Abb Safety Mannual

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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ABB Health and Safety MANUAL Table of Contents NUMBER

TITLE

PAGE

1

INTRODUCTION----Occupational Safety Health Act

2

2

PROJECT SAFETY MANAGEMENT PROCEDURE

6

3

15

4

discipline CONTROL OF SUB-CONTRACTOR

5

SAFETY & ACCIDENT PREVENTION

19

6

MANUAL MATERIAL HANDLING

27

7

GOOD HOUSE KEEPING

28

8

HEAVY LIFTING PRACTICE

29

9

CONTROL OF HAZARDOUS SUBSTANCE

32

10

ELECTRICAL SAFETY AT WORK

34

11

SULPHUR HEXAFLORIDE

12

FIRE AND EMERGENCY

84

13

FIRST AID

87

14

MANUAL HANDLING & ERGONOMICS

89

15

MECHANICAL HANDLING

91

16

SAFETY OF VISITORS(NON-EMPLOYEE)

92

17

OCCUPATIONAL HEALTH MANAGEMENT

93

18

PROCUREMENT AND SUPPLIERS

96

19

WORKING AT HEIGHT

97

20

NOISE & VIBRATION

101

21 22

(SF6) GAS

PAINTING ATTACHMENTS OF ALL REPORTS & PROJECT ORGANIZATION CHART

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41

101 102

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INTRODUCTION

A warm welcome to you by ABB by its management team, an organization which considers safe working practices, an integral part of its operations. Safety is everyone’s responsibility and ABB believes that accidents are preventable. This project has a NO ACCIDENT goal. We, at ABB emphasize a serious attitude towards the observance of our safety instructions and procedures. ABB is committed to a workplace free from incidents and over many years has developed strong Health& Safety policies and procedures in order to work safely. These Procedures are available at all Workplaces. This manual deals with SAFETY of each and every individual (Client/Contractor/SubContractor/Visitors) involved in the EPC contract Ref. 03-IN03-63. Introduction to Occupational Safety and Health Act ABB have adopted the Occupational Safety & Health Act as their standard for employee Safety. DEFINITIONS: Client: Equate petrochemical Company K.S.C.C, Kuwait. (Herein after referred to as “Owner”) Contractor: Consortium of 1) ABB AG Power technologies Division, GERMANY 2) ABB Engineering Technologies Company (KSCC), Kuwait 3) EXSYM Corporation, Japan. Sub- contractor: as defined in the contract, see in Project Organization chart. Attached in the attachments. Visitor: non-employee visits the sub-station.

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A Competent person is a person who is capable of identifying existing and predictable hazards in the surroundings, or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to eliminate them. OSHA Standards in brief: Before we proceed, let’s take a-brief look at the origin of the OSHA standards. Initially, the OSHA standards were taken from three sources: consensus standards, proprietary standards and Federal laws in effect when the Occupational Safety and Health Act became a law. Consensus standards are developed: by industry –wide-standard-developing organizations, and are discussed substantially agreed upon through consensus by industry. OSHA has incorporated the standards of the two primary standards groups the American National Standards Institute (ANSI) and the National Fire Protection Association (NFPA) Proprietary standards are prepared by professional experts within specific industries, professional societies, and associations. The proprietary standards are determined by a straight menthe ship vote, not by consensus. The Code of Federal Regulations, Labor, Title .29, Subtitle B, Part1926 - safety and health Regulations for Construction, Subpart - C, deals with general safety and health Provisions which are covered from Part 1926 section 20, to Part 1926 section 35. Section 20 covers Accident Prevention Responsibilities, stating that employers shall initiate and maintain such programs as is necessary to comply with this part. It also calls for frequent and regular inspections of the job site, materials, and equipment by the employer. The employer shall also ensure that not only safe machinery, tools, materials and equipment are used, unsafe items to be immobilized or removed from service. Section 21 covers safety training and education, stating that the employer shall instruct the employee in the recognition and avoidance of unsafe conditions and the regulations to control or eliminate any hazards or other exposure to illness or injury. It goes on to say that employers shall instruct employees in the safe handling of orisons, caustic substances, other harmful substances; plants or animals, how to avoid injury, the first aid procedures to be used in the event of injury and the personal hygiene and protective measures required. Employers shall also instruct employees in the safe handling of flammable liquids, ashes and toxic materials and make them aware of the specific requirements contained t,d,f and other applicable subparts of this part. The employer shall also instruct all employees who are required to enter confined or closed spaces on the the nature of the hazards involved, the necessary precautions to be taken and in the use of protective and emergency equipment required. A confined or enclosed space includes but is not limited to, storage tanks, process vessels , bins, boilers, ventilation or exhaust ducts, sewers, vaults, tunnels, pipelines id open top spaces more than 4 feet in depth such as pits, tubs, ‘vaults and vessels. Section 22 covers recording and reporting of injuries which are specific to each jobsite. Section 23 deals with First Aid and Medical Attention.It states that the employer shall make available for each employee First Aid services and provisions for medical care. The NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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regulations prescribing specific requirements for first aid, medical attention and emergency facilities are contained in Subpart D of this part, cabinet stocked with the necessary first aid requirements and a vehicle for emergency. Section 24 deals with Fire Protection and Prevention and states that the employer shall be responsible for the development and maintenance of an effective fire protection and prevention program at the jobsite throughout all phases of the construction, repair, alteration, or demolition work. The employer shall ensure the availability of fire protection and suppression equipment required by subpart F (OSHA). Section 25 deals with Housekeeping stating that during the course of construction, alteration, or repairs, form and scrap lumber (timber) with protruding nails, and all other debris shall be kept cleared from work areas, passageways and stairways in and around building and other structures. Combustible scrap and debris shall be removed at regular intervals during the course of construction. Safe means will be provided to facilitate such removal. Separate containers shall be provided for the collection and disposal of waste, trash, Oily and used rags and other rubbish. Containers for garbage and other oily, flammable, or hazardous wastes, such as caustics, acids, harmful dusts etc., will be equipped with Covers. Section 26 deals with illumination (Lighting). This states that all construction areas, aisles, stairs, ramps, runways, corridors, offices, shops and storage areas where work is in progress shall be lighted with either natural or artificial illumination. The minimum illumination requirements for work areas are contained in Subpart D of this part Section 27 refers to Sanitation and directs you to Subpart D for Health and Sanitation requirements. Section 28 (OSHA) deals with Personal Protective Equipment stating that the employer is responsible for the wearing of appropriate personal protective equipment in required work places. Section 32 deals with definitions some of which are: ANSI which means American National Standardize Institute. SAFETY FACTOR means the ratio of the ultimate breaking strength of a member or piece of material or equipment to the actual working stress or safe load when in use. SHALL mean mandatory. Contractor will do. SHOULD means recommended. SUITABLE means that which fits, and has the qualities or qualifications to meet a given purpose, occasion, condition, function or circumstance. Section 34 (OSHA)deals with Means of Egress and states that in every building or structure exits shall be so arranged and maintained so as to provide free and unobstructed egress from all parts of the building or structure at all times when it is occupied. No lock or fastening to prevent free escape from the inside of any building shall be installed except in corrective institutions where supervisory

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Personnel are continually on duty and effective provisions are made to remove occupants in the case of fire or other emergency. All exits shall be marked by a readily visible sign; access to exits shall be also marked by a readily visible sign in all cases where the exit or way to reach it is not immediately visible to the occupants. Means of egress shall be continually maintained free of all obstructions or impediments to full instant use in the case of fire or other emergency Section 35 deals with Employee Emergency Action Plans and states that emergency action plans shall be in writing and cover the designated actions that employers and employees must take to ensure employee safety from fire and other emergencies: As a minimum the Emergency Action Plan shall include the following elements;-, 1. Emergency escape procedures. 2. Emergency escape route assignments. 3. Employee procedures for operating critical plant before they evacuate. 4. Employee- headcount procedures 5. Medical and rescue duties for those who will perform them. If Method of reporting. Fires and other emergencies. 6. An alarm system 7. Evacuation plan. 8. Appointment of safety supervisor. 9. Hold regular evacuation drills. 10. Update the plan to accommodate the changes circumstances. 11. Review the plan with all employees.

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Safety is everyone’s responsibility; Project Safety is the primary responsibility of all management and supervision on the project. We believe accidents are preventable. The actions of the personnel will be responsible for the well being and safety of the personnel and of the fellow workers. This Project has a NO ACCIDENT goal. The Project Manager, Site manager, and the Safety Engineer, has the overall responsibility for safety at each respective location in the site. The safety Engineer monitors all safety activities at the job sites and reports his findings to management through the Project Manager .The safety Engineer administers the project safety and fire–prevention programs and maintains responsibility for first-aid and medical. This Safety manual is prepared in accordance with OSHA safety and health Regulation for construction (CFR1926), KUWAIT Government legislation, DIN, IEEE, NFPA and Owner specific safety rules and procedures. SAFETY GOALS Specific safety and health goals for the project are as follows:  No lost-time or restricted workday cases and no recordable cases and no fatality, through a safety plan and safety procedures that are aimed at modifying the behavior of all employees on the project to become safety conscious to prevent all accidents and injuries. Provision of medical and first aid facilities to provide immediate treatment and proper management of injuries to prevent it from developing into a more serious type of injury to the benefit of the injured and the project. 

No onsite damage incidents.



No offsite damage incidents as far it is within the control of the project management.



Optimization of the onsite working conditions, leading to the prevention of physical and mental complaints, prevention of occupational sickness disability leave, and prevention of the occupational illnesses of all workers.



Minimum nuisance (e.g. noise, light, traffic, smells) to the surrounding community, potentially caused by construction related activities, directed at zero nuisance reports from the surrounding community.

 

Maintain safe working areas and good housekeeping. Although the project goal is to have no injuries on the project and every project participant must do their utmost to reach this goal, the following maximum injury incident rates for the project are:-

Classification

Incident rate

Lost Workday Case (LWDC)

0

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Total Recordable Case (TRC)

0.2

Restricted Workday Case

0.2

Incident rates are based on injuries per 200 000 man-hours worked. FUNCTIONS AND RESPONSIBILITIES Project Management is committed to a Safety Program requiring that accountability will begin at the highest level of management. Each level of Project Management, Contractor Management, supervision and employees will claim ownership in, and take personal responsibility for their roles in the safety program and will act as a change agent to modify each employee’s behavior positively towards working safely. Each level of management shall take on the responsibility for the safety of employees and comply with the project safety standards and requirements. Contractor and Owner will perform inspections and audits and continuous field monitoring jointly and/or separately to determine compliance to safety. Accountability is a critical part of the safety program and will be implemented with positive reinforcement that will challenge everyone involved, irrespective of his level of responsibility, to achieve our mutual goal of “No Accidents.” All activities will be governed by the assumption that, "all accidents can be prevented” and that the “behavior of all employees can be modified to work safely”. In order to achieve a “No Accident and No Injury” culture,all levels of management will subscribe to the following:

Project Manager The Project Manager represents senior levels of management on the project site and is accountable for the following activities: Communicating to subordinates the safety values of the project. Ensuring the safety performance and accountability of subordinates. Visibly demonstrating to the organization that personal commitment to safety is a number one priority. Review and respond to safety reports. Issue memo of recognition when goals are achieved. Issue memo of concern when goals are missed Review all accident investigation reports Request and review weekly safety statistical reports. Visibly participate in safety programs. Provide the project with resources. Include safety as part of each project meeting. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Include safety performance when conducting subordinates and contractor performance reviews.

Site Manager The Site Manager is essential in the implementation of the safety accountability program. The success of the program is contingent upon the support of this level of management. The Site manager is accountable for the following activities:  Ensuring subordinates safety performance and accountability and compliance to the safety program.  subordinates.

Communicate



Ensuring the quality of contractor safety performance.

safety

requirements

and

Job

Bulletins

to

 Taking part in activities that emphasize the commitment to the project safety program. 

“Leading by Example” sending a message “safety is a value.”



Review and respond to contractor safety assessments.



Monitor morning Toolbox meetings.



Participate Weekly Area Safety Assessments.



Participate in Owner’s Safety audits.



Participate in incident investigations.



Enforce the disciplinary program.

Ensure all employees receive required training. Safety Engineer An appointed Safety Engineer will lead safety position on the project and is responsible for monitoring and administering a pro-active project safety program designed to provide assistance in recognizing, evaluating, and subsequently eliminating or controlling hazardous acts or conditions. He will work in close coordination of Owner Safety Manager in Conjunction with his Project manager and Site Manager assisting in the implementation of the safety program. Safety Engineer has the following responsibility activities:  Administering appropriate safe work practices / procedures for the project.  Promoting a high level of safety awareness on the project through new employee /subcontractor orientation and contact with project supervision.

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 Conducting Weekly Safety Self-Assessments, tracking performance and reporting trends to site management.  Participates in the Weekly Area Safety Assessments of Owner.  Conducting quarterly safety audits.  Maintaining all safety related records and files associated with the project.  Administer the first aid / medical program and maintain facility and supplies.  Maintain pertinent information (i.e. phone number, locations) of Emergency Response Services, physicians, and hospitals.  Lead and assist in accident / incident investigations to ensure all accidents and incidents are properly investigated including near miss incidents, first aid cases, all recordable cases, chemical spillage incidents, property damage, etc...  Complete and distribute applicable reports.  Evaluating contractor/subcontractor safety programs.  Attending contractor/subcontractor pre-bid and “Kick Off” meetings.  Chair the weekly meeting with safety supervisors.  Review the Supervisor Safety Logbooks.  Continuously evaluating project working conditions and safe work practices, and if warranted, developing positive recommendations for project management.  Monitoring the behavior of the people and provide coaching to change the attitude and behavior positively towards working safely and instills “think before acting” and “value of human life”.  Participate in work-site layouts to assure adequate work areas, traffic control, parking areas, lighting levels, receiving areas, etc. Assure that location of offices, shops, maintenance areas, fabrication shops, medical, and sanitation facilities reflect safety considerations. Review the work schedules as they are planned to be aware of the number of contractors and craft workers working in the various areas; anticipate hazards and implement supporting safety activities. Monitoring the contractor’s performance and assist with the implementation of the safety program where required. For day to day safety matters the field safety supervisor deals directly with the contractors to resolve problems. To ensure that contractors adopt, implement and maintain a safety process in accordance with the Project Safety Plan and Procedures as outlined in the Safety Manual. Superintendent/Supervisor. (Sub-contractor appointed) The Superintendent is the first line of reporting for the craft supervisor. Defining accountability tasks for the project / contractor supervisors begins at this level. Specific tasks that a superintendent is responsible for are: Inspecting the work areas to identify hazards and abatement measures.

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Log all hazards and safety deficiencies in the discrepancy logbook. Planning safety into work activities. Ensure the daily construction permit and other required permits are valid and those permit conditions are met. Monitor morning toolbox meetings. Participate in Weekly Area Safety Assessments. Ensuring subordinates safety performance and accountability and compliance to the safety program. Communicate safety requirements and job bulletins to subordinates. Coaching supervisors to build over all safety awareness and safety performance. Ensure supervisors use the weekly supervisor safety logbook and review the logbooks to determine areas, the supervisor needs help or needs coaching. Establishing and maintaining a motivational environment that includes positive recognition as well as enforcement. Investigating accidents to determine causes. Determine safety-training needs. Craft / Worker Craft and workers, like any other person on the project, has the responsibility to keep himself and the people around him safe. They work under the supervision of the Supervisor and have the responsibility to perform their work safely according to the training they received and instructions from the Supervisor. Craft and workers have the responsibility to ask when they are not sure and must think before they act. They are also responsible to coach co-workers should they not understand the work and/or safety requirements and therefore are about to perform an unsafe act or create an unsafe condition. Contractor/Subcontractor Safety Representative The contractor safety representative is responsible for implementing the contractor’s safety program on the project. He is responsible for monitoring and administering a proactive project safety program in accordance with the project safety program designed to provide assistance in recognizing, evaluating, and subsequently eliminating or controlling hazardous acts or conditions. He works in conjunction with his project/site manager, construction manager and site safety representative assisting in the implementation of the safety program as it pertains to the contractor.

Supervisor Training All supervisors will attend a special Safety Leadership Skill-path training course presented by Owner that aims to equip supervisors with the knowledge and skills to fulfill their safety roles, duties and responsibilities as formulated in the Owner’s Safety Program.

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Safety Officers Training All safety officers will attend a Safety Personnel Development course designed and presented by Owner. This course aims to equip the safety officers with the skills and knowledge to perform their duties. The course is similar to the supervisor training mentioned above but concentrates on the roles, duties and responsibilities of safety officers. In addition it includes safety administration and procedures and field execution safe work practices as per the project safety manual and procedures.

Work Assignments All work assignments by the Sub-Contractors will include specific attention to safety. "Follow-up" monitoring will be done by the contractor in order to prevent accidents. (Safety Action Plan / Job Safety Analysis / Safety Task Assignments / Safe Work Plan / Permits). Meetings on Safety will be properly conducted and recorded. Additionally, all meetings, staff, progress and others will have a portion of the agenda devoted to accident prevention and a safety topic.

Toolbox meeting Toolbox meetings will be held daily by all supervisors as a coaching tool to help modify the behavior of the employees to work safely, effectively assign permitted work and to constructively correct unsafe and to effectively acknowledge employees and crews for working safely.

