hazardous areas stanwell power station

8/17/2019 Hazardous Areas Stanwell Power Station

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Business Procedure

WRITTEN BY: ..................................NAME: Peter Cox

ENDORSED/CHECKED BY: ..............................

NAME: James Oliver

APPROVED BY: ....................................

NAME: Brad Perry

DATE: ........

Doc No: HB625195 Revision No: 8 Revision Date: 10.09.2014 Page: 1 of 19

THIS DOCUMENT IS UNCONTROLLED IN HARD COPY FORMAT

Hazardous Areas at Stanwell Power StationDocument Number – HB625195

This document applies to the following sites:

All Sites

Rockhampton Office Brisbane Office Tarong Site

Barron Gorge Hydro PS Kareeya Hydro PS Mica Creek PS

Koombooloomba Hydro PS Swanbank PS Mackay Gas Turbine

Wivenhoe Small Hydro PS Stanwell PS Meandu Mine

Table of Contents

1.0 Purpose ...................................................................................................................................... 2

2.0 Scope ......................................................................................................................................... 2

3.0 Hazardous Area Safe System of Work ...................................................................................... 2

3.1 Controls ...................................................................................................................................... 2

3.1.1 Classification Audits ................................................................................................................... 3

3.1.2 Risk Management ...................................................................................................................... 3

3.1.3 Managing Ignition Sources ......................................................................................................... 4

3.1.4 Competent Design ...................................................................................................................... 5

3.1.5 Authorised Modifications to Plant ............................................................................................... 5

3.1.6 General Hazardous Area Work .................................................................................................. 5

3.1.7 Electrical Work............................................................................................................................ 5

3.1.7.1 Electrical Installation Work ......................................................................................................... 6

3.1.7.2 Maintenance and Repair Work - Electrical ................................................................................. 6

3.1.8 Routine Inspections of Equipment - Electrical............................................................................ 6

3.1.9 Process for Managing Unrated Electrical Equipment................................................................. 7

3.1.10 Regular Auditing ......................................................................................................................... 7

3.1.11 Regular Cleaning ........................................................................................................................ 7

3.1.12 Maintaining a Hazardous Area Verification Dossier ................................................................... 7

3.1.13 Training and Authorisation of Workers ....................................................................................... 8

3.1.14 Maintaining a Hazardous Area Equipment Register .................................................................. 9

3.1.15 Signage ...................................................................................................................................... 9

4.0 Responsibilities........................................................................................................................... 9

4.1 Function Flowchart ................................................................................................................... 11

5.0 Review and Consultation .......................................................................................................... 12

6.0 Communication Plan ................................................................................................................ 12

7.0 References (Including Information Services) ........................................................................... 12


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Doc No: HB625195 Rev: 8 Rev Date: 10.09.2014 Page 2 of 19


8.0 Definitions ................................................................................................................................. 13

9.0 Revision History........................................................................................................................ 15

10.0 Attachments.............................................................................................................................. 16

10.1 Attachment “A” Routine Inspection and Cleaning SD’s ........................................................... 16

10.2 Attachment “B” Managing Electrical Equipment in Hazardous Areas Guide ........................... 17

10.3 Attachment “C” - Approval & Certification Process Required for Electrical Work in HazardousAreas on Entity Works .............................................................................................................. 18

10.4 Attachment “D” - Electrical Maintenance and Repair Flowchart .............................................. 19

1.0 PurposeStanwell Power Station as an operating site within Stanwell Corporation Limited has obligations tocomply with WH&S and Electrical Safety Legislation, AS/NZS standards and codes of practice toestablish and maintain a safe and healthy workplace. The presence of flammable gases andliquids and combustible dust may present a hazard to people, property and the environment.

Legislation places a responsibility on SCL and individuals to exercise a duty when designing,constructing and operating facilities to ensure the safety of people, property and the environment.

SPS will have a documented safe system of work in relation to hazardous areas to ensure theobligations of the Workplace Health and Safety Act and the Electrical Safety Act of Queenslandare met.

2.0 ScopeThis procedure will outline the SPS safe system of work for managing hazards associated withhazardous areas.

• The identification of hazardous areas.

• The identification of associated hazards and risks within the identified hazardous areas, withspecific consideration needs to be given to the non introduction of ignition sources.

• The elimination of the risks where possible, if elimination is not possible, then the hierarchy ofcontrols shall be applied to reduce the risk as far as reasonably practicable.

• The maintenance of control measures.

• The review of the effectiveness of the applied control measures.

This procedure is to be used in conjunction with the Business Strategy – Corporate HazardousArea Management (14/74811).

3.0 Hazardous Area Safe System of Work

3.1 Controls

The following controls exist within the fundamental elements and combine to become the definedsafe system of work that is being used by Stanwell Power Station to minimise the risks withinhazardous areas as far as reasonably practicable:

• Classification Audits

• Risk Management

• Managing Ignition Sources

• Competent Design

• Authorised Modifications to Plant• General Hazardous Area Work


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This graph is a visual representation of the risk carried depending on the controls in place whilst

transitioning to a risk position of as low as reasonably practicable.The red section represents the level of risk associated with compliant electrical equipment andminimal conditions of control to achieve the target risk.

