100-YER-PM-PPM-0228安全教育手册

Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
TABLE OF CONTENTS
1.0PURPOSE (3)
2.0SCOPE AND OBJECTIVES (3)
3.0AFFECTS (3)
4.0DEFINITIONS (3)
5.0REFERENCES (3)
6.0TRAINING (3)
7.0NON-ELECTRICAL MAINTENANCE PERSONNEL SAFETY REQUIREMENTS5
8.0ELECTRICAL REQUIREMENTS (7)
9.0QUALIFIED PERSONNEL (9)
10.0SHUTDOWN REQUEST (11)
11.0WORKING ON OR NEAR ENERGIZED EQUIPMENT (11)
12.0PERSONAL PROTECTIVE EQUIPMENT REQUIRED FOR VARIOUS TASKS17
13.0TEST INSTRUMENT AND EQUIPMENT (31)
14.0HAZARDOUS ENERGY CONTROL (Lockout/Tagout) (32)
15.0HOT STICKS (37)
16.0ADDITIONAL SAFE WORK PRACTICES (37)
17.0ELECTRICAL SAFETY PRINCIPLES (38)
18.0SUBSTATIONS (38)
19.0GROUNDING FOR PROTECTION OF PERSONNEL (40)
20.0MECHANICAL EQUIPMENT (41)
21.0OVERHEAD LINES (43)
22.0UNDERGROUND ELECTRICAL INSTALLATIONS (47)
23.0DE-ENERGIZING LINES AND EQUIPMENT FOR PERSONNEL PROTECTION48 ATTACHMENT 1 – REQUEST FOR ELECTRICAL SHUTDOWN (50)
ATTACHMENT 2 – ELECTRICAL HAZARDOUS WORK PLAN (51)
ATTACHMENT 3 – ENERGIZED MOTOR CONTROL CENTER UNIT INSERTION PROCEDURE CHECKLIST (53)
ATTACHMENT 4 – ENERGIZED MOTOR CONTROL CENTER UNIT REMOVAL PROCEDURE CHECKLIST (55)
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
1.0 PURPOSE
To provide minimum standards regarding electrical equipment and maintenance of such equipment on the Yanbu Export Refinery Project (YERP).
2.0 SCOPE AND OBJECTIVES
To detail the necessary precautions that shall be taken by all personnel to minimize their exposure to electrical sources of energy.
3.0 AFFECTS
All Contractors, subcontractors, venders and others using any type of electrical tools and equipment on the Project. Aimed at workers that perform electrical, as well as, non-electrical maintenance tasks, with emphasis on conditions that should be avoided.
4.0 DEFINITIONS
Person
4.1 Competent
A designated Contractor person who is capable of identifying existing and
predictable hazards in the surroundings or working conditions which are
unsanitary, hazardous, or dangerous to personnel, and who has authorization
to take prompt corrective measures to eliminate them.
4.2 Ground Fault Circuit Interrupter (GFCI)
An electrical wiring device that disconnects a circuit whenever it detects that
the flow of current is not balanced between the phase (hot) conductor and the
neutral conductor. GFCI’s are also known as: residual current device (RCD),
or residual current circuit breaker (RCCB).
Person
4.3 Qualified
A person who, by possession of a recognized degree or certificate of
professional standing, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve or resolve
problems relating to the subject matter and work. Qualified personnel must be
documented as being qualified by appropriate Contractor Management.
5.0 REFERENCES
5.1 NFPA 70: National Electrical Code
5.2 OSHA
1910
1926
5.3 OSHA
6.0 TRAINING
6.1 All personnel shall receive the following information regarding electrical safety
prior to being permitted to perform work on the Project:
6.1.1 Qualified Personnel
•Electrical repair work or diagnostic work on electrical equipment
shall only be performed by personnel that are qualified to perform
this task.\
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
• Instruction manuals from electrical tools and equipment manufacturers detail what work can be performed by specific
individuals. Consult the manuals for instruction.
•Electrical tools and equipment that warn “DO NOT REMOVE COVERS” (PC’s, typewriters, fans, pencil sharpeners, etc.) shall
only be repaired by a Qualified Person.