Specific Training The Safety Procedures require that employees performing specific tasks or operating specific equipment be trained and certified or designated as a competent person as defined. The following training / certification programs as required and verified by Owner will be conducted by the Owner. Equipment operators – specific to the type and or model of equipment operated. (Will be Certified Kuwait License holder) Forklift operators – initial training specific to the model and annual refresher training and they should have certificate /KUWAIT license required. Topics on which the Safety classes are conducted: a)

Electrical Lock Out Tag Out

b)

Working on or around energized electrical equipment / circuits

c)

Confined spaces – Supervisor, Entrant, Attendee

d)

Scaffold – Builder, User, Inspector NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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e)

Trenching and Excavation – Competent Person

f)

Fall Protection – Usage, Inspection, 100% fall protection and tie-off policy.

g)

All employees working at elevation must attend.

h)

Respiratory Protection – Use, inspection, care

i)

Hazard Communication

j)

Personal Protective Equipment

k)

First Aid – first aid, bleeding, CPR.

l)

Fire prevention – fire fighting, fire extinguisher, fire prevention.

m)

Hot work – gas cylinders, burning, welding, cutting.

n)

Crane and Rigging – Crane operation, signals, rigging/slinging, lifting equipment, lifts permits.

o)

Pre-commissioning and Startup.

p)

Grinder use.

q)

Other – as required.

Safety Log Book A log book will be maintained to track employee training. The logbook will identify type and date of certification / training each employee has received. ID Badges will be provided by the owner ,which will be color coded to indicate the training employees received. Safety Action Plan / Job Safety Analysis It is the responsibility of project supervision, including contractor / subcontractor supervision to perform a Safety Action Plan and Job Safety Analysis either individually or in a group, before any assigned task is undertaken. Supervisors shall complete the JSA form (Job Safety Analysis) identifying any hazards that may be associated with a task and the abatement measures required eliminating or protecting against the hazard. The JSA will be discussed during daily Toolbox talks .This Safety log book will be filled by the contractor in Owner’s log book.

Supervisor Safety Logbook

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Each field supervisor will use the Supervisor Safety logbook weekly and record his safety duties performed. The logbook is designed to guide the field supervisor through his safety duties and responsibilities and to record the safety issues he needs the help of management. Area Discrepancy Logbook Each work area on site will maintain an Area Discrepancy Logbook in which safety supervisors, superintendents and Owner log safety deficiencies. The area supervisor is responsible for correcting all safety deficiencies logged immediately and sign off against each entry. Weekly Safety Area Assessments, the Weekly Safety Area Assessment program will be used to conduct and document project inspections and corrective action. The assessment team will consist of the Owner, contractor, respective sub-contractor and Supervisor. Scores will be tracked and reported on weekly basis to the owner’s safety Department. Quarterly Safety Audits Owner Safety Department will conduct quarterly safety assessments. As part of the assessment a comparison will be made of the tree month’s average of Weekly Area Safety Assessments conducted by the project team and the final score of the Quarterly Assessment. Will be compared in the end. Recordkeeping and Accident Reporting It is the Safety engineer’s responsibility to maintain all records. This includes the maintenance of an accident log, annual summary and the posting of all mandatory posters. Records of the following safety activities must be maintained at the project; Employee training. Tool Box meetings. Weekly Safety Assessments. Weekly safety reports. Monthly safety reports. Safety Task Assignment forms by supervisor. Employee medical records. Mobil equipment inspections. Equipment, Assured Grounding, PPE, Rigging, Ladder inspections. Hazard Communication Program and Material Safety Data Sheet file. Accident and incident investigations – Employee’s Report – Supervisor’s Report. Disciplinary action NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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First aid log. Injury Log specific to the project and current for the year. Other as required. Accident, Incident Investigations All accidents, incidents, first aid cases and near misses will be investigated. (Where Possible) Affected employee(s) will complete an Employee’s Report of Occupational Illness/Injury and the employee’s supervisor shall complete a Supervisor’s Report of Accident. Safe Work Plan All work performed on the project shall be according to and controlled by a daily Safe Work Plan which is an extension of the Job Safety Analysis. It shall be in accordance with the project safety rules and regulations and project safety procedures and specific to the type and scope of work and work area per supervisor. Area superintendents shall visit each work location at the beginning of each work shift to check compliance to the planned work and the safety requirements thereof and sign the Safe Work Plan. The same will be carried out towards the end of the shift. Permits Certain specific work requires a permit as per the project safety rules and regulations and project safety procedures. Examples of such specific permits are confined space entry, excavation work, lifting, etc. Such work must have a valid permit to perform the work. After permit is issued only we start after Owner’s permits only.

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3. DISCIPLINE Smoking Policy

ABB is a smoke-free workplace. This means a total prohibition on smoking in all enclosed work areas.

ABB policy bans smoking from all offices, vehicles, recreation rooms and toilet facilities and areas where hazardous substances are being used and/or stored. Only allowed in designated area where Owner allows. RADIOS/CAMERAS No cameras will be permitted on the site without owners authorization Hand held radios may be permitted. Approval for use of radios shall be obtained through owner. The safety engineer shall keep a constant check on the methods used by supervisors and employees to prevent safety violations. He has the authority to correct and instruct employees concerning the violation of safety rules and shall stop work in situations of imminent danger. He must bring this to the attention of the Project Manager for carrying out the necessary corrective measures. The Safety Engineer may advise or recommend the type of reprimand or discipline to be applied, but shall not administer the discipline themselves, except for the serious safety violations requiring immediate dismissal/termination from the project as stated below. If appropriate discipline is not forthcoming, the chain of command shall be followed until appropriate corrective measures and discipline result. If satisfactory results are not achieved after working through the Site Manager, the Safety Engineer shall contact the Project Manager for resolution or further instructions. SERIOUS SAFETY VIOLATION: Violation involves a substantial probability that death, serious physical harm, major equipment damage, or work stoppage could result. Employees will be warned for first time and terminated next from the project site, if they commit one of the following serious safety violations: Employee must obey all the Danger & Caution signs.

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

Exceeding the specified/posted speed limit on the project. The maximum speed limit on the project is 20 kilometers per hour.



Not complying with the 100% fall protection and 100% tie-off policy.



Putting his live or the lives of others at risk (imminent danger).



Altercation (both parties will be dismissed).



Violating permit conditions or performing work without a permit where an approved permit is needed.



Disregarding barriers (Unauthorized access into marked as being unsafe or unauthorized access into a restricted area.



Energizing or de-energizing a power source without proper authorization.



Smoking in vehicles, offices and any other unauthorized area.



Operating or cause to operate equipment without a valid inspection and color coding.(with Owners specification)



Entering equipment without confined space entry permit.

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CONTROL OF SUB-CONTRACTORS Sub-contractors working on the site present a significant risk to co-workers and their own. This is because they may introduce new hazards into the workplace, and or not be aware of the hazards and controls within their areas. In adequate management of Sub Contractors can lead to injury of the co-workers and those of the Owner, as well as damage to property, and a consequent interruption to the progress of the project. Contractors present a significant risk to health and safety, so all our sub-contractor will have an induction program in work site, and continual safety training. Responsibilities and Accountability The Project Manager is responsible for ensuring that competent sub-contractors are employed, and that their performance is adequately assessed. Training Sub Contractors will receive a suitable safety induction before starting work. Contract Manager will have sufficient knowledge and experience, to ensure that the work being undertaken by the sub contractor is done safely. Risk Assessment and Controls Before commencing work a risk assessment with respect to safety will be undertaken. Any necessary prevention, and control measures will then be agreed. This will be normally in the form of a Method Statement. During the period of the contract both parties (Owner & Contractor) should ensure that any emerging risks are identified and controlled. Written ‘rules for contractors’ will be sent out to prospective sub-contractors. A contract will not be awarded unless a contractor can meet our Health and Safety requirements. The Sub-contractor’s rules will specify the insurance cover required. These ‘rules’ will set pre-qualification criteria, e.g. Safety policy, previous safety performance, training etc.  Pre-start A Sub contract supervisor will be appointed by each sub - contractor. Before work being on site a pre-entry site meeting will be held, attended by the Safety Engineer and contractor supervisor. At this meeting all Health and Safety measures will be agreed. Prior to starting work, the sub contractor will submit method of statement(s) for the work involved. These will be evaluated by someone with an adequate knowledge of health and safety standards required in the contractor organization. All areas where contractors are to work will be notified and any precautions taken.

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Sub-Contractors will ‘sign in’ when entering the company, and receive a ‘site badge’, by the owner. 

Work in progress The sub contract supervisor will monitor the work as often as necessary to ensure that the systems of work and the controls are being followed. A record of visits will be kept. Where there is a serious breach of the agreement, or serious risk to persons or property, the sub-contract supervisor will stop the work. None of the plant, equipment etc will be used by the sub- contractor, unless they have received prior authorization from the Contract Manager. End of Contract The health and safety performance of the sub contractor will be reviewed, to determine their suitability to do further work. MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team Active Monitoring - Safety Inspection The Sub-contractor supervisor will undertake monitoring visits as often as necessary to ensure that the agreed safety rules are being followed. The method statements will be used to evaluate actual work methods. Any records that the contractor is required to maintain will be inspected, e.g. scaffolding registers, accident records. Accident Reporting, Accident Investigation, all these will be done with forms See attachments at the end of the manual. APPENDIX-A Accidents and near misses involving contractors will be reported in the company accident book, and will be investigated. Forms are attached in attachments. AUDITING AND REVIEW Auditing The management of contractors shall be covered during the annual risk management audit. Review The management of contractors will be considered during the annual management review. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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4 SAFETY & ACCIDENT PREVENTION. 5

General

This procedure describes the method of conducting daily safety-monitoring activities, responsibilities, and reporting requirements. At work site,the following instructions are applicable:  Follow Safety Instruction And Sign Boards  If You Don’t Understand Ask.  Report any Dangerous Condition or Acts.  Keep workplace neat & Tidy.  Use Right Tools And Equipment.  Don’t Do Anything Without Right Permits.  Wear Right Personal Protective Equipment for the jobs,you are doing.  Stop the job if it is Unsafe.  In case of Improper Lifting in work site, ask help immediately from others.  Before lifting, if load is too heavy, GET HELP.  Check with your supervisor and crane operator for the correct lifting permit and requirements.  Report all accidents.

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First Aid / Injuries

All injuries are to be reported to the safety facility immediately. The personnel must fill out an accident investigation form immediately or his supervisor must fill out the form to start the investigation. When the investigation not has been completed due to the condition of the injured ,then it will continue as soon as the condition has been stabilized. The injured employees’ supervisor will fill out the Supervisor’s Accident Investigation Form as soon as possible but no later than the end of the shift. B.

PERSONAL PROTECTIVE EQUIPMENT

HEAD PROTECTION A Company issued hard hat must be worn at all times once entering the work area (instructor will define work area) with the exception of offices, equipment with fully enclosed cabs , lunch and break periods provided no work is going on in the immediate area. No metal hard hat will be permitted on this project. All hard hats must be in accordance with ANSI standards. Hard hats will also be worn when welding, grinding, cutting and other work requiring a hood or face shield and or goggles are performed. EYE AND FACE PROTECTION Approved safety glasses with shields are required at all times once the related work is assigned with the exception of offices, equipment with fully enclosed cab and wind shield, when superior eye protection is worn and during lunch or break periods provided. ANSI approved safety Glasses are to be provided by the sub contractors for all job activities. Dark lens safety glasses are not allowed. When grinding or buffing, a face shield and approved safety glasses will be provided by the sub-contractor for all jobs. When cutting or burning, burning goggles will be required. When welding, a welding hood or face shield will be worn. RESPIRATORY AND HEARING PROTECTION Respiratory and /or hearing protection in designated areas and or when performing specific tasks (instructor will address areas and tasks). Employee must be clean shaven. C. ELECTRICAL SAFETY NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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ELECTRICAL TOOLS & CORDS – APPLICABLE SAFETY RULES: Tools are to be visibly inspected by the personnel prior to use. Any tool or cord found to be defective is to be returned to the tool room. Check the RPM rating of grinding wheels disc. The RPM rating must be greater than that of the driver. Tools and guards are not to be altered. Electrical cords and welding leads will be maintained at seven-feet level, avoiding pinch points and creating trip hazards. Do not tie electrical cords to metal rods or nails. All electrical tools must be grounded and equipped with ground fault interrupter (GFCI) or (ELCB) to protect possible electrical shock. D. LADDERS Ladders must be free from defects and must have inspection color code. Use a ladder of sufficient length for the work to be performed. Place the ladder so that its base is out ¼ the distance of the height. Ladders are to be tied at the top. No extension ladder should extend its full length, it should overlap by one meter. Step ladders are not to be used in lieu of extension ladders. Step ladders are to be fully extended and locked in position. Only one employee is to work off of a step ladder. Do not stand or sit on the top of a step ladder. No work will be allowed on a ladder where both hands are needed at the same time to perform the work.

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E. SCAFFOLDS All scaffold, platform, and staging must be completely decked with decking secured and shall be built with standard handrails and toe boards on open sides and ends. The footing for scaffold shall be sound and capable of carrying the maximum intended load. No scaffold shall be erected, moved, dismantled or altered except under the supervision of a competent person. No scaffold shall be used unless it has a valid inspection tag indicating it is safe for use. Scaffold will be tagged by a competent person on its status as under with the following color code:

RED

DO NOT USE.

YELLOW

SAFETY HARDNESS REQUIRED – DUE TO SOME TYPE OF PHYSICAL RESTRAINT, A COMPLETE SCAFFOLD COULD NOT BE BUILT. THE OFF IS REQUIRED.

GREEN

SAFE FOR USE.

F. LOCKOUT Lockout the power source for making adjustments or repairs to any equipment. Do not tamper with energy source that are locked and /or tagged out. Do not depend on the control switch on drills, portable grinders etc., unplug them. G.

PERMITS

There are various permits required on the project. The following are examples of the more common permits. Cold work Work that does not ordinarily create enough heat to ignite flammable gas-air mixture of flammable materials.

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Hot Work: Mm Any work, tool or equipment (welding, burning, grinding, vehicles, portable welders, etc.,) which might provide a source of ignition for a flammable mixture. Opening / blinding Exposing the interior of any process equipment such as tanks, pipes, vessels, etc., to the atmosphere. Confined space Authorization from the Site Manager is required to enter any vessel, pipe, confined space, excavation etc., for any reason. Lock and tag Required to prohibit operation of a valve, switch, or piece of equipment when injury or property damage could result from the operation. Excavation To provide guidance for and protection of employees working in and around excavations and trenches. Lifting To control all lifts five ton and greater can be engineered lifts. (Required a “Green Lift Permit”). Closure of Access Roads. To close roads to prevent access when hazardous work is being performed.

H.

HANDLING OF COMPRESSED GAS: NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Special care is essential in the storage and use of gas cylinders. Their contents may be at high pressure with flammable and or toxic gases. The following guidelines are followed: Always store cylinders in a well ventilated area, away from the source of heat and out of direct sunlight. Flammable gas cylinders should be stored separately. Keep filled cylinders separate from empty ones. Cylinders should be stored vertical with valve ends up with protective caps in place. Secure cylinders in place with chain or clamp. Always report leaking cylinder and remove it from the area safely. Cylinders will not be used as rollers or supports. Turn off the gas when not in use. Always open the cylinder valve slowly. Close the cylinder valve sufficiently such that to shut off the gas only do not use excessive force and use only the standard key provided. Cylinders should not be rough handled. Never drop or throw the cylinders from the platform or truck. Do not allow the cylinders to strike each other during transportation. Cylinders will be lifted by approved lifting devices like cradle or lifting stand or fork lift. Never use web sling or wire rope. Always keep cylinders and valves clean and also clean out any grit by opening the cylinder valve momentarily before attaching to the regulators or fittings. Never test for leaks with open flame, use soap water. All cylinders must be kept at safe distance from welding or cutting operation or shielded from the same. All the cylinders must be placed away from an electrical circuit or from an electrical power boards. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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No gas cylinder will be taken into confined spaces. I. WELDING AND CUTTING Main hazards associate with welding and cuttings are: The obvious danger of fire. Always follow the instructions given in the hot work permit when welding or cutting work has to be carried out in a hazardous area. The possible dangers to personal health resulting from fumes and UV rays from an electric arc.  Always screen the area of work to prevent accidental ignition of combustible materials. Ensure all nearby sewers/drains are fully covered with fire retardant cloth. Always ensure that the fire extinguishers are available at the welding generator and at the work spot. Provide running water hose at the work spot. Always use the appropriate eye protection and protective clothing. Always secure welding gas cylinders in an upright position in a safe area, preferably in a trolley. Always lay gas hoses and welding cables neatly in such a way that they do not obstruct walk ways or become entangled. Ensure that there is adequate ventilation when working in a confined space. If necessary use a local forced extracting system for removal of welding fumes. Always leave cylinder keys at the cylinders for any emergency closure of the cylinder valve. Always ensure equipment is properly earthed and the welding return lead is clamped as close as possible to the job. Never leave equipment running unattended. Turn off gas or switch off power source, if you have to stop the work for any reason.  Never keep cylinder inside any confined space as they may leak.

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 Never use a regulator with gases other than the gas for which it is intended.  Always look around the welding area for any leaks or gas smell. If any do not start or continue the job and report to your superior immediately.  Ensure all welding cables are without any damages. Never try to strike arc on adjacent pipes or equipments except on the one which is to be welded.

6 MANUAL MATERIAL HANDLING NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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By adopting correct methods for manual handling of materials,strains and backaches are prevented. The following guidelines will apply for manual material handling:  Always assess the weight of the object to be lifted and get help if it is beyond your capacity. Whenever possible use the availability of lifting equipment or mechanical aids.  Always look out for any splinters, projecting nail or sharp edges or wire. Wear proper gloves when needed.  Always stand close to the object but few feet apart. Bend knees slightly to crovel position around the load. Keep your back straight and lift the object.  Always get a firm grip at opposite corners of the load with the palm and the roots of the fingers, arms are as close to the body as possible.  Always lift with your thigh muscles by looking up and straightening your legs.  Do not lift the load to your chest height.  Never change a grip while carrying.  Never twist or bend your back while working.  When two or more men are engaged to lift or move heavy object, all actions, such as lifting, lowering pushing, pulling etc. should be done at pre determined signals, coordinated by a leader of the group.  When lengthy pipes, ladders etc. are to be carried, keep the front end high so that they do not hit any object or others.  Always use handling aids, if possible.