The green section is the risk carried in addition to the target risk when there are increasedconditions of control and non compliant electrical equipment installed in the hazardous areas.

Therefore the level of risk on the left hand side is the current risk (minimised to as far asreasonably practicable) and the level of risk on the right hand side is the target risk.

During the transition from current risk to target risk two key elements need to be in place.

1. Increased controls such as high frequency cleaning, high frequency inspections and externalauditing of controls;

2. A process to replace unrated electrical equipment with properly compliant equipment as soon

as practicable.

3.1.3 Managing Ignition Sources

Where possible equipment to be taken into a hazardous area shall be rated as explosionprotected and/or intrinsically safe. Non-sparking hand tools (e.g. beryllium) where applicableshall be used. Prior to commencing hot work activities in a hazardous area, a Hot WorkControl Guide shall be completed.

The following equipment (not inclusive) may act as an ignition source, and as such, is NOTpermitted in a hazardous area unless under the controls nominated within a hot work controlguide or the equipment is appropriately rated for the hazardous area:

• Combustion engines;

• Mobile phones;• Hearing aids;

• Key-ring torches;

• Calculators;

• Car keys with automatic door locking features;

• Pagers;

• Watches;

• Transistor radios and communication radios;

• Battery chargers with their control equipment and batteries being charged (unlesssuitable for the hazardous area);

• Lasers;• Low pressure sodium vapour discharge lamps;

Risk

Time Diminishing Risk Graph


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• Nylon and other synthetic clothing; and other sources of static electricity;

• Alloy tools, scaffolding or ladders striking rusty metal, or rusty tools striking a light alloycould produce a thermite reaction and hence lead to an explosion in a hazardous area;

• Battery operated vehicles (e.g. fork lifts), to be used in a hazardous area are to be inaccordance with AS 1915 – Electrical apparatus for explosive atmospheres – Battery

operated vehicles; and• Non-certified / non-explosion protected portable equipment e.g. welding equipment.

3.1.4 Competent Design

The design of plant and installations in which flammable and / or combustible materials arehandled or stored must consider minimising the likelihood and frequency of releases by oneor more of the following:

• Replacing flammable products with non-flammable products;

• Not having joints in pipework;

• Using high integrity products for gaskets and glands;

• By having areas ventilated;

• Reducing inventories of flammable materials;

• Ensuring ignition sources are controlled;

• Ensuring life saving appliances and emergency control points are located in non-hazardous areas;

• Determining the maximum allowable surface temperature for a particular area;

• Determining the location of flammable gas detectors;

• Determining gas groups;

• Determining the types of release, duration and velocity; and

• Defining the extent of flammable gas level from vents.

• Any person performing hazardous area design work shall be a competent person in accordance

with AS/NZS 4761- Competencies for working with electrical equipment for hazardous areas.

3.1.5 Authorised Modifications to Plant

SCL has a project management and plant change process that ensures due diligence iscarried out when installing new or modifying existing plant. For more details on projects referto GenNet – Our business – Project Management and for more detail on plant change referto GenNet – Our business – Operations – Operations Systems and Processes – PlantChange.

3.1.6 General Hazardous Area Work

General hazardous area work is work that is not electrical installation or maintenance &

repair work, such as mechanical work and cleaning activities.Inspections are not considered a work activity for this procedure.

• Workers shall complete Hazardous Area Awareness Training HS043, prior to performinggeneral hazardous area work;

• A Hot Work Control Guide shall be completed for any work that has the potential tointroduce an ignition source into a hazardous area (refer to section 4.1); and

• A Work Method Statement shall be required for all work performed in a hazardous area.

3.1.7 Electrical Work

SPS has electrical equipment within the “works of an entity” and “electrical installation” asdefined in the Electrical Safety Act 2002. The obligations of electrical workers are different

depending on where the equipment is located. For electrical installations their obligation isto comply with the wiring rules and for entity works they follow the SPS hazardous area safesystem of work.


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For SPS, all electrical equipment within hazardous areas is considered “works of an entity”with the exception of equipment located in the following buildings:

1. Flammable liquids store.

2. Laboratory.

3. Main store including the unleaded fuel bowsers.

4. Main workshop.5. Waste transfer station.

3.1.7.1 Electrical Installation Work

All electrical installation work conducted within a hazardous area must be performed by anauthorised licenced electrical worker who has the appropriate EEHA competencies for thework they are to perform.

All “electrical installation work” (including modifications) must be inspected upon completionand an accredited auditor must audit the work and give clearance before connecting to asource of supply.

All documentation associated with “electrical installation work” and modifications to

hazardous area equipment must be included in the Hazardous Area Verification Dossier.The selection, installation and inspection of electrical equipment for use in hazardous areas,shall be in accordance with the applicable Australian Standards.