•Personnel shall be made to understand that some equipment, even when unplugged, could still cause an electrical shock if
unauthorized access panels are removed during servicing.
6.1.2 Effects of Electrical Energy on the Body
•An electrical circuit is composed of voltage (e.g., 120 volts), resistance (e.g., 1000 ohms), and current (e.g., 0.12 amperes). Of
the three, current is what causes electrical burns, shock, and
death.
•For a given voltage, the resistance of the electrical circuit determines the value of current flow in the circuit. The smaller the
current resistance, the more current will flow. Increasing the
circuit voltage increases current flow also. More current will flow
through a circuit of low resistance than a circuit of high resistance.
•During electrical equipment failures or circuit failures, electrical current can use the human body as a path of least resistance.
This can cause injury and death. When using electrical equipment,
anything that reduces the body’s resistance can significantly
cause more current to flow through the body during electrical
failures.
•Individual body resistance varies from person to person. Dry skin has higher resistance than wet or moist skin. A muscular person
has less body resistance than a thin or obese person. Women
have more body resistance than men.
•When electrical current flows through the human body, it is the combination of the magnitude of the current and the duration of
that current that determines the severity of the injury.
•The human body is usually assigned a resistance value of 250 – 2000 ohms. This value can be higher or lower depending on the
condition of the skin, the contact resistance and other factors.
•Using the value of 1000 ohms for a man, the current flow in an electrical fault path from a 120-volt circuit through a man would be
120 milliamperes (ma). From the following table, 120 milliamperes
(120/1000 amperes) can cause death! In fact, the current flow
through a 25-watt light bulb (over 200 milliamperes) is twice the
magnitude mentioned in our example.
• TABLE 1
Value of Current Observed Condition
o 1 ma Generally considered the threshold of
perception.
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
o 5 ma Trip setting of Ground Fault Circuit
Interrupters (GFCI’s)
o 8 ma Interrupters (GFCI’s)
o9 ma Limit of Let Go Current
o9 ma – 25 ma Current of this value can be painful and
result in lack of control can make it
difficult or impossible to let go.
o25 ma – 50 ma Muscular contraction will be
experienced that makes breathing
difficult.
o50 ma – 100 ma These values can cause the heart to go
into ventricular fibrillation.
o100 ma & higher The heart can stop, burns to the body
are observed, the breathing can be
inhibited and the nervous system can
become impaired.
6.2 Training requirements for specific electrical work are discussed in the
appropriate sections of this document.
PERSONNEL SAFETY REQUIREMENTS
7.0 NON-ELECTRICAL
MAINTENANCE
7.1 Outlined below are basic requirements that shall be followed by non-electrical
personnel:
7.1.1 Never handle electrical equipment or their extension cords when
hands are wet or if the floor surface is wet.
7.1.2 Always unplug equipment when performing maintenance. Equipment
should be unplugged by grasping the entire plug itself and not by
pulling on the cord. This applies activities such as, disconnecting a
portable drill, before changing a bit and disconnecting a portable saw
before replacing a blade.
7.1.3 Never use electrical equipment that has defective plugs or wiring.
Cords that are frayed or have insulation tears, cracks, breaks, or
abrasions shall not be used. Any repairs made to such defective-
equipment shall be done by qualified persons. Three prong plugs shall
be inspected for proper orientation of the plug prior to inserting it into
a receptacle.
7.1.4 During the initial installation of any equipment, the electrical cord shall
be visually inspected for defects. In addition, anytime the cord is
moved from one location to another location it shall be visually
inspected again. It is the user’s responsibility to visually inspect the
equipment or extension cords.
7.1.5 Extension Cords
7.1.5.1 The Project uses an “Assured Equipment Grounding
Conductor Program” (100-YER-PM-PPM-0226). This
program requires that portable tools, portable equipment and
extension cords/cord sets be tagged/color-coded to indicate
when they require re-testing. The user of such equipment
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and tools is responsible for ensuring that the inspection
dates are valid.
7.1.5.2 While the use of extension cords in offices is discouraged,
cords less than ten feet that are permanently left in one
location are not required to be part of the Assured
Equipment Grounding Conductor program.