7GOOD HOUSE KEEPING NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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House keeping is much more than cleanliness alone; it is cleanliness as well as keeping the things in an orderly manner. Good housekeeping improves employee morale, efficiency, confidence in operation & service and it also ensures good public relation for the company. It is one of the practical methods of getting high production and low accident rates. Following methods will be followed at site to maintain good house keeping:     

Keep floors free from grease, oil spillage, dirt, trailing cables etc. Properly marked aisles and no storage however ,if it is temporary. Clean windows, and keep tidy all machineries, tools and equipment in an orderly manner. Provide proper and adequate lighting and ventilation. No excessive materials or storage, keep wastage in proper thrash containers.

The check-list for good house keeping:  Never leave used cleaning materials such as dirty rags, cloths, contaminated with oil, paint etc., this must be properly disposed off in suitable containers.  Never dump waste, rubbish etc., on the ground it must be placed in the waste bins.  Never leave hoses, cables, wires and ropes on the floor, people might trip over them.  Always keep working place tidy. Tools and equipments in incorrect places, or obstructing the escape routes are all examples of bad housekeeping and same will contribute to the risk of accidents.  Always keep passages clear at all time.  Oil spills must be cleaned up immediately.  Never use flammable solvents to clean up oil spills or machinery  Parts,only approved solvents must be used.  All wastes must be disposed off inline with current environmental practices and legislations I.e., WTM (Waste transportation Manifest).  Hazardous waste must be disposed off in separate containers.  Ensure that suitable drip trays are provided for oil, water and other source of leakage.

8 HEAVY LIFTING PRACTICE: NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Set of Rules for Crane Operations: Working with cranes needs skill and experience. Unless qualified and experienced to do so, working with cranes is prohibited. Only authorized signalman will give signal to the crane operator. Test all hoist controls, brakes and limit switches every time before lifting operation. Do not operate if they are in unsafe condition. Cranes should be equipped with fire extinguishers. Move the load when you get signal from the signalman, and make sure that everyone is out of the lifting range. Before handling un usually heavy load, first test the brakes and then by a short lift make sure that you are in complete control of the situation. Observe crane and sling load capacities. Never carry loads over the people, warn them out of the way. Never carry load on the hook point. Never force a chain to link the hook. Chains and slings must have a ring attached to fit on the hook. Never overload or twist the kink or knot the chain or sling. Use the correct chain or sling for the loads. Keep cab and walkways clean and orderly. Center the hook on the load before lifting to avoid swinging of the load. Never walk under a suspended load. Stop the hoist before it trips the safety limit switch. All the areas within swing radius of the crane must be barricaded for safety of pedestrian and for vehicle movement.

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HOOK OF THE LOADS: Know the safe capacities of the chain or sling. Never over load.

 

When a sling is used and if it forms a wide angle as it leaves the hook, the strain is much more than when it forms a narrow angle. Apply load to a sling gradually.



Protect chains or slings when they passover the corner or edges.

 ` 

Rope or chain slings must be properly attached to the crane hook or other part of the lifting gear. E.g. by a ring or thimble or sling eye.



The rope strength can be reduced significantly due to corrosion, pitting or by heat. Damage is apparent from excessive kinking, crushing or several twist operation.



All hooks used for lifting must be fitted with a safety latch to prevent the sling eye or the load coming out of the hook.



Multiple slings (2, 3, 4 legged etc.) must be properly distributed so that no leg is overloaded.



Secure the proper length, never tie a knot in a sling or bolt with the chain to shorten or lengthen it. As much as possible avoid choke hitch and make use of straight hitch.



Reject a chain if inspection shows a flaw, welded, cracked, tractctured etc. put a notice “DANGER – DO NOT USE” tags.



A wire rope must be used if more than 5% (one in twenty) of the wires can be seen to be broken in any ten meter length.



Do not cross a chain, do not twist or kink chains or sling.

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LIFT TRUCKS:  Only qualified and designated persons are permitted to operate such vehicles.  Before starting, the operator must properly check the vehicle for safety. Unsafe vehicle is not to be used. Report any trouble, to your superior immediately.  No one except the operator is permitted to drive the vehicle.  Sound horn when approaching building entrance, exits and blind corners.  Position and apply emergency brake. When backing up or reversing, look in the direction of the motion.  Before switching off the vehicle, lower the forks or scoop to down.  Ensure one fire extinguisher min, of 12 kgs(DPC) is always available in the vehicle.  Unsafe driving or horseplay is not permitted.  Avoid sudden stop/breaks except in an emergency.  Watch overhead clearance.  Spread forks to suit load widths. Lift, lower and carry loads with the mast vertical or tiled back, never forward.  Break to full stop before changing from forward direction to reverse or vice versa.  For better vision with bulky loads, drive backward.  Keep ignition switch off or engine off whenever you leave or move away from the vehicle.  Ensure that vehicle has a valid safety certificate and work permit before entering inside the hazardous area.

9 Control of Hazardous Substance

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Exposure to substances hazardous to health ,can result in acute, and or chronic ill-health. Hazardous substances may include chemicals, pathogens, and secondary products like solder fume, or solvent vapor. Safety Engineer of the project shall ensure that all hazardous substances within the workplace are assessed, and controlled. Managers should ensure that all substances are assessed before purchase, and where necessary safer alternatives found. ORGANISING Responsibilities and Accountability The Safety engineer is responsible for ensuring that hazardous substances are managed to the required standards. The Safety supervisor of the sub-contractor shall ensure that contractors comply with the requirements of this hazardous substances standard. Training The company safety induction program will provide information on any hazardous substances, and manual, material handlings, confined space and permits. Instruction and training will be provided in the use and maintenance of PPE Safety engineers will attend hazardous substances awareness training. Depending on the level of risk, this may be a specific event, or part of a general health and safety awareness event. The hazardous substances coordinator, i.e. the Safety engineer will receive training from the Owner. Risk Assessment and Controls Safety engineers will have a procedure for undertaking hazardous substances assessments. This procedure will include the requirement for:   

Identification of jobs/tasks Identification of substances (i.e. an Inventory) Assessment of hazard and risk Review

When controls have been identified they will be documented in written safe systems of work. The assessment will involve the employees as much as possible, and they will be consulted on the controls to be introduced and the reasons for them. Assessments will be posted in the workplace, and employees briefed on the contents.

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To ensure that the assessments remain ‘live’ there will be a scheduled programmed for undertaking, and reviewing hazardous substances assessments. MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team Active Monitoring - Safety Inspection Where ever necessary, health surveillance programmers will be conducted Any engineering controls introduced to minimize the exposure to hazardous substances shall be subject to routine inspection, and maintenance. Reactive Monitoring - Accident Reporting, Accident Investigation There will be a system for the reporting cases of occupational illness. Employees shall be encouraged to report ‘minor’ conditions, because these can lead to more serious conditions. Where incidents of occupational ill health arise ,a detailed investigations will be undertaken. AUDITING AND REVIEW Auditing: Procedures shall be included in the annual risk management audit. Review: Performance shall be reviewed at the annual management review

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10 ELECTRICAL SAFETY AT WORK Note: ABB has a separate guidance/procedure while working with over 1kV. The following procedure of ABB which is followed for various electrical projects will be followed for this project also. The procedure is as under: Personnel working with electricity can suffer electric shocks and burns, while others can be exposed to the risk of electric fires. Working on and operation of electric power installations must be carried out in accordance with the guidelines laid down in VDE 0105 or an equivalent specification. General In addition to the following general safety instructions all applicable local, national and international safety regulations will be observed. Any specific safety instructions given in the manufacturer’s product specification publications will be followed. Only properly trained and authorised personnel shall be permitted to operate or handle any portion of the equipment. This also applies to settings, adjustments, inspections and maintenance. Every precaution shall be taken to prevent accidents and incorrect operation. Suitable protective equipment, warning notices and accessories will be available and maintained in a serviceable condition. Some examples are:

..................................................................................Insulating protective clothing (gloves, boots, overalls, headge

........................................................................................................................Eye protectors (goggles, protective mas

...........................................................................................Insulating protective devices (plates, mats, cloths, screen

...........................................................................................Insulated tools (hand tools, tools for replacement of fuse

..........................................Equipment and devices to provide security against reconnection (locks for actuators switches and isolators, warning signs)

...................................................................................Equipment to ascertain the absence of voltage (voltage teste

........................................................................................................................Equipment for earthing and short-circuiti

........................................................................Equipment for limiting the work area (portable partitions, ropes, flag warning signs) Working on Electric Power Installations The personnel responsible for carrying out the work must obtain information on the state of switches.

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Commencement of work Before beginning work on an installation, the Site manager will ensure that all persons who are at work are fully conversant with the work to be carried out. The following `Five Safety Rules' will be observed: 1.Disconnect completely 2.Secure against reconnection 3.Verify de-energised status 4.Carry out earthing and short circuiting procedures 5.Enclose or cover adjacent exposed live parts Disconnect completely The part of the installation on which work is to be carried out will be completely disconnected. (Every possible source will be switched off). Neutral conductors in high voltage installations are to be switched off. Capacitors without automatic discharge are to be discharged by using suitable devices. If the responsible person has not personally completely disconnected, he will wait for verbal or written notification of complete disconnection. Absence of voltage is no proof of complete disconnection. Secure against reconnection Equipment, e.g. switches, which have been used for complete disconnection will be secured against reconnection. For the duration of the work prohibition signs must be securely attached to switch handles, actuators, fuse mountings, and circuit breakers etc., which have been used for complete disconnection. (e.g. “Do not switch”, `Work in progress/place.../sign to be removed only by...'). Fuses shall be removed and kept secure, power drives will be rendered inoperative, switch locking devices shall be used, etc. Verify de-energised status The absence of voltage must be checked on all poles at the working point. The absence of voltage will be checked using suitable test equipment (voltage testers, etc.) The voltage test equipment must always be checked for correct functioning immediately before use. The absence of voltage may only be established by the responsible person authorized by the site manager. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Carry out earthing and short circuiting procedures At the work point, all parts which are to be worked on will first be earthed and then shortcircuited. If work is carried out on an interrupted circuit (broken line, etc.) where voltage (operating voltage, induction voltage) may be present on both sides, it is necessary to earth and short-circuit on both sides, or the interruption point shall be bridged in a short circuit proof manner and earthed and short-circuited on one side. Earthing and short-circuiting devices will always be first connected to the earthing system and then to the equipment to be earthed. Enclose or cover adjacent exposed live parts Protection against direct contact with exposed live parts adjacent to the working point is to be ensured by covering or enclosing the exposed live parts. The covering shall be sufficiently well secured and reliably attached. When protection against contact with exposed live parts adjacent to the working point cannot be ensured by the use of covers or enclosures (unless the whole equipment is dead) the responsible person must ensure that he does not reach the danger zone either with a part of his body or with an object. After ensuring that all the safety measures are carried out the engineer in charge must issue, to the head of the work crew, a 'permit to work' (an authorisation to carryout the work).

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Table 1: Danger zones in relation to rated voltage (Based on VDE 0105)

Rated Voltage

Limit of danger zone (Distance in air from live part)

up to 1000 V

The surface of the live part is the limit of the danger zone. Touching the part is dangerous

over 1 kV up to 6 kV

90 mm Indoor installations

over 6 kV up to 10 kV

115 mm Indoor installations

over 6 kV up to 10 kV

150 mm Outdoor installations

over 10 kV up to 20 kV

215 mm Indoor and Outdoor installations

over 20 kV up to 30 kV

325 mm Indoor and Outdoor installations

over 30 kV up to 45 kV

520 mm Indoor and Outdoor installations

over 45 kV up to 60 kV

700 mm Indoor and Outdoor installations

over 60 kV up to 110 kV

1100 mm Indoor and Outdoor installations

over 110 kV up to 220 kV

2200 mm Indoor and Outdoor installations

over 220 kV up to 380 kV

2900 mm Indoor and Outdoor installations

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Warning! A circuit will never be energized without first ensuring that no personnel are working on any portion of the circuit, and checking that the earthen switches are opened and/or all the temporary earthing links have been removed. Completion of work After completion of work, tools, accessories and safety measures are to be removed from the work point in such a way that no danger arises. When the operating condition of the equipment has been restored, the 'permit to work' must be returned to the engineer, duly signed by the head of the work crew and authorized by the site manager, before the equipment may be recommisioned.

Operating Electric Power Installations: Isolating Switches, Circuit Breakers etc. The switchgear must be operated within clearly defined safety rules. Mechanical and/or electrical interlocks provide a reasonable degree of safety, but cannot be expected to be entirely "fool proof" under all circumstances, i.e. they can be defeated by master keys or unauthorised bypassing etc. Care should be taken to synchronise all circuits that call for such operations. A 'permit to work' is not to be issued until all safety precautions have been taken (circuit isolated, current carrying parts earthed, area of work clearly defined by means of rope/red flags etc., disconnectors and circuit breakers safely locked or blocked open etc.). Irrespective of interlocks or other safety devices isolators, circuit breakers, etc. should be operated along the following lines: A LOG BOOK must be provided, in each station, for recording ALL OPERATIONS whether manual or automatic. All operations are to be entered in this book, in a concise form, together with origin of order, exact time of performance, name of operator and the cause or reason of the operation.

Note: Even normal routine operation will be performed with instructions from the engineer in charge. After receiving any instructions, the operator must proceed in a calm and logical manner, bearing in mind all direct and indirect involvement of the operation to be performed. Operations must be carried out one by one, in a logical sequence. Never proceed with simultaneous operations. After completing any operation, check the new condition of the position indicator of the apparatus and the related discrepancy switch. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Caution: No attempt is to be made to bypass interlock or to open or close an “offload” switch if there is a possibility, however remote, of breaking or making a current carrying circuit. Warning: A circuit must never be energised without first ensuring that no personnel are working on any position of the circuit, and checking that the earthing switches are opened and /or all the temporary earthing links have been removed. Operation of line earthing switches The engineer in charge (or operator) must obtain either a written order or telephone message (all telephone messages must be confirmed by a check back call) from the operating engineer concerned. This order or message should confirm that the other end of the line is isolated and that all parties involved have been duly informed.

Warning: Due to the nature of the risk involved, operation of these switches must be performed with the utmost care. After entering all details of the message in the log book, the engineer (or operator) must isolate the line at his end, lock the line isolator open and place warning instructions on it. The line must then be earthed and the time of earthing entered in the log book. Confirmation of the operation is to be given to all parties concerned. The line earthing switch must not be opened before all parties concerned have been duly informed or before an order has been received from the operating engineer

Warning! If any work has to be carried out on a line, the line must be earthed at both ends and a “permit to work” (giving the nature and location of the work, where the line is earthed, etc.,) will not be issued to the person in charge of erection until the owner have confirmed that the “permit to work” can be issued. The person in charge of maintenance must acknowledge receipt of the `permit to work' and sign the log book (signature, date and exact time). Local earths must be applied to the line, at each side of the point at which the work is to be carried out. Upon completing the planned work the person in charge of maintenance will sign the 'permit to work' under a clause stating: ``Above work completed, temporary earthing leads disconnected, all tools and equipment taken away, men instructed to consider line live, circuit ready for recommissioning''. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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The signature must be followed by the date and exact time. Upon receiving back the 'permit to work', the engineer concerned will enter the details of the permit in the log book, together with the date and exact time, followed by his signature. Instructions will be given, to the owner to open the earthing blades and recommission the lines.

Note: Where the operations performed on switchgear related to a circuit linking two stations, there must always be precise instruction given to all the involved parties and confirmation obtained that such instructions have been out. Operation of a Circuit breaker and associated isolators:

Warning! When a circuit breaker is opened, the associated isolating switches must also be opened. Circuit breakers are designed to work safely, carry and break load and system fault currents. Although they provide a reasonable degree of safety ,they are not interlocked to prevent operation and it is also possible that leakage currents can pass from one pole to the next and should therefore not be used as a disconnector (with a disconnector any leakage currents are passed to earth). For the above reasons and in order to avoid unnecessary stresses across circuit breakers under `system out of phase' conditions, they should not be left open across live circuits longer than required for routine operations.

Warning! An open circuit breaker must never be considered as providing sufficient safety when work is to be carried out on a circuit. A “permit to work “must never be issued unless the associated disconnections are opened.

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40(102)

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11 Sulphur Hexafluoride (SF6) Gas SF6 gas is:

....................................................................................................................................................................................Non to

......................................................................................................................................................................Non inflammab

..................................................................................................................................................................................Colourle

..................................................................................................................................................................................Odourle SF6 GAS PRESENTS NO DANGER TO HEALTH SF6 gas remains chemically stable even when in contact with oxygen. Provided that the concentration of SF 6 gas is not excessive, it can be inhaled without harm. When, due to the effect of a high temperature arc, the SF 6 gas is partially decomposed into solid and gaseous secondary products, it appears as a dust deposit. When the dust deposit is exposed to humid air, sulphur dioxide (SO 2) and Hydro-fluro (HF) are (slowly) produced.