3.1.7.2 Maintenance and Repair Work - Electrical

All electrical equipment maintenance and repair work conducted within a hazardous areamust be performed by an authorised licenced electrical worker who has the appropriateEEHA competencies for the work they are to perform. Maintenance and repair workincludes;

• Breakdown work;

• Like for like equipment replacements of rated or unrated hazardous area equipment; and

• Disconnect/reconnect of electrical equipment.Where maintenance or repair work is undertaken for electrical equipment, a HazardousArea Maintenance and Repair Work Report is to be completed and added to the HAVD.

When conducting maintenance and repair work on entity works the “Approval & CertificationProcess Required for Electrical Work in Hazardous Areas on Entity Works” guide inattachment “C” shall be used. Firstly select the applicable situation on the table and thenimplement the actions, gain approvals as necessary, perform tests, perform inspections andaudits as required for the work.

There is also a simplified version of this process in a flow chart in attachment “D”.

3.1.8 Routine Inspections of Equipment - Electrical

To ensure electrical installations and entity works are maintained in a satisfactory condition,regular periodic inspections shall be conducted.

• There will be a schedule in place to regularly inspect electrical equipment in hazardousareas. The length of time between inspections shall not exceed 4 years.

• Inspections must be performed by an authorised electrical person or authorised licencedelectrical worker who has the appropriate EEHA competencies for inspections.

• All defects and non-compliant equipment are to be detailed on the inspection sheets.

• Secondary work orders are to be raised for any rectification work identified from theinspections.

• The Service Definitions for the inspections are listed in attachment “A”.


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When performing routine inspection on entity works and on equipment which is unrated forthe hazardous area in which it is installed, the inspection is to specifically look at theintegrity of the equipment. The integrity of the equipment is a key control within the safesystem of work to manage the risk associated with unrated equipment until compliance isachieved. Hence the inspections shall focus on the

• IP rating e.g. IP5X for zone 22;

• Integrity of seals;

• Cable and gland integrity;

• Mechanical protection;

• Internal wiring integrity e.g. in local control panels;

• Equipment mounting security;

• Earth connections;

• Corrosion; and

• Dust build up.

3.1.9 Process for Managing Unrated Electrical Equipment

On “electrical installation” equipment the process shall be to have the equipment replacedand installed as soon as practicable to the relevant Australian standards by an authorisedlicenced electrical worker who is EEHA competent. The new equipment must be inspectedby a competent person and audited by an ESO accredited auditor prior to connecting to asource of supply.

On entity works equipment, the process shall be to follow the “Managing ElectricalEquipment in Hazardous Areas Guide” TRIM Doc number 13/2197469 refer also toattachment “C”. The flowchart in attachment “D” also provide guidance.

3.1.10 Regular Auditing

• There will be regular audits conducted on classified hazardous areas for systems

compliance and to ensure effectiveness of conditions of control such as cleaning ofcombustible dust plant areas.

• The maintenance management system will be used to schedule these regular audits.

• The time between audits will be no more than 12months.

3.1.11 Regular Cleaning

• A program of increased cleaning will be implemented in combustible dust areas until allequipment within the area is made compliant.

• A program of inspections of the increased cleaning program will also be in place until allequipment within the area is made compliant.

• Once equipment in an area is compliant the cleaning and inspections can be lessfrequent dependent on keeping dust levels to below 5mm thick.

• Cleaning and inspections will be scheduled within the maintenance management system.

• The Service Definitions for the cleaning are listed in attachment “A”.

3.1.12 Maintaining a Hazardous Area Verification Dossier

SPS will have a Hazardous Area Verification Dossier (HAVD) and have an appropriateperson ensure that it is kept up to date with relevant documentation.

The verification dossier will contain the following:

• Identity of the legal owner of the facility (person in control of the electrical equipment).

• Area classification drawings.

• Classification reports and associated documents;


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• Any risk assessments associated with hazardous areas(not Work Method Statements);

• Certificates of conformity for all items of equipment installed in the hazardous areas.

• Conformity Assessment Documents for uncertified or foreign equipment.

• Location of each equipment item.

• Calculations performed to verify compliance.

• Records of electrical tests performed on installation or commissioning.

• Inspection schedules.

• Records of inspections performed, including faults and defects and their rectification.

• Records of overhauls and repairs carried out by licenced repairers.

• Records of any modifications made to equipment and justification for them.

• Details of the competence of personnel working in hazardous areas.

• Completed Hazardous Area Maintenance and Repair Work Reports.

The Verification Dossier is to be readily available to all persons required to enter and / orwork in the hazardous area(s).

The SPS Hazardous Area Verification Dossier:

• Electronic version is in folder MIG/73441.

• Hard copy version is located in annexe 2/3 level 4.

3.1.13 Training and Authorisation of Workers

• There will be a process for training to authorise personnel to perform electrical workwithin a Hazardous Area, in accordance with relevant Australian Standards.

• All persons (including contractors) who are expected to, or who may enter a hazardousarea for any purpose, shall have first received appropriate training / instruction in relation

to the necessary precautions, particularly the need to ensure that no potential ignitionsources are taken into the hazardous area. Training shall be provided in accordance withHazardous Areas Awareness Training HS043 (13/1330264).

• All Hot Work activities shall be performed using a Hot Work Control Guide.