7.1.5.3 Extension cords in one office shall not be used to supply
power to another office, building or adjacent offices. Cords
may not be run through doors, windows or ceilings.
7.1.5.4 Extension cords used to supply power to office equipment or
to facilitate connections to multiple outlet power strips shall
not exceed ten feet in length. Regardless of length, these
cords shall be left in one stationary location and not moved
from location to location.
7.1.5.5 Extension cords as well as electrical equipment cords shall
not be modified to fit a receptacle. Specifically, ground
prongs on cords shall not be modified, removed or fitted with
adapters.
7.1.5.6 Extension cords shall not be overloaded. Care shall be taken
to insure that the cord has sufficient capacity to carry the
electrical load. Indications of overloads are breakers tripping,
receptacles that are warm to the touch, extension cords that
are warm or the smell of electrical insulation burning.
7.1.5.7 Extension cords that are frayed or have insulation tears,
cracks or abrasions or with bent, broken or “spread” prongs
shall not be utilized.
7.2 Grounding
7.2.1 With the exception of Underwriters Laboratories, Inc (UL) listed
“Double Insulated” equipment; all equipment shall have an equipment
grounding conductor that connects the frame of the device being
utilized to the electrical system grounding conductor.
7.2.2 The equipment ground is required to protect personnel. Equipment
shall be grounded or utilize a double insulated system. Ungrounded
equipment and tools represent a hazard to personnel.
7.2.3 Two prong plugs provided with double insulated equipment shall be
installed with the correct plug orientation (polarity).
7.2.4 Two wire extension cords shall not be used.
7.3 Plugs and Receptacles
7.3.1 Electrical equipment shall not be unplugged while the equipment
switch is turned on or plugged into receptacles with equipment’s
switch turned on.
7.3.2 Special circuits protected by Ground Fault Circuit Interrupters (GFCI)
shall be used to provide an added measure of protection to personnel.
Any equipment that causes these receptacles to trip or deactivate the
Document No.:100-YER-PM-PPM-0228
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circuit shall not be utilized unless inspected by an electrician. Do not
attempt to use such equipment on non-GFCI receptacles. Using a
device that trips a GFCI on a non-GFCI circuit can result in receiving
an electrical shock or death!
REQUIREMENTS
8.0 ELECTRICAL
8.1 All temporary electrical equipment on the project site shall be labeled
Underwriters Laboratory, Inc. (UL) or Factory Mutual approved. All temporary
electrical installations must conform to recognized international codes.
8.2 All electrically operated tools shall be rated and used at a voltage not
exceeding 125V. The use of 220V is prohibited
8.3 Portable electrical hand tools must be grounded or double insulated.
8.4 All electrical cords and cables shall be covered or elevated to protect them
from damage and to eliminate tripping hazards.
8.5 Power saws, grinders, and other power tools must have proper guards in
place at all times.
8.6 Qualified Personnel (electricians) are the only persons authorized to repair
electrical equipment. Field repairs or tampering with any electrical equipment
by unauthorized persons is not tolerated.
8.7 No work should be performed hot regardless of voltage. When it becomes
necessary to work on energized lines or equipment, the task shall be
reviewed and approved by the Contractor’s Site Manager and HSE Manager.
When working authorized hot jobs, approved rubber electrical gloves,
blankets, mats and other protective equipment must be used.
Note: Any work to be performed on energized systems shall require YERP Management approval.
8.8 Temporary lighting must have guards over bulbs.
8.9 Distribution panels must be dead front type, covering hot terminals and
properly constructed and grounded.
8.10 High voltage (600 volts or more) must be properly protected and identified
using approved signs.
8.11 Cord sets must have heavy duty insulation, weather and sun resistant with a
ground conductor, and be free of splices. All cord sets shall be approved for
“hard” or “Extra Hard” usage. Examples of these types of flexible cords
include hard service cord types S, ST, SO, STO and junior hard service cord
types SJ, SJO, SJT, SJTO.
8.12 All electrical equipment is to be visually checked by the user daily or before
each use. All electrical equipment is formally inspected by a qualified
electrician at least every 90 days or more often based on conditions found
during inspections. Such inspection includes a continuity test of the
grounding conductor (as applicable) and a complete examination of the
equipment/system to assure good and safe operating condition. No electrical
equipment is used unless it is in proper operating order. Records are
maintained by the Contractor and inspected equipment individually identified.