Note: The dust deposit has a pungent smell . Whether in a pure or decomposed state the SF 6 gas is harmless provided the following elementary precautions are observed when opening SF 6 gas filled modules: a).............................................The gas filled switchgear modules must be evacuated in a closed cycle. As far possible the gas must be pumped into a storage tank by means of a compressor.

b)............................................The module must be then evacuated down to 10 Torr (using a vacuum pump) th exhaust gas being released to atmosphere via a neutralising filter (1 % concentration of Sodium Hydroxide in water). The filter must be located outdoors.

c)...........................................................The module must then be filled with air or nitrogen and item b) repeate

d)....................................................................................................... The switchgear module may now be opene

..........................................................................................................................................................Wear protective glove

...........................................If there is a noticeable dust deposit (decomposition products) protective goggles and filter mask must be worn. .............................................Any areas of skin that become contaminated with decomposed gas products must rinsed clean with water.

......................................Avoid disturbing dust deposits. Dust deposits should be removed using a vacuum clean with a paper filter. The vacuum cleaner should preferably be of the cyclic type to ensure NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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maximum possible dust separation. A non fibrous cloth should be used to remove dust deposits adhering to surfaces. In the event of a major fault involving a high current arc, the operating room and any lower level rooms must be ventilated before entering.

Note: SF6 being heavier than air, will be collected at the lowest possible level (cable basement, cable channels etc.,) and displace the air. It is therefore essential that effective precautions are taken to ventilate these areas before permitting access. Operation of Electrical Power Installations The instructions also apply to setting up and modifying power installations where the installation or individual components are live, live components can be touched or the components of the system under construction can become live. These instructions, which are based on the well proven German standard VDE 0105 Part 1 specification, apply to the operation of power installation. They also apply to proximities to power installations during construction work and other non-electrical work. Terms and Definitions of Installations and Workshops Power installations Power installations are electrical installations with equipment for the generation, transformation, storage, extending, distribution and consumption of electrical energy for the purpose of work, e.g., in the form of mechanical work, to generate heat and light or for electro-chemical processes. Part of a power installation Part of a power installation is a single piece of equipment or several pieces of equipment connected together where it or the individual piece of equipment is functionally connected to the power installation. Electrical equipment Electrical equipment is, in short, all items which collectively or individually serve the purpose of the application of electrical energy. These include, e.g., items for the generation, extending, distribution, storage, measurement, transformation and consumption of electrical energy including the field of telecommunications. Protective equipment and accessories are considered as electrical equipment where they are subjected to the requirements of electrical safety. Outdoor installation Outdoor installation is an electrical installation in the open. Indoor installation Indoor installation is an electrical installation inside a building or in an enclosure where the equipment is protected against the affects of the weather. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

42(102)

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Electrical workshop Electrical workshop is a room or a location used essentially for the operation of electrical plant and which, as a rule, is not entered by lay persons. This includes, e.g. control rooms, switching stations in separate rooms, separate electrical test rooms and laboratories, machinery halls of power stations and similar places where the equipment is not operated by lay persons. Closed electrical workshop Closed electrical workshop is a room or a location used exclusively for operation of electrical installations and which is kept locked. Skilled electrical personnel and trained electrical personnel are allowed entry, but lay persons may only enter when accompanied by a skilled electrical person or trained electrical person. This includes, e.g., closed switching and distribution installations, transformer units, control rooms, distribution systems within metal housings or in other closed systems, mast stations. Terms and Definitions of Conductors and Conducting Parts Outer conductors Outer conductors are conductors which connect power sources with consumer equipment but which do not originate at a middle or star point. Neutral conductor Neutral conductor is a conductor which is connected to the middle or star point and which carries electrical energy. In circuits over 1 kV this conductor is also termed the star point conductor. Protective conductor (PE) Protective conductor (PE) is a conductor which, for some protective measures for indirect contact, is used to connect conducting parts with

...........................................................................................................................................................other conducting par

.................................................................................................................................................extraneous conducting par

................................................................................................................earths, earth conductors and earthed live par PEN conductor PEN conductor is a conductor which combines the functions of a neutral and protective conductor. Live parts Live parts are conductors and conducting parts of equipment which carry a voltage under normal operating conditions. This also includes neutral conductors, but not PEN conductors and those parts electrically connected to them. Terms and Definitions of Protection Against Electric Shock Hazards Protection against direct contact Protection against direct contact includes all measures which prevent a person contacting live parts or, for rated voltages above 1 kV, prevent approach to within dangerous proximity of these parts (reaching the danger zone). NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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This can mean a complete or partial protection. Partial protection consists only of protection against inadvertent contact. Protection in the event of indirect contact Protection in the event of indirect contact is the protection of personnel from dangers which could arise due to contact with conducting parts or extraneous conducting parts if a failure occurs. Protective device clearance Protective device clearance is the clearance between the protective device and the live parts (Fig. 1). Danger zone Danger zone is the area limited by the dimensions in Table 2 against which no complete protection against direct contact with live parts exists (Fig. 1). The danger zone can be narrowed by suitable protective devices. For voltages up to 1000V, the surface of the live part is regarded as the limit of the

Warning! For voltage over 1 KV, reaching the danger zone is considered the same as touching live parts. Safety distance Safety distance is the shortest distance between live parts without protection against direct contact and personnel, or tools, equipment, accessories and materials held by personnel, who for certain work operations must be maintained as a minimum Fig. 1). The distances are given in Table 3 and 4 in relation to voltage value, activity and personnel zone. Terms and Definitions of Operation Operation Operation of power installations includes control and work. Control Control of electrical equipment means monitoring and operation (switching, adjusting, controlling). Operation can also be by automatic devices. Work Work on electrical equipment and in electrical installations includes the repair (e.g. cleaning, rectification of defects), modification and commissioning. Maintenance includes preventive maintenance and the rectification of defects. This also includes:

.................................................................................................................................servicing, e.g., lubrication and painti .......................................................................monitoring, e.g., visual examination, measuring, testing on a regular opportunity basis

............................................................................................................................................................................................rep

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44(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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 replacement of components  checks and test runs Cleaning chiefly concerns electrical equipment. Cleaning in electrical workshops and closed electrical workshops also includes floors, walls, covers and similar items. Modification also includes extending and reducing electrical installations. Working in the vicinity of live parts Working in the vicinity of live parts includes activities of all kinds in the course of which a person does not maintain the safety distances, shown in Table 4, from live parts for which there is no complete protection against direct contact, either with parts of the body or objects, without touching live parts or, for voltages in excess of 1 kV, does not reach the danger zone.

Working on live parts Working on live parts covers activities of all kinds during which a person, either with Parts of the body or tools, touches conducting or live parts, for which no protection against direct contact exists, or, for rated voltages in excess of 1 kV, reaches or penetrates the danger zone. Contact between a person and live parts can also occur via a liquid, e.g., a water jet. Complete disconnection Complete disconnection is the complete switching off or disconnection of an installation on all sides, or of part of an installation or equipment from all non-earthed conductors. Terms and Definitions of Personnel A skilled electrical person A skilled electrical person is a person who because of his technical training, knowledge and experience together with knowledge of relevant standards is qualified to assess work assigned to him and recognise potential dangers.

Note: Several years experiences in a particular field can be used when assessing the technical training. Trained electrical person Trained electrical person is one who has been instructed by a skilled electrical person in how to carry out tasks assigned to him, in the potential dangers of inexpert actions and, if necessary, given on-the- job training as well as instruction in the necessary protective devices and safety measures. Lay person Lay person is one who is neither qualified as a skilled electrical person nor as a trained electrical person.

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45(102)

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Use of Personnel - General Requirements Personnel shall be informed of the safety regulations, operating requirements and protective measures applicable to their work and shall be required to comply with these. These instructions shall be repeated at regular intervals in accordance with the operating conditions. Before starting work the supervisor responsible for the task shall ensure that the safety regulations are adhered to and that personnel are made aware of special dangers which are not immediately apparent to them. Clearance that the work points are completely disconnected, which is required before commencing work, shall be in accordance with above paragraph. Before commencement of underground construction work the supervisor responsible for the work shall obtain information about the routing of cables and conductors. Personnel who are only temporarily employed or employed only on specific tasks, shall be instructed as to the dangers and safety regulations for these tasks and warned to proceed with caution. If one task is carried out by several persons together, one of them is to be designated supervisor. Accident Prevention, First Aid and Fire Control General If equipment, posters and accessories are required for accident prevention, first aid and fire control these shall be made available in sufficient quantities. First aid A sufficient number of the labour force shall be trained in First Aid including mouth to mouth resuscitation (CPR) and external heart message. This training shall be repeated at suitable intervals. Fire control For the procedure in event of fire refer to local regulations. Personnel shall be instructed in the operation of appropriate fire extinguishers for fire fighting. This instruction shall be repeated at suitable intervals. If fire breaks out, dangerous or endangered parts of the electrical power installation shall be disconnected unless required to be live for fire fighting or where switching off would give rise to other dangers. Defect Rectification If defects, which constitute a danger to personnel or equipment, are detected at or in power installations, the personnel working in that area shall immediately take steps to rectify the defect. If operating conditions do not allow this, the danger is first of all to be localised, e.g., by sealing off, identifying and erecting signs. The supervisor or appropriate authority shall be informed as soon as possible.

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46(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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Passage Ways and Operating Areas access to switching and distribution installations, switches, equipment with indicators, to machinery as well as to the area required for operation, monitoring and servicing shall be kept free. Storing and Securing Objects No object shall be stored or secured in dangerous proximity to unprotected live parts of installations. No objects shall be hung or attached to cables and conductors, protective clothing, protective screens, protective strips, actuating devices, housing of equipment or fire extinguishing equipment. This does not apply to items forming part of the actual installation such as identification and safety plates, protective covers and locking devices, e.g., padlocks. Prevention of Ignition Highly flammable materials and objects shall be located or stored at such distances from heating and resistance equipment, electrical machines, switching and distribution systems, fuse boards, other electrical equipment with exposed contact points and uninsulated conductors laid in an unprotected manner that they cannot ignite. Workshops Electrical workshops may not be entered by unauthorised personnel. Closed electrical workshops will be kept closed. The keys shall be held in such a way that they are not accessible to unauthorised personnel. Closed electrical workshops may only be opened by authorised personnel. Access is permitted to skilled and trained electrical personnel, but lay persons shall, however, only enter them when accompanied by skilled or trained electrical personnel. Electrical test rooms with voltages up to 1000 V shall only be entered by skilled and trained electrical personnel. Insulating Covering and Protection against Electrical Shock Hazard in Installations Over 1 kV Installations with rated voltages above 1 kV with an insulating covering are to be considered as uninsulated insulations with regard to protection against electric shock hazard unless the conditions of DIN 57 101/VDE 0101 and DIN 57 670 Part 7/ VDE 0670. Part 7 with respect to protection against electric shock hazard are fulfilled.

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47(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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Lay persons, excavations, lifting devices. Markings, barrier

Skilled electrical personnel, trained electrical personnel or others under supervision of skilled electrical personnel or trained electrical personnel for specific tasks. Marking, barrier or fixed covering

LIVE PART

PROTECTIVE DEVICE

Skilled electrical personnel, trained electrical personnel provided the danger zone cannot be reached

Skilled electrical personnel trained electrical personnel with protective device in front of danger zone provided this cannot be reached

DANGER ZONE

Figure 1: Graphic representation of danger zones and safety distances when working in the vicinity of live parts (refer to tables for actual values) Safety Requirements for Accident Prevention and Fire Fighting Accident prevention equipment in accordance with above Paragraph will be adapted to the requirements of the particular operation and safety. So far as the accident prevention equipment is to meet electrical requirements, e.g. dielectric strength or leakage current, the safety requirements are fulfilled if one of the conditions in a) to d) applies.

a)..............................................................................The equipment satisfies the relevant valid VDE specificatio

b)....................................................Existing equipment was manufactured in accordance with VDE specification

c).............................................................Existing equipment was manufactured in accordance with drafts of VD NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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d)...................................For existing equipment to which the conditions of a) to c) do not apply, the main opera ensures that the deviations from current applicable VDE Specifications have no significance with regard to safety Accident Prevention Equipment The following are examples of accident prevention equipment, which may be used separately or in combination. Insulating body protection equipment Insulating protective clothing which prevents dangerous flow of current from live parts of installations with rated voltages up to 1000 V to the human body, e.g. gloves, boots and overshoes, protective overalls, headgear. Eye protectors which protect against the effects of arcing are protective goggles and protective masks. The protective goggles protect the eyes against the effects of arcing; the protective mask also protects the face, the ears and the front part of the neck. Insulating protective devices Equipment and devices made of insulating material for covering live e.g. shaped parts, plates, mats, cloths.

parts,

Medium for insulating the location, e.g. insulating mats, insulating working platforms, insulating floor coverings, insulating walls. Insulated tools Hand tools made of insulating material or tools of conducting material partially or completely covered by insulating material with sufficient mechanical and electrical strength, e.g. spanners, screwdrivers, pliers, knives. Operating poles Switching poles for rated voltages up to 1000 V, switching poles for rated voltages over 1 kV. Current discharge poles for rated voltages up to 1000 V for discharge of current from overhead lines. Insulated poles Insulated poles for rated voltages above 1 kV to take heads such as test equipment or tools, e.g. mirrors or lopping saws. These also include, for example, measuring poles and poles for knocking off hoarfrost deposits.

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49(102)

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Protective devices and equipment for enclosing Protective devices and equipment for protection against contact with live parts, e.g. plates, grids, strips, chains, ropes or poles which are to be positioned at a suitable distance. Equipment and devices to provide security against reconnection Locking and inhibiting devices are locks for actuators of switches and isolating switches (isolators) or similar items together with prohibition signs. Insert able insulating plates for manual switches and isolators with rated voltages up to 1000 V. Equipment for establishment of freedom from voltage and for scanning cables Two-pole voltage testers for rated voltages up to 1000 V. Single-pole voltage testers for rated voltages up to 250 V. Voltage testers for rated voltages above 1 kV. Measuring equipment and measuring devices, shot firing devices for cables and cable scanning equipment. Equipment and devices for earthing and short-circuiting Freely guided devices for earthen and short-circuiting. Force-guided equipment and special devices for earthing and short-circuiting. Equipment for limiting the work area Portable partitions, insulating plates, enclosures, barrier ropes and chains, strings of flags, flags, warning crosses and warning bands. Tools and equipment for removal and refitment of fuses NH (H.R.C. high rupturing capacity) fuse handles for rated voltages up to 1000 V. Fuse tongs for rated voltages over 1 kV up to 30 kV. Accessories to prevent confusion between switch panels Additional, prominent indicators for the duration of the work, e.g. warning crosses and warning bands. Extinguishing Fires To combat fires in fire installations, fire extinguishers or fire extinguishing equipment of a type suitable for the class of fire, and of a type and size adapted to the installation, shall be kept ready. If fire breaks out, they shall be readily accessible. The requirements that fire extinguishers and fire extinguishing equipment be of a suitable type shall be observed. Fire extinguishers, fire extinguishing media and fire extinguishing equipment shall be maintained ready for use and shall be inspected at stipulated intervals. Fire extinguishers shall carry an inspection mark.

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50(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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Occupied installations with rated voltages above 1 kV shall have at least one fire blanket available for extinguishing burning clothing and this shall be kept in a readily accessible place. In extensive installations, additional information should be provided on the works fire brigade or public fire brigade. Circuit Diagrams The circuit diagrams shall meet the operating requirements and shall cover the area which has to be monitored during operation. Standardised graphic symbols, in accordance with IEC specification 617, should be used for circuit diagrams. Electrical workshops and in closed electrical workshops In electrical workshops and in closed electrical workshops, particularly in switching installations and transformer substations, circuit diagrams of the installations shall be available.

Note: This can be in the form of an overall circuit diagram in a simplified singlepole representation of the circuit without ancillary lines. Depending upon the particular requirement, it shall show the type of current, voltage, frequency, number and cross-section of conductors, number, type and output of generators, transformers, rectifiers or inverters, batteries, capacitors, number, type and value of inputs and branches. Mimic diagrams or plug boards also constitute a circuit diagram. Power installations with rated voltages up to 1000 V Circuit diagrams are not necessary for power installations with rated voltages up to 1000 V provided the circuit can be clearly seen from the annotations. Power installations with rated voltages over 1 kV In power installations with rated voltages over 1 kV with up to 6 switch panels, circuit diagrams are not required provided the circuit can be clearly seen from the annotations. This also applies to single level, easily supervised installations with a single busbar and up to 12 switch panels. Display of Specification and Leaflets First aid instructions for accidents due to electricity, shall be displayed or hung up in electrical workshops, even if they are not occupied, and in closed electrical workshops. If there are several such rooms in a building, there is no need to provide the leaflet in each room. It is generally sufficient if the leaflet is kept at one point in the building, unless there are several completely separate installations. In local network stations, mast stations, sub stations which cannot be entered, sub-control rooms and control cabinets, there is no need to display or hang up the leaflet. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

51(102)

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Safety Signs To secure against reconnection and to prevent a switch-off which would interrupt an earth path or short circuit a prohibition sign is to be placed in position with the statement `Do not switch' And if necessary the additional statement `Work in progress/place.../sign to be removed only by ...’. This prohibition sign shall also be used to identify switches and installation which may not be operated, or where a restricted operation only is permissible (refer to above Paragraph). For control panels, minor control points and similar installations as well as for special purposes, other equivalent measures may also be taken, e.g. fitting caps. If signs are to be used to indicate the mandatory observance of the five safety rules (refer above Paragraph), a suitable sign shall be used for this purpose. The dimension of the safety signs shall be selected to ensure that they are clearly recognisable taking account of their particular use. Maintenance or Serviceability of Installations and Equipment Power installations are to be maintained in a serviceable state in accordance with regulations. The maintenance of a serviceable condition does not generally mean that existing installations have to be constantly adapted to the requirements of regulations which subsequently come into force. However, they shall be adapted to the new regulations if the new Standards expressly require this. Defects which constitute an immediate danger to personnel or equipment shall be rectified without delay.