• Authorised electrical workers, technicians and engineers who install, maintain, inspect ortest electrical equipment in a hazardous area shall receive Hazardous Area Training 1 –Installation and Maintenance of Electrical Equipment HS072 (13/1269196).

• Refresher training shall be provided in accordance with Hazardous Area Training 1-Installation and Maintenance of Electrical Equipment Refresher (13/1810710).

• Persons who are required to carry out design for explosion protected and associatedelectrical equipment in hazardous area installations shall receive Hazardous AreaTraining 2 - Design of Electrical Installations (13/1779536).

• Refresher training shall be provided in accordance with Hazardous Area Training 2 -Design of Electrical Installations Refresher (13/1810435).

• Persons who develop maintenance management programs for hazardous areainstallations shall receive Hazardous Areas Training 3 - Maintenance Management ofElectrical Equipment (13/1797125).


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3.1.14 Maintaining a Hazardous Area Equipment Register

• SPS will have a register of all electrical equipment items installed in hazardous areas(14/132200).

•

The equipment register shall be kept with the site HAVD (MIG73441).• The equipment register shall be updated with any changes to equipment installed in

hazardous areas.

• The equipment register shall include the following details for each item:

o Tag ID / KKS;

o Item Description;

o Item Location;

o Protection Type;

o Manufacturers Name;

o Model Number;

o Serial Number;

o Certifying Authority;

o Last Inspection Date;

o Zone; and

o Classification Drawing Number.

3.1.15 Signage

Hazardous areas shall be clearly defined and marked / signed in accordance with AS 1319 -Safety Signs for the Occupational Environment.

Signage for a hazardous area shall:

• Identify the nature / type of hazardous area (e.g. gas or dust hazardous area); and

• Specify requirements / precautions whilst in the hazardous area (e.g. signage is toidentify equipment which is not permitted in the hazardous area).

4.0 Responsibilities

Person Conducting a Business or Undertaking (PCBU):

Sections 32 to 38 of the WH&S Regulation 2011 outlines the requirements for eliminating orminimising risk so far as is reasonably practicable by identifying the hazards, managing the risk,applying hierarchy of control measures and maintaining and reviewing the nominated controlmeasures.

Section 51 of the WH&S Regulation 2011 states that a PCBU must manage risks to health andsafety associated with a hazardous atmosphere at the workplace.

Section 355 of the WH&S Regulation 2011 relates to specific controls around fire and explosion. APCBU must ensure ignition sources are not introduced into hazardous areas.

Section 29 of the Electrical Safety Act 2002 states that the duty of an Electrical Entity is to ensurethat its works are electrically safe and operated in a way that is electrically safe. It is theresponsibility of the PCBU for the Electrical Entity to ensure, the Entity meets its obligations underthe act.


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Section 30 of the Electrical Safety Act 2002 states that the duty of PCBU is to conduct thebusiness in a way that is electrically safe. This means that equipment is electrically safe, electricalwork is performed safely and ensuring all people and property are electrically safe for anyequipment and electrical work on that equipment that is not part of “entity works”.

Person in Control of Electrical Equipment in Relation to the Electrical Safety Act

At SPS this is the Site Manager as defined in the Legacy Corporate Authority to Work – ElectricalSafety Standard.Section 38 of the Electrical Safety Act 2002 states that the person in control of electricalequipment must ensure the electrical equipment is electrically safe.At SPS the nominated person in control of electrical equipment shall be the person for both theentity works and the electrical installation as defined in the Electrical Safety Act 2002.

Electrical Workers

The licensed electrical worker is responsible for ensuring compliance to the wiring rules whenperforming work on an “electrical installation” under section 70 of the Electrical Safety Act 2002.Note: As the works of an entity is not considered an electrical installation (as defined within the

act), the licensed electrical worker needs to ensure the safe system of work that has beenestablished by the Entity, in relation to its obligations, under the acts and regulations, are metwhen performing electrical work on “works of an entity”.

Electrical Contractors

When performing “electrical work” on “entity works” the electrical contractor will comply with thesafe work system established by the entity. This means that for the “electrical work” they haveconducted they will inspect, test and commission the equipment to verify that the electricalequipment is suitable for service and can be operated safely when initially installed or altered inaccordance with the procedures established by the entity.Electrical contractors performing “electrical work” on an “electrical installation” have an obligationunder Section 70 of the Electrical Safety Act 2002 to be in compliance with the wiring rules.

Hazardous Area Technical Person

This role is to provide expert knowledge and guidance to manage safe work in hazardous areas.At SPS this role is performed by the Electrical Systems Technologist – Compliance.

The role shall perform the following duties:

• Determine the frequency of periodic inspections and the grade of inspections.

• Ensure that the HAVD is kept up to date.

• Maintain the hazardous area equipment register for the site.

• Check that skilled personnel are receiving appropriate training and refresher training.

• Check that documentation is being completed correctly and added to the HAVD.

• Provide adequate technical support to the skilled personnel.

• Conduct audits and inspections and produce reports so that the state of the electricalinstallation is known.

• Check on effectiveness of controls implemented under conditions of control documents.