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
(Refer to 100-YER-PM-PPM-0226, Assured Equipment Grounding Conductor Program)
8.13 Ground fault circuit interrupter (GFCI) protection must be used on all
electrical systems, 120 volts receptacle outlets, extension cords and equipment connected by electrical cords and plugs. Electrical distribution panels used on site shall incorporate GFCI's for 120 volt usage.
8.13.1 All GFCI’s shall be approved by Underwriters laboratory and bear the
“UL” mark or have approval from an equivalent international approval
agency.
8.13.2 GFCI’s shall be inserted in the circuit as close to the electrical source
as practical.
8.13.3 Portable GFCI’s shall be kept weather-proof to eliminate nuisance
tripping of the circuit.
8.14 All circuit breakers/GFCI's shall be positively identified as to which outlets
they protect by numbering each breaker and its corresponding outlet.
8.16 When performing maintenance on temporary electrical systems, lockouts and
tagouts must be used (see 100-YER-PM-PPM-0235, Control of Hazardous Energy (Lockout/Tagout/Try).
8.17 During testing of permanent plant equipment, the lockout and tagout program
established by YERP must be complied with.
8.18 Only qualified electricians make electrical connections.
8.19 Be certain the circuit has been de-energized before the connection is broken.
8.20 Notify all personnel who may be affected when the power is turned off, and
again before it is turned on.
8.21 Do not render interlocks unserviceable by removing or modifying them. They
are there for a purpose.
8.22 Know the voltages and frequencies of circuits before any work is done.
8.23 Know the capacity of fuses and circuit breakers.
8.24 Check all cords to all electric tools and all portable electrical equipment to
ensure they are serviceable and properly grounded.
8.25 Water must not be used on electrical equipment fires. Whenever possible,
de-energize electrical equipment before fighting the fire.
8.26 Enclose and protect all un-insulated conductors.
8.27 Extreme caution must be used when equipment is being operated near power
lines. The lines must be de-energized if possible. (See 100-YER-PM-PPM-
0255, Operating Equipment Near Overhead Electrical Lines/Piping)
8.28 Do not work on electrical equipment when clothing is wet or any part of the
body is in contact with water.
8.29 Do not wear rings, watches or carry other metal objects such as lighters or
keys when working on any electrical system.
8.30 Use only explosion proof electrical equipment in flammable or potentially
explosive atmospheres such as may be found in confined spaces.
8.31 Grounding devices shall be engineered and installed for each particular site.
Document No.:100-YER-PM-PPM-0228
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8.32 Any equipment or structure on which electric charges may accumulate, such
as storage tanks must be grounded.
8.33 Lightning protection must be provided on all tall structures or buildings.
8.34 Do not bypass fuse terminals to keep current flowing in any circuit.
8.35 Bulbs or lamps must not exceed the allotted voltage for that fixture.
Ensure that bulbs are screwed firmly into their sockets. Convenience
outlets are not installed on any temporary lighting circuits.
PERSONNEL
9.0 QUALIFIED
9.1 Contractor shall establish, with YERP approval, appropriate levels of
authorization for performance of any work classified as hazardous.
9.2 Contractor shall supply YERP with a list of the individuals (Qualified Personnel)
authorized to perform electrically hazardous work and the Approach
Boundaries that each may work within.
9.3 Electrical repair work or diagnostic work on electrical equipment shall only be
performed by personnel that are qualified to perform this task. Qualified
personnel must be documented as being qualified by appropriate Contractor
management (Project Manager or Electrical Superintendent or person in
equivalent position).
9.4 Diagnostics shall only be performed by a Qualified Person who is trained in:
•The hazards of the diagnostic tasks,
•The proper selection and use of test instruments,
•Proper work methods, and
•Selection of the proper personal protective equipment to perform the task.