Note: A defect is a condition which adversely effects safety and can be brought about because the installation is not in a serviceable condition within the requirements of the regulations or the Standards do not cover the particular operating requirements. Depending upon the nature of the work, defects are to be rectified by skilled or trained electrical personnel, or by lay persons under the supervision of skilled or trained electrical personnel. At suitable intervals, the state of power installations, accept those in dwellings, shall be checked by skilled electrical personnel, or under control and supervision of skilled electrical personnel in the case of electrical equipment. Where the operating conditions change, e.g. type of workshop (dry, damp, endangered by fire or explosion), the existing installation shall be adapted to the requirement of the current valid regulations. The condition of the insulation of power installations with rated voltages up to 1000 V shall be maintained to the requirement laid down in Paragraph Protection in event of indirect contact shall be maintained in an effective state in accordance with the regulations. Alterations to such things as trigger current and trigger NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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times may only be carried out by a skilled electrical person after prior checking of permissibility. Where it is possible to touch live parts, electrical equipment, including luminaries, shall be switched off to a voltage-free condition for cleaning.

Note; the voltage-free condition can, for instance, be achieved by withdrawing a plug or taking the measures laid down in Paragraph Electrical equipment shall always contain sufficient quantities of insulating and arc quenching materials and these shall be replaced at intervals which ensure the safe operation of the equipment. Safety devices and protective and monitoring devices required for safety shall not be rendered inoperative or inadmissibly adjusted or modified. This does not apply to actions taken during testing, defect location or during brief switch-over operations.

Maintenance of Serviceability of Protective Equipment and Accessories Insulated tools, insulating body protection equipment, insulating protective devices, equipment for actuating, testing and enclosing, earthing and short circuiting equipment as well as other accessories shall be maintained in a serviceable condition. Before use, the user shall check for obvious damage. Damaged items shall not be used unless they can clearly be used without danger.

Note: For earthing and short circuiting equipment, the condition of the cable in the vicinity of terminals and connectors can be critical. Insulating body protection equipment and other accessories which must have insulating properties to perform their function shall be kept dry. Insulated tools shall be kept separate from other tools. At suitable intervals and after every repair, the dielectric strength of insulating protective clothing shall be tested. Damage to insulating protective clothing may only be repaired by specialist workshops. Gloves shall not be repaired. Damaged gloves shall invariably be discarded. If exposed to damaging materials, e.g. oils, greases, acids, all accessories shall be cleaned using a suitable cleaning agent. The necessary Instructions for Use shall be available for accident prevention equipment. Safety signs, notices and posters shall be clearly legible, prominently positioned and maintained in a serviceable condition. Obsolete safety signs, notices, posters and designations shall be remove Circuit diagrams installations.

shall

be amended

without

delay to

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show modifications to 53(102)

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Periodic Servicing The purpose of periodic servicing is to discover defects which can occur after an electrical installation or electrical equipment have been commissioned or after a repair or modification.

Note: It is a prerequisite of periodic servicing those installations as well as fixed and moveable equipment met the requirements of the relevant Specifications after erection/or manufacture and that the intended tests were carried out before the initial commissioning. General To establish the serviceability of electrical installations and equipment they are to be periodically serviced. Such servicing may comprise visual examination, checking or measuring. Servicing shall be carried out using suitable material. No dangers of accident, fire or explosion shall arise during servicing. During servicing it shall be ascertained whether the existing electrical installations have been adapted as required in regulations. Required extent Depending upon individual requirements and operating conditions, the extent of servicing may be confined to random checks and also limited with regard to location (parts of installation) and also to extent of servicing operations, provided it is still possible to assess the serviceability. If, in particular cases, measurement cannot be taken in or at electrical installations without incurring unacceptable economic or technical expenditure, e.g. where there are extended earthing systems, large conductor cross-sections or intermeshed networks, other methods, e.g. calculations or use of network models shall be used to prove that the required values are maintained. Visual examination Examine electrical installations and equipment for externally visible damage and defects. Carry out a visual examination to establish whether electrical installations and equipment withstand the external influences at the location where they are used and still meet the additional requirements of the regulations for workshops and rooms as well as for special installations. Carry out a visual examination to establish whether protection against direct contact to live parts of electrical equipment is still present.

........................................Carry out a visual examination to establish whether the protective measures in eve of indirect contact still meet the requirements of the regulations.

a)..................................................................For protective measures with a protective conductor ensure th

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54(102)

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.....................................protective conductors, earthing conductors and equipotential bonding conductors ha the minimum required cross section,

.......................................protective conductors, earthing conductors and equipotential bonding conductors a correctly routed and still securely attached, .......................................................protective conductors and protective conductor terminals are still marked accordance with the regulations,

................................................................................................protective conductors are not connected to live par

...................................................................................protective conductors and neutral conductors have not bee interchanged,

...................................................for protective conductors and neutral conductors in switching installations an distributors, the requirement regarding identification and terminal points are maintained,

..............................................................................................the protective contacts of connectors can be effectiv

..........................................in protective conductors there are no excess current protective devices or switche

...................................................in PEN conductors no excess current protective devices are present and PE conductors cannot be switched on their own,

.............................................protective devices, e.g. FI (Differential current earth leakage protection), circu breakers, insulation monitoring devices, excess voltage dissipation devices, are still present as selected to the requirements of the regulations.

b)...........................................................For protective measures without protective conductors ensure th

........................................for protective low voltage and protective isolation, the current sources, conducto and other equipment are still present as selected to the requirements of the regulations

.......................................................................connectors fitted for protective low voltage are not used for oth voltages, .....................................................where there is a mandatory laid down protective isolation, only one item consumer equipment can be connected,

...................................................for protective isolation with more than one item of consumer equipment, th equipotential bonding conductor is not earthed,

..................................................the protective insulation is not rendered ineffective by conducting parts or b damage,

.........................................................................The insulation of the location still meets the requirements of th regulations.

......................................Carry out a visual examination to check that the overload protective devices are s correctly allocated to relevant conductor cross sections.

......................................................Carry out a visual examination to check that the overvoltage and overloa protective devices required for operation are still present and correctly adjusted. Carry out a visual examination to check that the required circuit diagrams, circuit annotations and instructions for use or operation are still present and applicable. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Carry out a visual examination to ensure that equipment for accident prevention and fire fighting, e.g. protective devices, accessories and safety signs are complete, of the correct size and type and show no signs of damage or defects. Checking Check the insulation monitoring equipment, e.g. in non-earthed auxiliary circuits, in the IT system (protective conductor system), as well as the FI (differential current protection) and FU (differential voltage protection) circuit breakers by operation of the test devices. Check the effectiveness of emergency off devices and locks.

protective

devices,

e.g.

protective

relays,

Check the effectiveness of safety circuits. Check the right hand rotation field for 3-phase wall and connector sockets. When doing so view the sockets from the front in a clockwise direction. Check the necessary signalling and indicating devices for correct functioning, e.g. signalling of switch setting indications to remote switch boards and indicating lamps. Testing Carry out testing using approved equipment Take readings to find the values which enable the protective measures in the event of indirect contact to be assessed. For equipment of Protection Class 1 (with protective conductor), connected via connectors, and also for extension leads, test the protective conductor for continuity and correct connection

Note: the correct value for continuity may be regarded as 1 Ohm Measure the insulation resistance in installations with rated voltages up to 1000 V. a) For tests in accordance with the following points b) to d) it is generally sufficient to measure the insulation resistance between: 

the outer conductor and PEN conductor or

 the outer conductor and neutral conductor as well as between the neutral conductor and earth separated for the purposes of the test. Measuring the insulation resistance of outer conductors against each other is necessary only when there is no earthed conductor in the conductors to be tested and no earthed sheathing. This dispensation does not apply to electrical workshops where there is a fire hazard. This test may be omitted for switch wiring in lighting circuits. b) For consumer equipment which is connected up and switched on: In this case the insulation resistance of the connected current path behind the overload protective device including it or the consumer equipment shall be at least 300 Ohm/V rated voltage. (refer also to d) If the reading is less than the laid down value, the test shall be repeated with the consumer equipment disconnected (refer to c).

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56(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

c) Without consumer equipment connected or switched on: In this case the insulation resistance between the overload protective devices, between switches or after the final overload protective device shall be at least 1000 Ohm/V rated voltage, i.e. the fault current of each of these sections at rated voltage shall not exceed 1 mA for each conductor (however, see d)). d) For outside installations or in rooms or areas where the floors, walls and installations are sprayed for cleaning purposes the insulation resistance:  for connected and switched-on consumer equipment shall be at least 150 Ohm/V rated voltage,  without consumer equipment connected or switched-on shall be at least 500 Ohm/V rated voltage, e) In deviation from b) the insulation resistance in the IT system (protective conductor system) shall be at least 50 Ohm/V rated voltage. f) For wiper conductors or wiper rings which have to be operated under unfavourable environmental conditions, e.g. outside cranes, coking plants, foundries and sintering plants, the values stipulated in c) to e) need not be maintained provided other measures, e.g. earthing of non-live attaching parts of the wiper conductor or ensuring that combustible materials are kept clear of wiper conductors, are taken to ensure that the leakage current does not cause dangerous shock voltages or fires g) The insulation resistance values are to be measured using DC The test voltage, with a load of 1 mA on the test set, shall be at least equal to the rated voltage of the installation. For circuits operated by protective low voltage, an insulation tester with a rated voltage of at least 250 V shall be used to measure the insulation resistance. For electrical equipment of Protection Class 1 (with protective conductors) and Protection Class II (protective insulation) connected via connectors, measure the insulation resistance of the equipment circuit against touchable metal parts. The insulation resistance is satisfactory when it is at least 1000 Ohm/V rated voltage for equipment of Protection Class I and at least 2 M Ohm for equipment of Protection Class II. Other tests

..............................................Check whether the existing installations and equipment still withstand any increase thermal or dynamic stresses due to the short circuit current following modifications in the conductor network or in the installation. ......................................In installations with rated voltages over 1 kV, check that the requirements, established the planning of the installation, for the earthing voltage and/or contact voltage, e.g. earth fault current in accordance with DIN 57 141/VDE 0141 are still maintained.

.....................................Carry out a visual examination at some stations and certain selected masts of a networ to check the conditions of earthing systems.

Note: For this examination a periodicity of approximately 5 years is suitable. It is generally sufficient to carry out this examination by excavation at individual positions

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57(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

..............................................Other or additional periodic servicing can be specified in `additional requirements´ `special requirements´ to the VDE Standard or may derive from the regulations. Examination and test of protective clothing Insulated protective clothing shall be examined and tested as follows:

a)................................................................................................................................................. Visual examinati

......................................................................................The relevant items shall be examined for any signs of extern damage.

b)............................................................................................................................................. Electrical voltage t

......................................Reduced test voltage of 1.5 kV for protective overalls and 2.5 kV for footwear and glove

............................................The test is considered to have been satisfactory if the protective overalls and footwe showed no breakthrough over a period of 1 minute and the gloves showed no breakthrough over a period of 30 seconds. Items of clothing which show a voltage breakthrough when tested shall not be reused. To monitor the test periodicity, the test position and the time of the test (month and year) shall in each case be marked on the tested items of protective clothing. This marking shall be durably made on the square allocated for that purpose. Operation of Power Installations - Accessories To operate power installations without danger, the necessary accessories shall be used. Operation of Power Installations - Access For rated voltages in excess of 1 kV, closed electrical workshops may only be entered provided at least partial protection against direct contact is ensured. Installations and Switches Which May Not be Operated or May Only be Operated in a Limited Manner Installations or parts of installations which may not be operated shall be switched off and as a minimum requirement be protected against switch-on by a prohibition sign at the positions where the installation can be brought into operation. In addition, the means for actuating or control of remotely controlled switches shall be rendered inoperative. Switches which do not meet the requirements at the installation point without restriction shall be marked and their operation suitably restricted, e.g. by de-activating relays, locking switches etc. Protection against Arcing When switching isolation switches (disconnectors) at the installation point in indoor installations, whose construction does not protect personnel against the dangerous effects of short circuit arcs and which are not locked against incorrect switching, the following apply:

a)........................................................Only those persons involved with the switching operation shall be prese

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 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

b)...................................At rated voltages above 1 kV where there is a risk of confusion, the individual switchi operations shall be indicated by inscriptions on the switchboards showing which switches are to be operated before the switching operations are carried out. Exceptions to this are switching operations for avoiding and rectifying faults and those carried out on individual orders from a higher authority where each switching operation is reported back or when such operations are supervised by a second person also authorised to carry them out.

Note: A danger of confusion may exist, e.g. where switching operations take place in installations with more than one busbar, with isolators connecting busbars, and in installations covering several floors which are difficult to supervise. Procedure in Event of Short-Circuits to Earth If a short circuit to earth which is not immediately, automatically switched off, occurs in a power installation with a rated voltage above 1 kV, measures shall immediately be taken to locate the point of the earth short circuit. If it is not possible to switch off after locating the position of the earth short circuit, immediate danger to personnel shall be prevented by e.g. erecting barriers around the earth short circuit point. Use of Electrical Equipment When using electrical equipment, e.g. moveable equipment, leads and connectors, it must be ensured that they satisfy local and operating requirements. Note: Serious damage can in particular occur to moveable leads and connectors due to severe mechanical stresses such as jamming, impact, blows, being run over by heavy vehicles and appliances. Excessive pulling when moving the equipment can loosen, or detach, the terminals. Leads can also be damaged by oil, acid, heat, cold and the like. Electrical equipment, particularly heating equipment shall be set up and operated in such a way that it cannot cause a fire. Extension leads with protective contact connectors and protective conductors only shall be used. Prior to use, moveable connecting leads

.................................................................................................................................................of moveable equipme

.............................................of equipment whose nature and normal use involves holding or moving by ha when live

..............................................of fixed equipment if moveable connecting leads are subject to special stress

.......................................................................................................................................................and extension lea shall be visually examined for signs of damage. Damaged electrical equipment shall not be used until repaired, unless further use clearly involves no dangers. Equipment which has been temporarily repaired may only be used for a short time if there are compelling reasons to justify this, e.g.

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59(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

maintaining important operating functions, in which case permanent repairs shall be carried out without delay. Earthing and short circuiting equipment shall only be used in installations where they can withstand the short circuit currents. For accident prevention equipment, the inscriptions, markings and instructions for use shall be observed. If for protective isolation due to special dangers presented by a metallic conducting location the regulations require the conducting housing of the equipment to be connected to the location by a special conductor for equipotential bonding, the equipment may only be operated when this connection has been made and visibly routed outside the power lead.

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60(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

Replacement of Fuses

Warning! Repaired or bridged fuses shall not be used Removal or insertion of fuses for rated voltages up to 1000 V. If there is no protection against direct contact when removing or fitting fuses and removing removable circuit breakers without tools, these may only be removed or fitted by skilled or trained electrical personnel. Fuses may be removed or refitted if

a)................................................................................................................ circuits are completely disconnected,

b)......................................................for equipment without load isolators, before replacement of the related fus

........................................it is shown by measurement that one of the switching devices ( in case of contactors a includes related auxiliary contactor) is switched off, or

...............................................................................................the separation of the contacts can be confirmed by visu examination, or

.........................................the inadvertent switching on of a switching device after the fuses during the fitting of t fuse is prevented, e.g. by removal of control fuses or observation of the switched state of auxiliary contactors NH (H.R.C. high rupturing capacity) fuses may only be removed or fitted using NH fuse detachable handles in cases where safety isolators, slide-in modules or similar items are not used. Live fuses may only be replaced when this can be accomplished without danger. This can, for example, be accomplished without danger under the following conditions:

.............................................................................................................In circuits with low power such as auxiliary circu

........................................................In circuits with high power such as motors, capacitors, heating circuits by use equipment such as load isolator facilities, e.g. safety load isolators but not however, multipole safety isolators.

...........................................For fuses of DO and D systems within the conditions of the Table in above Paragrap

....................................................For fuses of NH (H.R.C. high rupturing capacity) systems, provided accessories accordance with above said Paragraph are employed and these are used by specially trained, trained electrical personnel or skilled electrical personnel. Removal or fitment of fuses for rated voltages above 1 kV. For removal of fitment of fuses with rated voltages above 1 kV a voltage-free state in accordance with above Paragraph shall be established and ensured. Live fuses may be removed or fitted using fuse tongs or similar to-type isolating accessories provided this can be accomplished without danger (refer to above Paragraph). This applies also to installations with fused assemblies which can be hinged out or moved clear.

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61(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

Note; Fuse assemblies are in this case still regarded as live even when completely disconnected if their mountings are not earthed and short-circuited Fuses in an installation with fuse assemblies which can be hinged out or moved clear may be removed or fitted by hand without isolating accessories provided at least partial protection against direct contact with live parts and against penetration of the danger zone is provided and ensured. Where there are mast and tower stations as well as transformer sub-stations in which the switching devices for the upper and lower voltage sides are arranged in such a way that they cannot be interchanged, fuses on the upper voltage side of transformers with rated voltages from 1 kV to 30 kV may be removed or fitted by hand without use of insulating accessories provided the following conditions are fulfilled:

a).........................................................................The upper and lower voltage sides are completely disconnecte

b).....................................Each disconnection point for the upper voltage side is visible from the ground and fro the work station.

c).................................Each disconnection point for the lower voltage side can be monitored from the work poi if disconnection points cannot be seen from the work point, suitable measures shall be taken.

d)............................................The upper and lower voltage sides are secured against reconnection. On the upp voltage side a prohibition sign alone is not sufficient.

e).........................................................The freedom from voltage is at least established on the lower voltage sid Note: Transformer sub-stations are, e.g. garages and cellar sub-stations in which the transformer and its upper and lower voltage switching devices are located in the same room, junction stations and compact stations

Replacement of Lamps For rated voltages up to 250 V, 200 to 1000 W lamps which are in live circuits may be replaced only by skilled or trained electrical personnel. For higher voltages or power, lamps may only be removed or fitted to circuits in a de-energised condition. Producing and Maintaining a De-energised before the Start of Work and before Clearance is Given Notification

State

Before starting work which can only take place in a de-energised state, the operator responsible shall be notified of the intended work. Information on the switching state The supervisor or personnel working alone shall, in conjunction with the person responsible for complete disconnection, obtain information on the state of switches either by means of a valid circuit diagram or in some other way.