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4.1 Function Flowchart

The following flowchart outlines the process of determining controls for activities within

hazardous areas.

Entry required into a classified hazardous area

Is the work “electrical

installation work” or work on

an electrical installation?

Type of work to be

performed

The work is electrical

maintenance or repair work

on entity works.

ElectricalGeneral o

Identify hazards and

controls for the

work

!repare "#$ usin%

%uide in attachment

“&”

'es

!erform work followin% controls

on "#$ and (")G.

Implement controls on "#$

and perform electrical work

followin% *ustralian $tandards.

Implement controls on "#$

and perform electrical work

followin% $!$ safe work process

refer to attachments “&”+ “)”,

“-” for further details.

Is the entry for a work

actiity?

!erform the actiity/ i.e. inspections0

and ensure i%nition sources are left

outside the hazardous area.

'es

o

-oes the work inole hot work or

introducin% an i%nition source into

a hazardous area?

Ensure there is a

hot work control

%uide are in place.

!erform the work followin% controls on

"#$ and ensure i%nition sources are left

outside the hazardous area.

'es

o


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5.0 Review and ConsultationThis Document is required to be reviewed, as a minimum, every 3 years.

6.0 Communication PlanThis document will be communicated to affected employees through information sessions at teammeetings, through the site electrical safety committee meetings and incorporated into thehazardous area awareness and the EEHA training and refresher packages.

7.0 References (Including Information Services)

13/1330264 Hazardous Areas Awareness Training

13/1269196 Hazardous Area Training 1-Installation and Maintenance of ElectricalEquipment HS072

13/1810710 Hazardous Area Training 1-Installation and Maintenance of ElectricalEquipment Refresher

13/1779536 Hazardous Area Training 2 - Design of Electrical Installations

13/1810435 Hazardous Area Training 2 - Design of Electrical Installations Refresher

13/1797125 Hazardous Areas Training 3 - Maintenance Management of ElectricalEquipment

13/1269696 HEHI Hot Work - HS021

14/13767 Hazardous Area Maintenance and Repair Work Report

13/2198197 Hazardous Area Classification Report - Coal Handling Plant

13/2188564 Hazardous Area Classification Report - Liquids and Gasses

13/2197876 Hazardous Area Classification Schedules for Coal Handling Plant – Materials

13/2198200 Hazardous Area Classification - Stanwell Power Station Coal Dust Risk

Assessment & HAC Report13/2197871 Hazardous Area Classification Schedules - Coal Handling Plant

13/2188358 Hazardous Area Classification Schedules - Liquids and Gasses

13/2188563 Hazardous Area Classification Schedule of Materials - Liquids and Gasses

14/132200

MIG/73441

621013 series

Hazardous Area Equipment List

Electronic Hazardous Area Dossier - SPS

Combustible Dust Classification Drawings

621018 series Flammable Liquids Classification Drawings

621020 series Flammable Gas Classification Drawings

T-2681 to T-2685 Hazardous Area Inspection Sheets

QLD WH&S Regulations 2011

QLD Electrical Safety Act 2002

QLD Electrical Safety Regulation 2013

AS 1319:1994 Safety Signs for the Occupational Environment

AS 1915:1992 Electrical apparatus for explosive atmospheres – Battery operatedvehicles

AS/NZS 3000:2007 Wiring Rules

AS/NZS 3800:2012 Electrical equipment for explosive atmospheres – Repair and overhaul

AS/NZS 4761.1:2008 Competencies for working with electrical equipment for hazardous areas(EEHA)


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AS/NZS 60079 Series Electrical apparatus for explosive atmospheres

HB 13:2007 Electrical equipment for hazardous areas – TAFE NSW Technical andFurther Education – Manufacturing and Engineering Education ServicesDivision

8.0 Definitions

Area: A three-dimensional region or space.

Certificate ofConformity:

A certificate that has been issued for a piece of equipment that provides proofthat it meets manufacturing standards acceptable in Australia.

ClassificationDrawings:

Drawings showing the extent of the classified hazardous area. They also havedetails of the hazardous material, zone, temperature class and apparatusgroup.

Classification ofHazardous Areas:

Is a method of analysing and classifying the environment where an explosiveatmosphere is present or is expected to be present

Combustible dust: Dust that can burn or glow in air and could form explosive mixtures with air at

atmospheric pressure and normal temperatures. Combustible dusts includedusts, fibres and flying’s.

Competentperson:

A person who has through a combination of training, education andexperience, acquired knowledge and skills enabling that person to performcorrectly the specified task.

Dust: Small solid particles in the atmosphere which settle out under their ownweight, but which may remain suspended in air for some time.

EEHA: Electrical Equipment in Hazardous Areas

ElectricalEquipment:

Means any apparatus, appliance, cable, conductor, fitting, insulator, material,meter or wire that is used for controlling, generating, supplying, transformingor transmitting electricity at a voltage greater than extra low voltage or

operated by electricity at a voltage greater than extra low voltage.ElectricalInstallation:

A group of electrical equipment items that are permanently electricallyconnected together and can be supplied with electricity. This does not includeitems that are works of an entity.

