensure safe working and freedom from hazards where high-voltage electrical supplies, cables and equipment exist, particularly in installation, maintenance or construction work. The Permit To Work must only be issued by an appointed and authorised person. They must be signed by an authorised person and by the competent person carrying out the works described on the permit. The authorised person should keep a record of all permits that are issued and cancelled on the project, a copy of all Permit To Work are to be held in the Site HSE Office. Before work starts, the authorised person should ensure that the Permit To Work will cover the making safe from all possible sources of supply. The Site HSE Manager should monitor what permits have been issued and that the permit is being adhered to by the persons who it has been issued to.

Under no circumstances should anyone work on, maintain, repair or otherwise adjust high voltage apparatus except in accordance with the instructions and terms of a formal permit to work.



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7.0 WORKING NEAR OVERHEAD POWER LINES

The local electricity authority should be consulted before any work commences and a safe system of work should be devised and implemented

Practical steps that can be taken to prevent danger from any live cable or apparatus could include the placing of adequate and suitable barriers.

Any ground level barriers should consist of either:

a. A stout post and fence rail. b. A tension wire fence, earthed at both ends, flags on the wires. c. Large steel drums filled with rubble or concrete, placed at frequent levels. d. Substantial timber baulks, to act as wheel stops. There should be a general rule prohibiting the storage of materials in the area between the overhead lines and the ground level barriers. Precautions are necessary even though work in the vicinity of the line may be of short duration.

All work must be carried out under the supervision of a competent person/responsible supervisor who is familiar with the hazards associated and likely to be encountered.

8.0 UNDERGROUND SERVICES

The greatest risk of injury lies in contacting electricity cables. Some people are electrocuted, but the majority suffer burns from the explosive arcing of the damaged cable. Most injuries are caused to persons using pneumatic drills or jackhammers and involve 415-volt cables within 0.5 metres of the surface.

If mobile cranes or excavators are used, the minimum distance from the ground level barrier to the line should be length of jib plus 9 metres if slung on a wooden pole and 15 metres if slung

on a metal post or pylon



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8.1 Use of Cable and Pipe Locators

A wide range of instruments are available for the detection of buried services. Several different principles may be applied in the task of detection and an instrument may incorporate more than one of these:

a. Hum Detection

Virtually all electricity cables give off or radiate a magnetic field while current is actually flowing through them. This magnetic field or hum is usually easy to detect.

b. Radio Frequency

Metal pipes and cables can act like radio and re-broadcast low and very low frequency radio signals, which can be detected.

c. Transmitter and Receiver

A small portable transmitter or signal generator can be connected to a cable or pipe, or so placed very close to it so that the signal is fed into or inducted in the pipe or cable.

d. Metal Detectors

Conventional metal detectors will usually locate flat metal covers, joint boxes, etc, but may miss round cables or pipes.

8.2 Sweeping

It is essential to sweep an area as shown in the diagram below.

8.3 Digging Mechanical or manual Once the approximate location of a service has been identified using all available information, trial holes should be dug carefully by hand, to establish the exact location and depth of the service. Where two holes are dug at intervals, it should not be assumed that the service runs in a straight line between them.

Mechanical excavators and power tools should not be used within 0.5 metres of the indicated line of a service, unless prior agreement on a safe system of work has been reached with the service owner.

Excavations must be supported adequately, especially if more than 1.2 metres deep or dug in poor ground or at a location exposed to traffic vibration or near a building etc.



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8.4 Exposure and Protection When a service is exposed in the bottom of a trench or excavation, it should be protected with suitable timber or other material to prevent it becoming damaged.

A service across a trench or along a trench above the bottom should be supported by slings or props, to avoid unnecessary stresses. If in doubt, consult the service provider. 8.5 Reporting Damage

Any damage to buried services must be reported to the owners. Most damage to the sheath of a cable or to coating on a pipe can result in moisture penetration, corrosion and subsequent failure.

9.0 WORKING IN CONFINED SPACES (OR-00-FAT-F21-013)

9.1 Use of Low Voltage Electrical Equipment

Inside conductive confined spaces, low voltage (24 volt or less) lighting must be used. Cables to be used in confined spaces shall be heavy duty neoprene rubber cables, carefully inspected, to ensure there is no damage or deterioration, by a competent electrician, and installed overhead as much as practicable. Protection shall be given to all cables as they enter into the confined space / vessel to ensure they are not damaged by sharp edges.

9.2 Grounding/Earthing Requirements

Grounding/earthing shall be provided for all electrical equipment. Grounding/earthing cables shall have their continuity and conductivity checked by a competent electrician.

10.0 RECORDS

All records and documentation relating to this procedure shall be maintained at the Site Office by the Site HSE Manager and will be made available for auditing purposes at mutually convenient times.

370. or 00 fat f21 020 electrical safety procedure

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