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62(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

Safety precautions to be observed Before beginning work on an installation, carry out the following `Five Safety Rules´ Disconnect completely Secure against reconnection Check systems de-energised Carry out earthing and short circuiting procedure Enclose or cover adjacent live parts Disconnect completely The part of an installation on which work is to be carried out shall be completely disconnected. In installations with rated voltages over 1 kV the required isolated gaps shall be established.

Note: Devices which fulfil the requirements for isolating gaps are: pull-out switching devices which meet the isolation gap requirements, isolators and fuse mountings. Safety isolators satisfy the insulating gap requirements only when switched off. The isolating gap requirements are also met by devices which have air gaps of at least 1.2 times the value given in table 2.E.g.isolating links or cable loops. In installations with rated voltages above 1 kV it is also necessary to switch off the switch in the neutral conductor, except in solidly earthed networks. Capacitors, whose automatic discharge is not ensured, shall be discharged using suitable devices. If the supervisor, or the person working on his own, has not himself completely disconnected, he shall wait for a verbal, written, telex or telephoned notification of complete disconnection. Other means of conveying information regarding complete disconnection may only be used when special measures are taken to ensure that no misunderstanding can arise. The notification shall give the name and, if necessary, the position of the person responsible for complete disconnection and correct transmission of the information. To avoid hearing errors when the message is transmitted verbally or by telephone, the supervisor or person working on his own shall repeat the message and await confirmation. The fixing of a time at which the installation is to be completely disconnected does not override these requirement

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63(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

Warning! The absence of voltage is not proof of complete disconnection . Secure against reconnection Equipment, e.g. switches which have been used for complete disconnection shall be secured against reconnection. For the duration of the work, a prohibition sign in accordance with above Paragraph shall be securely fitted to switch handles or switch actuators, controls, push switches, fuse mountings, circuit breakers, etc., which have been used to completely disconnect a part of the system or which could be used to make it live. If this is not possible, a prohibition sign prominently positioned in the vicinity is sufficient. If fuses or screw-in circuit breakers are used for complete disconnection, they shall be removed and kept securely or replaced by screw caps or blank inserts which can only be removed using a special tool, e.g. spanner. Fixed circuit breakers which were used for complete disconnection shall be secured against reconnection by suitable measures, e.g. adhesive foils or caps. For power drives, the means used to drive or control them, e.g. spring force, compressed air or current shall be rendered inoperative. For manually operated switches, existing mechanical locking devices shall be used to prevent reconnection. Remote control devices may also be used to secure against reconnection provided a reliable transmission is guaranteed. For remote-controlled switches in closed electrical workshops, there is no need to secure against reconnection at the point of installation provided the following conditions are fulfilled:

a)......................................................................The switch position is reliably signalled to the remote control poi

b)...................................A prohibition sign with the statement `Do not switch´ or a corresponding device, points the danger of actuating the relevant control switch. Inadvertent actuation of the switch is prevented by a suitable device.

c)..........................................The remote-controlled installation shall have a sign, in a prominent position, with t following wording: `Switching operation on this installation may only be carried out on the order of or with the authorisation of ...'. The particular remote control point shall be inserted in each case.

d)............................................The person responsible shall be informed by operating instructions of the restrict switching authority. Establish system is de-energised The de-energised state may only be established by a skilled or trained electrical person. The de-energised state shall be established on all poles at the work point. The voltage-free state shall also be established on all poles at the switch-off point if earthing and short circuiting is required to be carried out in accordance with above Paragraph . The de-energised state of completely disconnected parts of the installation shall be established:

............................................................................................................................................................using voltage testers 64(102) NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

.........................................................................................................................................using moveable test equipment

.........................................using fixed test equipment, indicating lamps or other suitable devices where a change the indications is observed when the voltage is switched off, or

.........................................by inserting fixed earthing devices, e.g. switch-on proof earthing switches in accordan with DIN 57 670 Part 2/VDE 0670 Part 2 or by moving earthing trolleys into position, or

..................................................by positioning suitable, driven moveable equipment for earthing and shortcircuitin If the de-energised state is achieved by remote controlled earthing switches, the switch position indications of the earthing switch are to be reliably transmitted to the remote control point. De-energised state may also be established:

........................................when working on overhead lines with rated voltages over 1 kV by positioning Cu (copp earthing cables with a minimum cross-section of 25 mm 2 with the aid of insulated poles.

.........................................................................................on overhead lines with only one circuit by using test earthin Earthing to establish a de-energised state is not required to meet the requirements of Paragraph 2.3.32, but it shall be carried out in such a way that the person performing the task is not endangered. When using voltage testers and moveable test equipment, the following precautions shall be observed:

..............................................Voltage testers and moveable test equipment shall be checked for correct functioni immediately before use. ......................................When using voltage detectors they must only be gripped by the handle and be handled such a way that the user maintains the necessary safety distance from all parts of the installation which might be live.

......................................................................When applying the test electrode of voltage testers, they shall be as f removed as possible from other live or earthed parts of the installation After the de-energised state has been established at the switch-off positions, there is no requirement to check for de-energised state at cables and insulated conductors or their accessories at the work point provided:

..........................................the cable or the insulated conductor can be clearly traced from the switch-off position the work point, or

..........................................................the cable or the insulated conductor is clearly located, e.g. by circuit diagram inscriptions, cable detecting equipment or cable scanning equipment. If the completely disconnected cable or completely disconnected insulated conductor cannot be clearly established, other safety precautions shall be taken before commencing the actual work in order to protect the workers from danger. Note: The cable can, e.g. be cut using a suitable cable cutting device or a mandrel can be driven into the cable using a shot firing device. Under unfavourable conditions a voltage can be created in the shot firing device after it has been operated. This can, generally, only be established using suitable organisational methods (e.g. communication with the department responsible for the network) or by using special technical equipment NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

65(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

Carry Out Earthing and Short-Circuiting Procedures General requirements At the work point, all parts which are to be worked on shall firstly be earthed and then shortcircuited.

Note: Test earthing is not earthing but only a measure to establish the deenergised state (refer to above Paragraph. The earthing and short-circuiting shall be visible from the work point. As a deviation from this, earthing and short-circuiting may be carried out in the vicinity of the work, point provided the location or safety reasons make this necessary. When working on transformers with flange end fittings, the nearest switching points to the transformer shall be earthed on the upper and lower voltage sides.

Note: Contact-protected connector mountings for rated voltages above 1 kV shall be treated as flanged terminals (refer the above Paragraph). The earthing and short-circuiting of the separated connector can be achieved using to-type devices and accessories If during working, a line is broken or if work is carried out at an interruption point, e.g. disconnected line or switch where voltage (operating voltage, induction voltage etc.) may be present on both sides, it is necessary to earth and short-circuit on both sides of the work point, or the interruption point shall be bridged in short-circuit-proof manner and earthed and short-circuited at one side of the work point. Earthing and short-circuiting devices shall always be firstly connected to the earthing system or to an earth electrode and then to the components to be earthed. When using earthing switches, it is possible to simultaneously earth and short-circuits. In this case, earthing and short-circuiting are considered to be established if this is indicated by the switch position indicator. For the duration of measurements, short-circuiting and earthing can be removed if the measuring procedure demands. Before commencing work to locate faults in cables, there shall be brief earthing and shortcircuiting. If cables or insulated conductors with continuous metal sheeting earthed on all sides are located in an area affected by AC current paths or rigidly earthed high voltage networks, at least 16-mm2 Cu conductor before separation shall bridge the sheathing at the work point. If when working on the wires of such cables or insulated conductors it is not possible to establish by calculation or measurement that both in the operating state and when earth short-circuiting the influencing installation the values given in Fig. 2 are not exceeded at the work point, the worker shall take protective measures against potential high shock hazard NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

66(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

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voltages, e.g. induction voltages. Suitable protective measures and devices in accordance with Paragraphs will be used. If cables without a metallic sheath or metallic sheathed cables with insulating joints are used, only one switch-off point shall be earthed and short-circuited; the others shall be short-circuited only. To establish and remove each of these short-circuits, temporary earthing shall be provided at this point and during this period, the earthing at the other switch-off points shall be removed. The above work may only be carried out by skilled electrical personnel or by trained electrical personnel under supervision of a skilled electrical person. Equipment for earthing and short-circuiting Earthing and short-circuiting may not be carried out without using the equipment of the installation designed for this purpose, e.g. earthing switches, earthing trolley, force-guided electrode earthing and short-circuited equipment except by using free-guided earthing and short-circuiting equipment. The cross-section of the short-circuiting equipment shall be selected in accordance with Table 1 to match the type of installation, the short-circuit current arising at the point of use and the duration of the short-circuit. This does not apply to temporary earthing. Metallic structural parts, e.g. chassis parts, and masts may be used for earthing and shortcircuiting provided they satisfy the requirements and their mechanical strength is not impaired. Where cables are used for earthing and short-circuiting, the length of cable between each two terminals shall be a minimum of 1.2 times the distance between the terminals. Where short-circuiting equipment-using cables is connected in parallel, the following requirements shall be fulfilled:

......................................................................................................................................The cables shall be of equal leng

..........................................................................................................................The cables shall be of equal cross-sectio

........................................................................The same connecting parts and connecting components shall be use

......................................................The items of equipment shall be fitted close together with the cables laid parall The cross-sections of parallel-connected cables may be fully loaded provided that the short-circuit cables are only loaded once with the full short-circuit current. This applies generally to installations with rated voltages from 110 kV. Switching devices used to transfer earthing or short circuiting to other equipment, e.g. wires, cables or busbars shall be secured against switch-off (see also the above Paragraph ) Additional requirements for installation with rated voltages up to 1000 V Earthen and short-circuiting is not necessary in installations with rated voltages up to 1000 V provided the de-energised state is established in accordance with the `five safety rules' This also applies to protective insulated overhead lines.

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67(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

REV-2

When working on overhead lines with rated voltages up to 1000 V, except protective isolated overhead lines, all conductors, including the neutral conductor as well as switching and control wires, e.g. for road lighting, should, if possible, be earthed in the immediate vicinity of the work point and, in all cases, shall at least be short-circuited. Short-circuiting using bare copper cables or wires is permitted in installations with rated voltages up to 1000 V. Additional requirements for installation with rated voltages above 1 kV For overhead lines with rated voltages above 30 kV, earthing and short-circuiting is required at each switch-off point in addition to earthing and short-circuiting at the work point. For overhead lines with rated voltages between 1 kV and 30 kV, earthing and short-circuiting shall take place at least one switch-off position. Mast switches may be earthed and short-circuited at one of the adjacent masts. When working on cables and insulated conductors with rated voltages above 1 kV, e.g. on terminals and joints and when working on electrical equipment with rated voltages above 1 kV connected by means of branch cables or insulated open feeders, e.g. motors, earthing and short-circuiting may be omitted at the work point but, however, all switch-off points shall be earthed and short-circuited. When doing cable work, the transition from cable to overhead line shall be earthed and short-circuited at the transition point. When earthing and short-circuiting is achieved by remote controlled earthing switches, the switch position indication of the earthing switch shall be reliably transmitted to the remote control point. For rated voltages above 1 kV the equipment for earthing and short-circuiting shall be brought into position on the conductor using an earthing rod unless a temporary earth had already been fitted in the immediate vicinity. Copper cables used for temporary earthing shall also be positioned using an earthing rod. This does not apply to earthing devices, e.g. earthing trolleys which are in integral part of the installation and whose very construction prevents any risk of contact with parts of the installation to be earthed. If all switched-off points of electrical installations and overhead lines with rated voltages above 1 kV have been earthed and short circuited it is sufficient to provide Cu earthing and short circuiting cables of 25 mm 2 cross-section at the work point. When working on only one conductor of an overhead line, no short circuiting is required at the work point provided the following conditions are fulfilled:

a).......................................................................................... All switch-off points are earthed and short-circuit

b)........................................The conductor upon which the work is being carried out and any parts of the me mast within the working area are bonded and earthed by a Cu earthing cable of at least 25-mm2 cross-section.

c)......................................The earthed conductor, the work point and the work force maintain a distance to t remaining conductors of the same system and to other live parts of:

...................................................................................................................at least 2 m for rated voltages up to 110 k NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

68(102)

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REV-2

................................................................................................As detailed in Table 3 for rated voltages above 110 k Cover or Enclose Live Parts For the requirements for covering and enclosing, refer to above Paragraph Clearance to Work The work point may only be cleared for work by the supervisor, or a person working alone may only commence working, when the measures detailed in the `five safety rules' have been carried out.

Figure 2: Shock hazard voltage U B in relation to the duration tf of the fault current when carrying out work in accordance with the above paragraph .

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69(102)

 Safety Manual Project: DOW-PIC Olefin2 Project, Contract Ref:03IN03-063

Cross section of copper cable

REV-2

Maximum permissible short-circuit current in kA for a duration of: 10 s

5s

2s

1s

0.5 s

16 mm 2

1.0

1.4

2.2

3.2

4.5

25 mm 2

1.6

2.2

3.5

4.9

7.0

35 mm 2

2.2

3.1

4.9

6.9

10.0

50 mm 2

3.1

4.4

7.0

9.9

14.0

70 mm 2

4.4

6.2

9.8

13.8

19.5

95 mm 2

5.9

8.4

13.2

18.7

26.5

120 mm 2

7.5

10.6

16.7

23.7

33.5

150 mm 2

9.4

13.2

20.9

29.6

42.0

These values were established in accordance with DIN 57 683 Part 1 / VDE 0683 Part 1

Table 2: Earthing and short-circuiting cables in AC and 3-phase installations Restoring Power after Work is completed Removal of equipment and withdrawal of personnel Tools and accessories no longer required shall be removed from the work point and all personnel except those necessary shall be withdrawn. Only then shall work begin at the work point on removal of the safety measures put into force for the work. Removal of safety measures at the work point The safety measures taken for the work shall be removed in such a way that no danger arises. The short-circuit connection shall always be removed before the earth connection. State after removal of the safety measures After the short-circuiting and earthing have been removed, the parts of the installation, which were completely disconnected for the work, shall be regarded as live. Restoring the operating condition Protective devices and safety signs required for operation shall be correctly refitted. Notification The personnel responsible for operating shall be notified that the work is ended. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Switch-on readiness at the work point If the supervisor or person working alone switches on in person, he shall only restore power to the installation or parts of the installation after the measures detailed in above paragraph. If the supervisor or person working alone does not switch on in person, he shall only report the installation or part of the installation ready for switch-on after the measures detailed in above paragraph is carried out.  The person switching on shall await the report of switch-on readiness. In no case shall switching-on be carried out at a pre-determined time without a previous report of switch-on readiness for the work point.  The switch-on readiness of the work point may be reported verbally, by telephone, in writing or by telex. Other means of communication for confirming the switch-on readiness may only be used when specific measures are taken to ensure that there can be no misunderstanding.  The report of switch-on readiness shall contain the name, and if necessary, the department of the person responsible for switch-on readiness of the work point.  If this report is given verbally or by telephone, it shall be repeated by the point receiving the report, to avoid misunderstanding. The person reporting shall await correct confirmation. The work point may only be reported ready for switch-on by the supervisor or person working alone. Removal The safety measures may only be removed at the switch-off points after the work has reported switch-on readiness. If several work-points are involved, the safety measures shall only be removed at the switchoff points when reports of switch-on readiness have been received from all work points. The short circuit connection shall always be removed before the earth connection. Working in the Vicinity of Live Parts General Before work is planned in the vicinity of live parts, a check is to be carried out to ascertain whether it would not be more suitable to create and maintain a de-energised state of these parts in accordance with the `five safety rules'. Work may only be carried out in the vicinity of live parts with rated voltages over AC 50 V or DC 120 V provided safety measures against direct contact be taken as follows:  Protection is provided by covering or enclosing  Protection is provided by safety distance.  The measure taken shall take account of the work force personnel used.  If the above mentioned measures cannot be carried out, the requirements for creation and maintenance of a de-energised state before commencement of work and the clearance for work in accordance with the `five safety rules' shall be followed, or the requirement of the Paragraph for working on live parts shall apply.refer the above paragraphs.

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 Where the safety measures used against direct contact consist of covering or enclosing, the live parts:  up to 1000 V shall be at least partially protected against direct contact  Over 1 kV shall be at least partially protected against access to the danger zone. The covering shall be sufficiently well secured and reliably attached, and enclosures shall be suitable.  The type of protection used shall depend upon the type, extent and duration of the work to be carried out, and the qualifications of the work force personnel. Before fitting covering or enclosures, observe the requirements of above paragraph.  Where the safety measures against direct contact consist of the use of a safety distance, it shall be ensured that the workers  due to unintentional or unconscious movement, e.g. depending on the type of work, the movement area available, the location, the tools used, accessories or materials, or  due to uncontrollable movement of tools, accessories, materials and scrap items, e.g. by slipping or falling cannot contact live parts, or for rated voltages above 1 kV cannot reach the danger zones shown in Table 2 or when carrying out the work detailed in the following Paragraphs are unable to move closer than the laid down safety distances.