Electrical Risk: In relation to a person, the risk to the person of death, shock or injury fromelectricity or in relation to property, the risk to the property of damage causedby electricity.

Electrically Safe: Means that persons and property are free from electrical risk

Electrical Work: Means connecting or disconnecting electricity supply wiring to electricalequipment or manufacturing, constructing, installing, removing, adding,testing, replacing, repairing, altering or maintaining electrical equipment or anelectrical installation.

ElectricalInstallation Work:

Means electrical work associated with an electrical installation, but does notinclude testing, repairing or maintaining equipment included in the electricalinstallation or electric line wok associated with the electrical installation.

Entity Works: Means the electrical equipment and electric line associated equipmentcontrolled or operated by the entity to generate, transform, transmit or supplyelectricity. SCL generating equipment is deemed to be entity works under thisdefinition.

Explosiveatmosphere:

Mixture with air under atmospheric conditions, of flammable materials in theform of gas, vapour, mist, dust or fibres in which, after ignition, combustionspreads throughout the unconsumed mixture.

Explosion

protection:

Specific measures applied to electrical equipment to avoid ignition of a

surrounding explosive atmosphere.


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Flammable gas orvapour:

Gas or vapour which, when mixed with air in certain proportions, will form anexplosive gas atmosphere.

Flammable liquid: Any Class 3.1 or Class 3.2 liquid having a flashpoint of not more than 610C.

Flammablematerial:

Gas, vapour, liquid, dust or solid which can react continuously underappropriate concentration conditions with atmospheric oxygen and which may

therefore sustain fire or explosion when such reaction is initiated by a suitablespark, flame or hot surface.

NOTE: Many liquids and solids, though regarded as flammable, nevertheless do not normally burn.The application of heat to such materials serves to release vapour, which may burn withatmospheric oxygen. The heat of the subsequent reaction serves to release further vapour forcombustion. Flame may propagate throughout suspensions of dusts by this mechanism.

Free fromelectrical risk:

Means that the electrical risk to a person or property has been eliminated, sofar as reasonably practical or if not able to eliminate the electrical risk then therisk has been minimised so far as is reasonably practicable.

Flying’s: Airborne particles.

HAVD: Hazardous Area Verification Dossier.

Hazardous area: An area in which an explosive atmosphere is present or may be expected tobe present, in quantities such as to require special precautions for:

any access or activity that presents an ignition source;

the construction, installation, testing, inspection and use of electricalequipment;

installing mechanical equipment. (There are no standards yet thatdirectly govern the installation of mechanical equipment within ahazardous area i.e. air compressors, conveyor systems).

Hot work: Welding, thermal, friction or oxygen cutting, grinding, heating and other fire-producing or spark-producing operations that may increase the risk of fire orexplosion.

Ignition source: Source of energy, which may comprise of naked flames, sparks or hot

surfaces / particles, sufficient to ignite an explosive atmosphere.Examples of typical sources of ignition from electrical systems and apparatusinclude:

electrical arcing / sparking when circuits are switched by devices suchas motor contactors, auxiliary relays, switches and contacts; and

Hot surfaces produced by motors, relay coils, transformers, ballasts,hot joints, cables, light globes, etc.

Intrinsically safe: a device termed intrinsically safe is designed to not contain any componentsthat produce sparks or which can hold enough energy to produce a spark ofsufficient energy to cause an ignition.

ServiceDefinitions (SD’s):

An automatically generated work request from the maintenance managementsystem.

Thermite reaction: An aluminothermic reaction in which aluminium metal is oxidised by the oxideof another metal, most commonly iron oxide.

Wiring rules: Means: AS/NZS 3000:2007 - Wiring Rules

Note Section 7.7 of the wiring rules outlines the requirement to comply withthe relevant AS/NZS hazardous area standards for classification, equipmentselection, installation and competency.

Worker: A person who carries out work in any capacity for a business or undertaking.

Zone 0: An area in which an explosive gas atmosphere is present continuously, or ispresent for long periods. Examples may include the vapour space of ventedvessels, vapour space of vented storage tanks and immediately adjacent to acontinuous source of release.


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Zone 1: An area in which an explosive gas atmosphere is likely to occur in normaloperation. Examples may include where pumps are liable to leak under normalconditions, or where vents, relief valves or sample points are likely to releasevapour into the atmosphere.

Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normaloperation and if it does occur it will exist for a short period only. Examplesmay include where vessels, pumps, compressors and pipes containingflammable gases and liquids are constructed and maintained to preventleakage under normal operating conditions.

Zone 20: An area in which combustible dust, as a cloud, is present continuously orfrequently, during normal operation, in sufficient quantity to be capable ofproducing an explosive concentration of combustible dust mixed with air, and /or where layers of dust of uncontrollable and excessive thickness can beformed.

Zone 21: An area not classified as zone 20 in which combustible dust, as a cloud, islikely to occur during normal operation, in sufficient quantities to be capable ofproducing an explosive concentration of combustible dust mixed with air.

Zone 22: An area not classified as zone 21 in which combustible dust clouds may occurinfrequently, and persist for only a short period, or in which accumulations orlayers of combustible dust may be present under abnormal conditions andgive rise to combustible mixtures of dust in air. Where, following an abnormalcondition, the removal of dust accumulations or layers cannot be assured thenthe area is to be classified zone 21.

9.0 Revision History

Rev. No. Rev. Date Revision Description Author Endorse/Check Approved By

0-7 Legacy Hummingbird versions P Cox

8 10.09.2014 Document revised and updated P. Cox J. Oliver B. Perry


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10.0 Attachments

10.1 Attachment “A” Routine Inspection and Cleaning SD’s

Periodic Electrical Equipment Inspection SD’s

SD Number DescriptionFrequency

(Weeks)Compliance

SDResponsible

Group

1150 - SI34000 U1 IGNITION GAS HAZARDOUS AREA INSPECTIO 208 N T5E




1150 - SI34010 LPG IGNITION GAS HAZARDOUS AREA INSPECTIO 208 N T5E

1265 - SI44500 HAZARDOUS AREA CHECKS - TOOL STOR 208 N T5E

2030 - SI51000 HAZ AREA - FLAM GAS/LIQ STORE, FUEL BOWS 208 N T5E

2030 - SI51005 HAZ AREA - SOLVENT ROOM AND DECANTING RO 208 N T5E

1105 - SI29520 TRAIN R1 R3 HAZARDOUS AREA INSPECTIONS ⃰208 N T5E

1105 - SI29522 SLOT BUNKER HAZARDOUS AREA INSPECTIONS ⃰208 N T5E

1105 - SI29524 BUNKER BUILDINGS HAZARDOUS AREA INSPECTIONS ⃰208 N T5E

1130 - SI32020 U1 H2 SYSTEM HAZARDOUS AREA INSPECT 208 N T5E




1130 - SI32030 H2 SUPPLY AREA HAZARDOUS AREA INSPECTION 208 N T5E

2030 - SI51000 MISCELLANEOUS HAZARDOUS AREA INSPECTIONS 208 N T5E

Routine Cleaning SD’sSD Number Description

Frequency(Weeks)

ComplianceSD

ResponsibleGroup

2030 - 51063 CLEANING - COAL DISTRIBUTION SYS - 12MTH ⃰52Y CSC

2030 - 51040 CLEANING - COAL DISTRIBUTION SYS - 2WKLY ⃰2N CSC

2030 - 51051 CLEANING - COAL DISTRIBUTION SYS - 3MTHL ⃰12N CSC

2030 - 51061 CLEANING - COAL DISTRIBUTION SYS - 6MTHL ⃰24N CSC

2030 - 51041 CLEANING - COAL DISTRIBUTION SYS - MTHLY ⃰4N CSC

2030 - 51112 CLEANING - BOILER HOUSES - 12 MTHLY ⃰52N CSC



2030 - 51106 CLEANING - BOILER HOUSES - MTHLY ⃰4 N CSC

2030 - 51023 CLEANING - BOILER HOUSES - WKLY ⃰1N CSC

2030 - 51103 CLEANING - FDR & SHUTTLE LVLS - 12 MTHLY ⃰52N CSC

2030 - 51046 CLEANING - FDR & SHUTTLE LVLS - 2 WKLY ⃰2N CSC

2030 - 51038 CLEANING - FDR & SHUTTLE LVLS - 2 WKLY ⃰2N CSC

2030 - 51102 CLEANING - FDR & SHUTTLE LVLS - 3 MTHLY ⃰12N CSC

2030 - 51101 CLEANING - FDR & SHUTTLE LVLS - MTHLY ⃰4N CSC

⃰The frequency of these SD’s is currently under review as part of the conditions of control to reduce the level of riskcarried as there is unrated electrical equipment installed in these areas.Note: Cleaning inspections SD’s are to be created and implemented.


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10.2 Attachment “B” Managing Electrical Equipment in Hazardous Areas Guide

The purpose of this guide is to provide information to workers to assist with the preparation of WorkMethod Statements in relation to managing unrated electrical equipment in Hazardous Areas during theinterim period until compliance of each hazardous area is achieved.

Hazard Identification and Control

Hazard Control

1. Unrated electricalequipment

a) Equipment manualsb) Documented Periodic ‘close’ inspectionsc) IP Ratings of equipmentd) Routine plant inspections and mechanical maintenance

Examples:

• Mechanical valve and connections repairs maintenance for gas systems

• Housekeeping

• Fuel sources isolated when not in use

e) Documented routine maintenancef) Sample testing of key electrical aspects (earth bonding and equipotential bonds etc.)g) Hazardous Area Dossier updated and maintainedh) Plant protection, automated control and alarmingi) Physical location and guarding from damage

2. Personnel performinginspections andmaintenance andrepairs in hazardousareas with unratedelectrical equipment.

a) Periodic plant inspections performedb) IP Ratings of equipmentc) Personnel complete hazardous area training as specified by AS/NZS 4761d) Signagee) Locks where applicablef) WMS incorporate risks associated with activities e.g. may require the use of a hot

work control guide.g) Use the “Approval & Certification Process Required for Electrical Work in Hazardous