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Table 3: Danger zones in relation to rated voltage Rated Voltage up to 1000 V

Limit of danger zone (distance in air from live part) The surface of the live part is the limit of the danger zone. Touching the part is dangerous

over 1 kV up to 6 kV

90 mm Indoor installations

over 6 kV up to 10 kV

115 mm Indoor installations

over 6 kV up to 10 kV

150 mm Outdoor installations

over 10 kV up to 20 kV

215 mm Indoor and Outdoor installations

over 20 kV up to 30 kV

325 mm Indoor and Outdoor installations

over 30 kV up to 45 kV

520 mm Indoor and Outdoor installations

over 45 kV up to 60 kV

700 mm Indoor and Outdoor installations

over 60 kV up to 110 kV

1100 mm Indoor and Outdoor installations

over 110 kV up to 220 kV

2200 mm Indoor and Outdoor installations

over 220 kV up to 380 kV

2900 mm Indoor and Outdoor installations

Suitable measures shall be taken to ensure that work points cannot be inadvertently interchanged. If necessary, the limits of the work area shall be clearly distinguished from adjacent areas which are not cleared for work.

Note: Markers (also as decals), flags or barrier ropes with signs etc. are suitable for this purpose. Adjacent live switch panels can also be distinguished by additional, clearly visible methods, e.g. fixing boards in front of doors, hanging up warning crosses, fitting barrier chains or barrier grids.

.....................................Care shall be taken to ensure that a firm location is provided which leaves the worker w both hands free.

....................................................Before commencement of work, the person responsible for the work shall instru personnel who are not familiar with working in areas adjacent to live parts on the maintenance of safety distances, on the safety measures which have been put into force and on the need for safety conscious behaviour. The work area shall be clearly detailed in each case and attention shall be brought to peculiarities. These instructions shall be

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repeated at periods or after a change in working conditions.

REV-2

suitable

......................................................................................Laypersons shall be supervised by skilled or trained electric personnel.

.........................................................................................................................Personnel shall wear close fitting clothin

.....................................The worker shall always ensure that he does not reach the danger zone either with part his body or with an object. For work on overhead lines he shall not approach closer than the safety distances laid down.

Note: Particular care shall be taken when handling metal parts, e.g. tools, cable ends and pipes Frameworks are normally used for protection.

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Table 4: parts

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Safety distances in relation to rated voltage when working in the vicinity of live

Rated voltage

Safety distance from live part without protection against direct contact

up to 1000 V

0.5 m

over 1 kV up to 30 kV

1.5 m

over 30 kV up to 110 kV

2.0 m

over 110 kV up to 220 kV

3.0 m

over 220 kV up to 380 kV

4.0 m

............................................................................................When moving ladders or cumbersome objects ensure th

........................................in closed electrical workshops they do not touch live parts, or for rated voltages above kV cannot reach the danger zone,

.......................................the safety distances given in Table 3 are maintained in the vicinity of overhead lines. A exception to this requirement is the use of non-metallic ladders in the vicinity of overhead lines with rated voltages up to 1000 V. This work shall be carried out by skilled or trained electrical personnel or supervised by them.

......................................To dissipate dangerous induction voltages when installing cables parallel to live overhe lines, special instructions for earthing the equipment used and to regulate the behaviour of the work force shall be formulated and observed.

......................................If cables have to be cut, parted, or separated in some other way, the dangers of inducti voltages shall be prevented beforehand by measures such as earthing.

.......................................................................If conductors or air cables are passed above or below live conductor suitable devices are to be used, to ensure that when the cables are pulled, clamped or when they fall they do not touch the crossing conductors or they do not come within their danger zones.

Note: Frameworks are normally used for protection

..........................................Where overhead lines or conductors in outside installations underneath a work positi are required to remain live, tools, materials and similar items may only be raised or lowered outside the safety distances given in Table 3. This work shall be carried out by skilled or trained electrical personnel or under their supervision.

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............................................................................................................................................................................................... Additional requirements for installations with rated voltages above 1 kV If work is required to be carried out in inside installations with rated voltages above 1 kV on open installations where one side is live and where an isolating path is created, and where this means that the danger zone could be reached, the live parts shall be protected against direct contact.

Note: For this purpose, suitable insulating plates for example, can be inserted or insulating shaped parts and insulating covers with sufficient electrical and mechanical strength used

For equipment with rated voltages above 1 kV, insulating covers can be used as a protection against direct contact also with reduced safety distance as per Table 2 provided they possess sufficient electrical and mechanical strength. If the safety device clearance is less than the corresponding distance given in Table 2, the danger zone at this point shall be limited by the amount of clearance of the protective device (see Fig. 1). If the protective device, even temporarily, is removed, opened or otherwise rendered ineffective, the distance given in Table 2 shall apply. Note: This can occur, when, for example, the door of a type-tested system is opened When working in switch panel positions of inside installations with rated voltages above 1 kV without isolating walls, the work point shall be protected against adjacent switch panels or other live parts by a protective device against direct contact. In closed, electrical workshops, vehicles or other driveable or mobile equipment may pass underneath live parts without protective devices (see Fig. 4) provided:

.............................................................at rated voltages up to 30 kV a minimum distance of 500 mm is maintaine

....................................................at rated voltages between 30 kV and 380 kV the distance given in Table 2 are n reached Under these circumstances, personnel may only remain on vehicles or mobile equipment when there are adequate protective measures on the vehicle or mobile equipment, e.g. cab roof to ensure that the previously mentioned distance cannot be reached. In the case of overhead lines with several circuits (systems) with rated voltages over 1 kV on a common mast, work may only be carried out on one system provided the safety distances given in Table 3 are maintained or access to the danger zone of live parts is prevented by the type of equipment or by protective devices. In addition, measures shall be taken to ensure that the systems cannot be confused. This is achieved by precise notices and descriptions, e.g. with numbers, symbols or colours. This work shall be carried out by skilled or trained electrical personnel or under their supervision.

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Note: These measures can be supplemented by, e.g. the work force wearing arm bands with the same symbols as the switched-off circuit. When climbing masts of overhead lines with rated voltages above 1 kV which also carry bare telecommunication lines, the latter shall be earthed and short-circuited at the work point or in the vicinity of the work point. this also applies when the power installation overhead lines have already been completely disconnected, earthed and short-circuited. The telecommunications lines may not be touched before they have been earthed. Painting and renovating on overhead lines

......................................................When painting and renovating masts, portal towers and similar items, the safe distances given in Table 3 from live parts of overhead lines with rated voltages above 1 kV shall be maintained.

...............................................This work shall be carried out by skilled or trained electrical personnel or under th supervision. If earthing and short circuiting measures in accordance with the above said Paragraph have been carried out at all switch-off points of overhead lines or a system with rated voltages of 110 kV, there is no requirement for earthing and short-circuiting at the work point when painting masts provided the following requirements are fulfilled.

a).................................................The conductor and circuit are clearly identified at the work point, e.g. by circ diagrams, labels or tracing the run of the conductor from the switch-off point to the work point.

b).....................................It is ensured that when working in the vicinity of the earthed and short circuited circu the danger zone of this circuit as shown in Table 2 is not reached and the safety distances from other circuits as shown in Table 3 are maintained.

c)..............................................................This work shall be carried out by skilled or trained electrical personn If the operating voltage of the overhead line is lower than its rated voltage, the safety distance given in Table 3 can be based on the values of the operating voltages when carrying out work in accordance with above said Paragraph. Construction work and other non-electrical work For construction work and other non-electrical work, such as:

.............................................................................................................................................................................staging wo

.........................................................................working with lifting equipment, construction machines and conveyo

......................................................................................................................................................................installation wo

..........................................................................................................................................................................transport wo

.....................................................Painting and renovating except for work in accordance with painting standards

...............................................Positioning of other equipment and building equipment the safety distances given Table 4 from live parts of electrical installations without protection against direct contact shall be maintained. When swinging out loads, carrying and lifting equipment, the safety

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distances given in Table 4 shall also be maintained. The dimension in Table 4 is taken from the conductor cable in the swung-out position.

Figure 2: Clearance when passing under live parts in closed electrical workshops with rated voltages above 1 kV Rated vo VOLTAGE

RATED

Safety distance from live parts protection against direct contact

up to 1000 V

1.0 m

over 1 kV up to 110 kV

3.0 m

over 110 kV up to 220 kV

4.0 m

over 220 kV up to 380 kV

5.0 m

without

Table 5: Safety distances in relation to rated voltages When transporting, retractable ladders, lifting devices and crane jibs are to be lowered. If work in accordance with the above condition workwill be carried out under the supervision of skilled or trained electrical personnel of the main operator of electrical installations, the safety distance given in Table 3 apply. Working on Live Parts General Working on live parts leads to increased dangers to personnel, the electrical installation and the surrounding area. It demands a high degree of knowledge, experience and NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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responsibility both on the part of the worker and his supervisor and must constitute an exception to the work carried out generally on electrical installations. For this reason therefore work may only be carried out on live parts when it is governed by the provisions of above Paragraph and when the superior responsible for this work has provided the necessary technical, administrative and personal safety measures. When doing so the following points are to be observed.  accident prevention equipment shall be used (refer the above two Paragraph) and such equipment shall be adapted to the nature of the work, the voltage level, the dangers of possible arcing in event of a short circuit and also to the ambient conditions at the work point, e.g. moisture, confined space conditions etc.  In principle, no work shall be carried out on live parts in workshops and storage areas where there is a fire risk. In special cases, however, work may be performed on live parts provided it is ensured that the working area is not subject to a fire hazard Carrying out work Work can be carried out on live parts if: a) the rated voltage between the live parts as well as the voltage between live parts and earth does not exceed AC 50 V or DC 120 V, or b) the circuits are intrinsically safe c) the short circuits current at the work point does not exceed AC 3 mA (RMS) or DC 12 mA or the energy does not exceed 350 mJ or d) Significant risks, e.g. to the life and health of personnel or fire and explosion risks can be prevented. Such work may only be carried out by skilled electrical personnel and using suitable safety measures. e) For rated voltages over AC 50 V or DC 120 V up to rated voltage of AC 1000 V and DC 1000 V For rated voltages over AC 50 V or DC 120 V up to rated voltage of AC 1000 V and DC 1000 V the following are permitted: a) The positioning of suitable test and measuring equipment, voltage testers, operating poles and suitable tools for moving easily moveable parts. b) The positioning of suitable tools and accessories for cleaning as well as fitting suitable covers and enclosures. c) The removal or fitment of fuses not protected against direct contact. d) The spraying of live parts during fire fighting. e) Working on batteries using suitable safety precautions. f) Working in test rooms and laboratories using suitable safety precautions when demanded by the working conditions. g) Knocking off hoarfrost deposits using suitable insulating poles. h) Confining defects to auxiliary circuits and functional testing of equipment and switches. i) Other work on live parts when it is not feasible to completely disconnect the parts of the installation on which the work is to be done, this applies particularly where there are compelling reasons for it. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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In addition, the supervision of a responsible person is required unless he carries out the work himself. This person shall particularly when working in damp and wet rooms as well as outside, shall lay down, or carry out, all necessary further technical administrative and personal safety measures.

Note: Compelling reasons for working on live parts exist when removal of the voltage would,e.g. -give rise to a danger to life or health of personnel, -considerable economic harm would result in industry, -when working on public power supply systems, particularly when making connections, Switching timers it over conductors, etc. or changing meters, central control receivers and Would be necessary to interrupt power supply to a large number of consumers Administrative measures can, e.g. include the constant. At rated voltages above 1 kV At rated voltages above 1 kV the following are allowed: a) The positioning of voltage testers and phase comparators b) The positioning of suitable tools except cleaning tools, for moving easily moved parts etc. aided by insulating poles as well as fitting suitable insulating plates and enclosures. c) Removal or refitment of fuses not protected against direct contact using fuse tongs when this is possible without danger. (see above paragraph Paragraph). d) Spraying live parts during fire fighting. e) Spraying insulators in outside installations. f) Working on batteries using suitable safety precautions. For this task a skilled electrical person or trained electrical person shall be present as a second person. g) Working in test rooms and laboratories using suitable safety precautions if the working conditions require. h) Knocking off hoarfrost with the aid of suitable insulating poles. i) Other work on live parts when the main operator has stipulated in individual cases that there are compelling reasons why it is not feasible to completely disconnect the parts upon which the work is to be done. These include e.g.  defining authority and responsibilities,  defining work methods and procedures,  special training of personnel,  ensuring direct lines of communication between the work point and the relevant control position,

.................................................................................................................................consideration of the effects of weath NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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.................................................................................................................................disabling automatic switch-on device Using operating and insulating poles When using operating and insulating poles note the following: a)Operating poles (e.g. voltage testers) may only be used in installations for which they are intended as indicated by appropriate inscriptions, e.g. rated voltage, place of use etc. b)Operating and insulating poles may only be used from a safe location which ensures that the user is sufficiently removed from live parts that they do not represent a danger to him. c) Operating and insulating poles may only be gripped by the handle when used. Replacement of live fuses

Fus e syst em Typ e

Rated voltage

Current

Lay persons

Skilled or trained electrical personnel

DO, D

up to AC 380 V

up to 63 A

yes

yes

over 63 A

no

no

up to 16 A

no

yes

over 16 A

no

no

D

over AC 380 V

DO, D

up to DC 24 V

over 0 A

yes

yes

DO

over DC 24 V up to DC 60 V

up to 6 A

no

yes

over DC 60 V up to DC 110 V

up to 2 A

no

yes

over DC 110 V

over 0 A

no

no

over DC 24 V up to DC 60 V

up to 16 A

no

yes

over DC 60 V up to

up to 5 A

no

yes

D

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DC 110 V over DC 110 V up to DC 750 V

up to 1 A

no

yes

over DC 750 V

over 0 A

no

no

The currents given are the actual currents flowing but not, however, the short circuit current which might flow when the fuse is fitted.

Training All those carrying out electrical installation, repairs, maintenance, and testing will be competent, and authorized in writing. When controls have been identified they will be documented in written safe systems of work. The assessment should involve the employees as much as possible, and they should be consulted on the controls to be introduced and the reasons for them. Assessments should be posted in the workplace, and employees briefed on the contents. To ensure that the assessments remain ‘live’ there will be a scheduled programme for undertaking, and reviewing Assessments. Depending on the nature of the job, and risks involved the assessment may be part of a general assessment, or be a specific one. MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team Active Monitoring - Safety Inspection A programme for the inspection, testing, and maintenance of fixed installations, and portable appliances should be operated. The records for testing and registration should be checked. Reactive Monitoring - Accident Reporting, Accident Investigation

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Any accidents or near misses should be reported, and investigated. AUDITING AND REVIEW Auditing These procedures should be included in the annual risk management audit. Review Performance in this area should be reviewed at the annual management review.

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12 FIRE AND EMERGENCY Fire includes the potential for explosions, and other emergencies.This may include, flood, major spillage, product failures. Policy, Statement of intent The prevention of fire and emergencies is the best way to avoid, and or minimize injury, property loss, and business interruption. The potential for fire and emergencies should be considered at the design, and project planning stage. When considering controls, the hierarchy of control should be applied. Where risks cannot be eliminated, there should be a fire and emergency contingency plan that has been developed and is owned by the site management team. Responsibilities and Accountability Safety engineer and Sub-contractor supervisors will establish emergency plan. How to respond when there is Fire: -Sound alarm warns your co-worker. -Stay calm but move quickly. -Head towards the nearest emergency exit. -Crawl low to ground if there is smoke in the building. Fire extinguishing agent selection for various fires set by different flammable materials.

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Training All persons responsible for fire and emergency, and or providing specialist support should have received suitable training. Risk Assessment and Controls The risks of fire and emergency should be identified at the design, planning stage of a project, task etc. Where it is not possible to eliminate the hazards or risk suitable controls should be introduced. Managers (safety) shall have a procedure for undertaking Fire and emergency assessments. This procedure should include the requirement for:Identification of Jobs/tasks Identification of hazards and risks Assessment of Hazard and Risk Application of the Hierarchy of Control(s) Review When controls have been identified they should be documented in written safe systems of work. The assessment should involve the employees as much as possible, and they should be consulted on the controls to be introduced and the reasons for them. Assessments should be posted in the workplace and employees briefed on the contents. Fire Risk water Foam Co2 Dcp Fm200

yes

-

-

-

-

-

yes

yes

yes

yes

Flammable vapor/ Gasses H2, H2S, Acetylene.

-

-

yes

yes

yes

Electrical

-

-

yes

yes

yes

Yellow

Black

Blue

Green

Wood ,Paper, Cloth, etc., Flammable Oil, Paint.,)

liquid(petrol,

Cylinder colour of extinguisherRed

To ensure that the assessments remain ‘live’ there should be a scheduled programme for undertaking, and reviewing these assessments

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This assessment should take account of the requirements of Fire Certificates, and or ABB Risk Engineering Survey Reports. MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team The fire and emergency contingency plan should be reviewed by the management team annually. The results of planned, and unplanned drills, and evacuations should be reviewed by the management team. Active Monitoring - (Safety Inspection) A scheduled programme for inspecting and maintaining all critical fire and emergency controls should be in place, e.g. fire alarms, detection systems, fire fighting equipment, fire points, emergency exit routes etc. Reactive Monitoring - Accident reporting, Accident investigation All fire and emergency accidents, and near misses should be reported, and investigated. AUDITING AND REVIEW Auditing These procedures should be included in the annual risk management audit. Review Performance in this area should be reviewed at the annual management review.