Areas”h) Plant protection, automated control and alarming

3. Personnel performingelectrical fault finding inhazardous areas withunrated electricalequipment

a) Periodic plant inspections performedb) IP Ratings of equipmentc) Personnel complete hazardous area training as specified by AS/NZS 4761d) Signagee) Corporate Fault Finding Proceduref) WMS incorporate risks associated with activities e.g. may require the use of a hot

work control guide.g) Plant operating procedures/instructionsh) Plant protection, automated control and alarming

4. Personnel entering a

hazardous area toinspect the area oroperate equipment

a) Equipment manuals

b) Periodic plant inspections performedc) Periodic electrical equipment inspections and maintenanced) IP Ratings of equipmente) Trained and authorised to perform these tasks as part of the plant familiarisation and

authorisation process (i.e. as per ATW authorisation process, PT training)f) Signageg) Locks where applicableh) WMS incorporate risks associated with activitiesi) Documented plant operating procedures/instructions j) Hazardous area rated tools and equipment used


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10.3 Attachment “C” - Approval & Certification Process Required for ElectricalWork in Hazardous Areas on Entity Works

Situation Actions by Qualified Electrical Worker for Electrical Equipment inHazardous Areas

Approvalby RPEQElectrical

AS3000mandatory

tests &ESTR

required

HazardousArea

EquipmentCertificaterequired

Auditrequired by

anaccreditedhazardous

areaauditor

1 Unrated equipment isdamaged.

• Hazardous Area Safe System of Work Implemented• Repair if possible or replace equipment with “like for like” component.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVD

No

Yes ifcircuit

integrity isaltered.

No No

2 Unrated equipment isunserviceable i.e.Components requirereplacement. (“likefor like” partsavailable)

• Hazardous Area Safe System of Work Implemented• Determine components that require replacement.• Determine if “like for like” component/s can be obtained.• If “like for like” component/s can be obtained then obtain and repair

equipment as necessary.

• Complete mandatory testing, perform close inspection and fill outElectrical Safety & Test Report and update HAVD

No

Yes ifcircuit


No No

3 Unrated equipment isunserviceable i.e.

Components ORParts requiresreplacement. (“likefor like” parts not available)

• Hazardous Area Safe System of Work Implemented• Determine component/s – Part/s that require replacement.•

If “like for like” component/s cannot be obtained then determine ifalternate component/s – Part/s can be used.

• If alternate components/parts are available then seek approval from anRPEQ Electrical to use them for repairs.

• If RPEQ approves use of alternate components/parts, obtaincomponents/parts and repair equipment as necessary.


• Included in the final hazardous area audit for the particular area.

Yes

Yes ifcircuit


Yes(Refer s5.1 of

ASNZS60079.14)

No

4 Unrated equipment isdisconnected to allowworkshop repairs andthen reconnected onplant.

• Hazardous Area Safe System of Work Implemented• Reconnect equipment after repairs.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVDNo Yes No No

5 Unrated equipment isunserviceable i.e.

equipment requiresreplacement.Compliant equipmentis available for thetransition period (Thisis treated as areplacement only since it isinserted into a remainingnon-compliant hazardousarea circuit)

• Hazardous Area Safe System of Work Implemented• Determine equipment that requires replacement.

• If “like for like” component/s cannot be obtained and alternatecomponent/s not available.

• If alternate equipment is available then seek approval from an RPEQElectrical to use it for repairs.

• If RPEQ approves use of alternate equipment, obtain equipment andreplace equipment as necessary.


• Included in the final hazardous area audit for the particular area.

Yes

Yes ifcircuit


Yes(Refer s5.1 of

ASNZS60079.14)

No

6 Correctly ratedequipment isdamaged

• Hazardous Area Safe System of Work Implemented• Repair if possible or replace equipment with “like for like” component.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVD.• Obtain a certificate for any new equipment and include in HAVD.

No

Yes ifcircuit


Yes No

7 Correctly ratedequipment is

unserviceable

• Hazardous Area Safe System of Work Implemented• Replace only with appropriately certified equipment.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVD

• Obtain a certificate for any new equipment and include in HAVD.

NoYes ifcircuit


Yes No

8 Correctly rated equipment isdisconnected to allowworkshop repairs andthen reconnected onplant.

• Hazardous Area Safe System of Work Implemented• Reconnect equipment after repairs.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVD.No Yes

Yes toindicate thatmaintenance

has beenperformed.

No(this is

awaitingclarification)

9 (New) Installation.New equipment andcircuit installed into ahazardous area

• Hazardous Area Safe System of Work Implemented• Install only appropriately certified equipment.• Complete mandatory testing, perform close inspection and fill out

Electrical Safety & Test Report and update HAVD.

• Ensure an accredited auditor audits the electrical installation workbefore connection to a source of supply.

• Obtain a certificate for the new equipment and include in HAVD.

Yes Yes Yes Yes

10 Compliant HazardousArea

• As per Act, Regulation, AS/NZS etc. - - - -


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