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13 FIRST AID First aid is the initial assessment and supportive treatment of injuries and illnesses which may arise in the workplace, including the full treatment of minor injuries, initial life saving treatment to serious injuries i.e resuscitation, care of unconscious casualty, severe bleeding. Policy, Statement of intent The prevention of accidents should be the main objective, but where people are injured, or suffer sudden illness at work suitable first aid support should be available. The compliance with statutory requirements should be the minimum requirement. Responsibilities and Accountability The management team is responsible for the assessment, and provision of First aid support. The company should have access to an Occupational Health professional who can provide specialist advice and guidance on First Aid support.(ABB has regional and country health and safety advisor for guidance on first aid and various occupational health &safety programs) Suitably trained First aiders shall be available on site to provide First aid, from Al-Shuiba Medical Center (Approved by Kuwait Gov.) A First Aid Coordinator should be appointed to assist the line manager with their first aid responsibilities. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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IMPLEMENTING Training First aiders, and Appointed Persons should be suitably trained (KUWAIT TRAINEED). In addition, the First Aid Co-ordinator should organise monthly refresher sessions, providing the opportunity to practice resuscitation etc. Risk Assessment and Controls An assessment of First Aid need should be made and include:       

Type of work number of employees Remoteness of premises Peripatetic workers Workforce distribution Workers at increased risk Absence of first aiders First Aid provision for visitors, and contractors First Aid requirements should be identified at the design, planning stage of a project, task etc. But the overriding objective should be to eliminate the potential for injury in the first place. When controls have been identified they should be documented in the written safe systems of work. The assessment should involve the employees as much as possible. Assessments should be posted in the workplace, and employees briefed on the contents. To ensure that the assessments remain ‘live’ there should be a scheduled programme for undertaking, and reviewing these assessments. MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team Active Monitoring - Safety Inspection A scheduled programme for the inspection, and maintenance of all critical first aid equipment and facilities should be in place, e.g. First Aid stations, equipment, rooms, records etc. Reactive Monitoring - Accident Reporting, Accident Investigation NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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All first aid incidents should be recorded, and investigated. AUDITING AND REVIEW Auditing: Procedures should be included in the annual risk management audit. Review: Performance should be reviewed at the annual management review.

14 MANUAL HANDLING AND ERGONOMICS Policy, Statement of intent Safety Engineers and sub-contractor shall ensure that operations involving manual handling are eliminated or controlled. In this context of standard manual handling includes lifting, putting down, pushing, pulling, carrying, and manipulation. Ergonomics should be considered when designing a task or operation, so that the ‘human factor’ is considered, and the work station is tailored for the operator. Responsibilities and Accountability The Management team will be responsible for managing manual handling and ergonomics. With supervisors and employees being encouraged to take an active part in the assessments and implementation of any controls that are agreed. Training The Company’s safety induction will provide information on any manual handling and controls.Safety engineer will attend manual handling and ergonomics awareness training. Depending on the level of risk, this may be a specific event, or part of a general Health and Safety awareness event. Employees will receive safety training on manual handling &ergonomics from the contractor Safety engineer. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Risk Assessment and Controls Managers will make procedure, undertaking Manual Handling Assessments. procedure should include the requirement for:-

This

Identification of Jobs/tasks Identification of hazards and risks Assessment of Hazard and Risk.  Review Once controls have been identified they should be documented in written safe systems of work. The assessment should involve the employees as much as possible and they should be consulted on the controls to be introduced and the reasons for them. Assessments should be posted in the workplace and employees briefed on the contents. To ensure that the assessments remain ‘live’ there should be a scheduled programme for undertaking, and reviewing noise and vibration assessments

MEASUREMENT OF PERFORMANCE Reports to the Board Reports to Management Team Active Monitoring - Safety Inspection The use of any mechanical lifting devices provided should be checked on a regular basis with test certificate. (Approved by KUWAIT government) Any engineering controls introduced to minimize manual handling should be subject to regular inspection, and maintenance. Reactive Monitoring - Accident reporting, accident investigation There should be a system for reporting cases of musculo-skeletal, repetitive strain injuries, and other related conditions. Employees should be encouraged to report ‘minor’ conditions, because these can lead to more serious conditions. Where injuries are reported a detailed investigation should be undertaken, AUDITING AND REVIEW Auditing These procedures should be included in the annual risk management audit. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Review Performance in this area should be reviewed at the annual management review.

15 MECHANICAL HANDLING The use of mechanical plant and equipment to lift and or move goods etc. This includes the use of fork lift trucks, over head cranes, cranes, lifts, and hoists. Responsibilities and Accountability Project managers, Safety engineer Contract manager responsible to ensure that they consider the risks and hazards at the work site. They will be able to identify, access risks and hazards, and recommend suitable solutions in work site. Safety engineers and Supervisors, employees, and contractors will ensure that they follow the controls introduced to ensure safe mechanical lifting. IMPLEMENTING Training All persons involved with mechanical handling will receive suitable training in the safe systems of work to be followed, and the use and care of any engineering controls, and or protective equipment to be used. MEASUREMENT OF PERFORMANCE Reports to the Board NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Reports to Management Team Active Monitoring - Safety Inspection All persons authorized to operate mechanical handling plant and equipment should have received a suitable and regular health check, medical assessment. Reactive Monitoring - accident reporting, accident investigation Incidents, including near misses will be reported and investigated. AUDITING AND REVIEW Auditing These procedures will be included in the annual risk management audit. Review Performance in this area will be reviewed at the annual management review and corrected.

16 SAFETY OF VISITORS (NON-EMPLOYEES) Visitors may be unfamiliar with the risks associated with our activities. Policy The risks to non-employees should be assessed, and suitable controls introduced. The objective should be to eliminate, or if not possible to minimize the risk to the lowest level of reasonabl practicability. Responsibilities and Accountability The Site manager, Safety engineers is responsible for ensuring non-employee safety. All non-employees should be accompanied when on company premises. They must be required to ‘sign-in’, and display a visitors badge. On completion of their visit they should ‘sign-out’, and return their badge. When ‘signing-in’, non-employees should be briefed on the risks and controls and advised on what action to take in the event of an emergency. Measurement of Performance The visitor signing in, badging and induction process will be checked in a programmed way and reported to the owner. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Any accidents and near misses will be reported and investigated. Audit and Review: All systems and procedures should be subject to audit and review.

17 OCCUPATIONAL HEALTH MANAGEMENT Definition: Occupational Health involves identifying what can cause or contribute to ill health in the workplace, determining the action required to prevent people being made ill by work, and the introduction of suitable control measures to prevent ill health. Following are some guide lines to keep personnel in good health for efficient work: -Periodic medical check up will l be done for all employee at least once in a year, but but duration is mainly depends on the hazards. Insurance policy is given under Kuwait Labor Law. -Pre employment Medical check up shall be done; this means Medical fitness prior to the job. Nature of the job whether he/she is fit for that or not. -Personnel who are allergic to some chemicals in the process area shall not be continued the job in some place, if possible transfer them to non chemical areas. -if anyone found unfit for particular job, they will be given suitable medical treatment and assigned for another sutiable job. Awareness and Competence Safety engineer and employees will have awareness and understanding of occupational health risks, this should include causes, symptoms, and their prevention and control. Project managers and employees will be aware of their occupational health responsibilities. 93(102) NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Anyone managing the pre-employment medical process must have received suitable training. In addition to statutory First aid training, first aides will participate in short refresher practicals throughout the year. All employees should be consulted on the development, implementation, operation, and performance of the occupational health management program. Normally this will be achieved through the safety committee, and company team briefing process. Documentation Safety Engineers along with sub-contractor supervisor will establish and maintain information, in a suitable medium that describes the elements of the occupational health management Program, and provides direction to related documents using the owner’s reports and forms.

Document and Data Control Safety Engineer will establish and maintain procedures for controlling all documents and data required by the Occupational Health Management Program. Operational Control Owner’s Safety managers should establish and maintain procedures relating to the management of occupational health. These should include procedures for:          

Pre-employment health screening Sickness absence referral Medical reviews Rehabilitation within the workplace Routine health screening Workplace assessment Health education, and advice First aid Occupational disease reporting and investigation Employee welfare arrangements Emergency Preparedness and Response Safety Engineers will establish and maintain Occupational Health plans and procedures to identify the potential for and responses to, incidents and emergency situations, and for

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preventing and mitigating the likely illness and injury that may be associated with them. These will be reviewed, and tested periodically. Checking and Corrective Action Owners Safety Manager will do the checking and corrective actions. Performance measurement and monitoring Reports Occupational Health performance will be reported to the Owner on a regular basis. The senior management team will receive quarterly reports on occupational health performance. Proactive Monitoring To ensure the program is operating effectively proactive monitoring will be undertaken by Owner. This will include:  Pre-employment Health Screening  Routine health screening  A scheduled program for reviewing the efficacy of occupational health controls Near misses and work conditions that could have lead to ill-health will also be included e.g. accidental exposure to carcinogens. All incidents will be investigated to prevent a recurrence. Those persons undertaking investigations will be suitably trained. Accidents, incidents, non-conformances and corrective and preventative

action

Safety Engineers And Sub-Contractors supervisor will establish and maintain a procedure to ensure that incidents of Occupational ill-health recorded, and investigated, with any nonconformances being corrected, and any necessary preventative action taken. Please note: These forms are attached in the end this safety manual. Records Managers should establish and maintain procedures for the identification, maintenance and disposition of occupational health records, as well as the results of audits and reviews. Audit &Review

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The Occupational Health Management Programme will be audited annually. An audit will also be undertaken after significant change, and after a serious incident. The Senior Management Team shall undertake an annual review of the performance of the occupational health management programme.

18 PROCUREMENT AND SUPPLIERS The management of our supply chain is important to prevent site safety and product safety problems and business interruption. An incident within our supply chain may also effect our business reputation. Policy, Statement of intent To prevent and reduce the risks of our employees, contractors, and customers it is important to manage our supply chain in a proactive way. The early identification, elimination or reduction of supply chain risks will improve employee safety and re-in force our reliability to customers. Responsibilities and Accountability Project management team is responsible for assessing the risks within their supply chain, and implementing suitable controls. The Supply Co-coordinator ensures that the risks within their supply chain are assessed and controlled. Supply Co-coordinator will receive suitable training in the assessment and control of supply chain risks.

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Supplier Control: A supplier list will be established. Only those suppliers that are legally compliant with all health and safety legislation, and who have eliminated, or are working to reduce potential risks to our supply will be entered on the Project Organization list. Attached our project organization chart in attachments. Only those suppliers listed will be used. MEASUREMENT OF PERFORMANCE Reports to Project Management Team Active Monitoring - Safety Inspection The supply chain controls will be subject to a scheduled programme of monitoring. Reactive Monitoring - accident reporting, accident investigation Any significant incidents within the supply chain will be reported, and investigated. Auditing& reviewing: These procedures should be included in the annual risk management audit. Performance in this area should be reviewed at the annual management review.

19 WORKING AT HEIGHT Definitions Use of scaffold, tower scaffold, access platforms, ladders, step ladders with ANSI standards. Particular consideration should be given to work above 2m, but work at any height presents a risk of injury and will be considered. Safety harness will be used where working level is more than 6feet or 2 mts height. And also where there is no guard rails system. Safety engineers, employees, and contractors will ensure that they follow the controls introduced to ensure safe access and egress. All persons involved in working at height will receive suitable training in the safe systems of work to be followed, and the use and care of any engineering controls, and or protective equipment to be used. The risks and hazards from access and egress will be identified at the work site and required fall protection will be given. NO SAFETY, KNOW PAIN! KNOW SAFETY, NO PAIN!

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Sub-Contractor will issue safety belt, lanyard (TWIN)/and tie off., i.e. 100% fall protection and tie-off, where required in work site. Safety engineer should have a procedure for undertaking Working at Height Assessments. This procedure should include the requirement for:Identification of Jobs/tasks Identification of hazards and risks Assessment of Hazard and Risk Application of the Hierarchy of Control(s) Review When controls have been identified they will be documented in written safe systems of work. The assessment will involve the employees as much as possible, and they will be consulted on the controls to be introduced and the reasons for them. Assessments will be posted in the workplace, and employees briefed on the contents. A work permit system should be considered for particularly hazardous tasks where working near cranes, over machinery or whenever contractors are used. To ensure that the assessments remain ‘live’ there will be a scheduled programme for undertaking, and reviewing these Assessments Rules Where high risk is involved, ABB sets minimum rules, which are as follows:1. Do not work at height unless inevitable , consider alternatives first, like assembly on the ground; 2. Anyone working 2m or above ground level will be protected on all sides by guardrails and or other suitable barriers. Where this is not practical suitable safety harnesses, lanyard (TWIN) with fall arrest system must be provided and used.Ensure those working at height are competent and trained persons. 3. The required Insurence will be provided by the Contractor. (Workmens compensation Insurence as per KUWAIT LABOUR LAW). 4. Wherever possible use permanent access instead of temporary working platforms; 5. Ensure that the access and other equipment is properly constructed and maintained; 6. All working platforms, and other access equipment must be thoroughly examined by a competent engineer at least every six months, Scaffolds must be of suitable design, material, and construction, inspected and maintained by a competent/trained person. Personal Protective Equipment (PPE) 7.Personal Protective Equipment will be used as a last resort, only after all other control options have been evaluated;

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8.Ensure that those who use safety harnesses, lanyard, with fall arrest system are suitably trained and experienced. 9.Those working at height must be trained in emergency recovery and have emergency rescue kits available. 10. Before project work commences, or when there has been a significant change in workplace layout a working at height assessment and plan will be written and implemented. MEASUREMENT OF PERFORMANCE Active Monitoring - Safety Inspection Access and egress plant and equipment should be part of a formal scheduled programmed of preventative maintenance. The frequency and detail of inspection, and maintenance should be as per the manufacturers’ recommendation, and as a minimum comply with the statutory requirements. Reactive Monitoring - Accident Reporting, Accident Investigation Incidents, including near misses should be reported and investigated.

AUDITING AND REVIEW Auditing: Procedures should be included in the annual risk management audit. Review: Performance should be reviewed at the annual management review. Site Manager will establish and maintain information, in a suitable medium that describes the elements of the procedure, and provides direction to related documents. Document and Data Control Safety Engineer will establish and maintain procedures for controlling all documents and Safety records required to enable staff to Work Off-Site. Operational Control Safety Engineer will establish and maintain procedures relating to working off-site. These should include procedures for:  Risk assessment and control at all stages of the project life cycle  Reporting and investigation of Incidents, and accidents  Facilities and arrangements for employees normally based on customers sites (Using their vehicle in emergency case if required, communication, first aider room)

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 Occupational Health Provision Emergency Preparedness and Response Safety engineer will establish and maintain plans and procedures to identify the potential for and responses to incidents and emergency situations that could occur when working on customers premises and for preventing and mitigating the likely illness and injury that may be associated with them. These should be reviewed, and tested periodically. Checking and Corrective Action: Safety engineer will have a corrective action check. Performance Measurement and Monitoring Reports Working off-site performance should be included in the safety report to your board. Working Off-Site performance should be included in the safety report to the Senior Management Team.

Proactive Monitoring To ensure that Work undertaken off-site is being conducted safely proactive monitoring will be undertaken. This will include:  Regular checks at each stage of the project life cycle. Including the checking of Risk Assessment records, selection of controls.  A schedule of regular site inspections, including the assessment of physical conditions, and work practices. Reactive Monitoring Accident, incident and near miss data should be collected, and interpreted. This should include Reportable accidents, other incidents, and near misses. All incidents will be investigated to prevent a recurrence. Those persons undertaking investigations will be suitably trained. Accidents, Incidents, Non-conformances and Corrective and Preventative Action

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Safety Engineer will establish and maintain a procedure to ensure that all incidents are recorded, and investigated, with any non-conformances being corrected, and any necessary preventative action taken. Records Safety Engineer will establish and maintain procedures for the identification, maintenance and disposition of records covering all customers and their sites, significant risks as well as the results of audits and reviews. Audit The procedure will be audited annually. An audit should also be undertaken after significant change, and after a serious incident.

20 Noise& vibration limits: All work will be carried out without unreasonable noise, vibration or distrubance. All air compressors and all other machines utilized on the work site must have acoustic enclosures to limit the noise level emitted to not more than 85-90db (A) Appropriate ear protection will be provided by sub-contractor and used by personnel in work site. The code recommended that exposure to noise should not exceed 90 db(A),over an eight -hour period. To do this: -Ensure all new plant and equipment brought into the work place meet standards set for noise levels. -Report any increase in the noise level of plant or equipment -Consider others and the work environment by controlling noisy activities. -Wear, and look after any personal hearing protection provided for your use. Proper ear protection (earplugs/ Ear muffs) will be given in the work for noisy Environment.

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21 PAINTING: -Paint will be stored in a separate store with adequate Fire extinguishers. -Handling of paint will be done with proper care as it is a chemical. -Do not keep paint and thinner in open air (care will be taken). -Care will be taken in such a way that the ignition source is away from the paint storage. -All painters will wear PPE and proper respiratory protection during painting. -Barricade will be provided or warning sign where the painting activity is done. -Proper care will be taken for not contaminating polluting the land, air and other surrounding with paint. Please note: 1) ABB Has released a booklet “Occupational health, safety &Environment handbook” To help all employees in planning daily activities and to familiarize with various company safety and environment policies. (Will be attached with this safety manual). 2) All reports has attached in this Safety manual. -incident report form. -Non-conformance report. -Sub Contractor Induction Form. All other forms will be reported through the Owners forms with permissions in case of accidents. All reports are attached. Daily reports, weekly reports, monthly reports, occupational injury /illness reports, equipment incident/accident reports will be reported through Owners report with permission.

22. ATTACHAMENTS OF ALL REPORTS & PROJECT ORGANIZATION CHART. Appendix-A (PROJECT SAFETY FORMS)     

Incident Report Form Accident report Form Non Conformance Report Integrated Site Management Form Risk Review Analysis.

Appendix-B (ORGANIZATION CHART)

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