9.5 A qualified person shall be trained and knowledgeable of the construction and
operation of equipment or a specific work method, and be trained to
recognize and avoid the electrical hazards that might be present with respect
to that equipment or work method. Such persons shall also be familiar with
the proper use of special precautionary techniques, personal protective
equipment, insulating and shielding materials, and insulating tools and test
equipment. A person can be considered qualified with respect to certain
equipment and methods but still be unqualified for others. Such persons
permitted to work within limited approach of exposed energized conductors
and circuit parts shall, at a minimum, be additionally trained in all of the
following:
9.5.1 The skills and techniques necessary to distinguish exposed energized
parts from other parts of electrical equipment.
9.5.2 The skills and techniques necessary to determine the nominal voltage
of exposed energized parts.
9.5.3 The approach distances specified in Section 11, Working Safely Near
Energized Electrical Equipment of this procedure and corresponding
voltages to which the qualified person will be exposed.
9.5.4 The decision-making process necessary to determine the degree and
extent of the hazard and the personal protective equipment and job
planning necessary to perform the task safely.
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
Note: A person, who is undergoing on-the-job training and who, in
the course of such training, has demonstrated an ability to
perform duties safely at his or her level of training and who is
under the direct supervision of a qualified person shall be
considered to be a qualified person for the performance of
those duties.
9.5.5 Unqualified persons shall be trained in and familiar with any of
electrical safety-related practices that might not be addressed
specifically by this procedure, but are necessary for their safety.
9.6 Training
Retraining
or
9.6.1 A person shall receive additional training (or retraining) under any of
the following conditions:
9.6.1.1 If supervision and inspections indicate that the person is not
complying with the safety-related work practices, or
9.6.1.2 If new technology, new types of equipment, or changes in
procedures necessitate the use of safety-related work
practices that are different from those which the person
would normally use, or
9.6.1.3 If he must employ safety-related work practices that are not
normally used during his or her regular job duties.
Note: Tasks that are performed less often than once per
year necessitate retraining before the performance of
the work practices involved.
9.6.1.4 The training shall be of the classroom or laboratory on-the-
job type.
9.6.1.5 The training shall establish personnel proficiency in the work
practices required by this section and shall introduce the
procedures necessary for compliance.
9.7 Responsibilities of Supervision:
9.7.1 Before each job, the supervisor responsible for the work shall conduct
and document a Safe Working Plan discussion with all personnel
involved with the task (see 100-YER-PM-PPM-0268, Safe Working
Plan). A revised Safe Working Plan shall be conducted with all
affected personnel regarding any changes in conditions or other
factors that might affect the safety of persons performing the work.
9.7.1.1 The Safe Working Plan discussion shall include:
• A list of job steps,
•Identified hazards associated with the job steps
•Methods to be used to eliminate or reduce the identified
hazards to an acceptable level,
•Energy source controls, and
•Personal protective equipment requirements.
Document No.:100-YER-PM-PPM-0228
Revision No.: 0 Issue Date: 10 Apr 2008
9.7.2 Supervision shall determine, through regular supervision and through
inspections that each person is complying with the safety-related work
practices.
9.7.3 Supervision shall certify that each person has received the required
training. This certification shall be made when the person
demonstrates proficiency in the work practices involved and shall be
maintained for the duration of the person’s employment.
Note: Employment records that indicate that a person has received
the required training are an acceptable means of meeting this
requirement.
10.0 SHUTDOWN REQUEST
10.1 The first consideration in all electrical work 50 volts or more is determining if
the work can be done in a de-energized state. Justification for performing
work on or near energized electrical equipment must be based upon an
analysis of the hazards, qualification of personnel, and the reason the
equipment can not be placed in an electrically safe working condition.
Consider re-scheduling work to the next available shutdown to avoid
performing electrically hazardous work. A written request must be made to
de-energize the equipment for the duration of the work (see Attachment 1 –
Request for Electrical Shutdown). If the shutdown request is denied, the
appropriate Owner representative must give a written explanation of why the
equipment will not be de-energized.
10.2 The safest work environment is one in which electrical energy is completely
removed and isolated from the equipment. Live parts of electrical equipment
operating at 50 volts or more shall be guarded against accidental contact.
Electrical installations having exposed live parts shall be accessible to
qualified persons only. The entrances to all buildings, rooms, enclosures, or
barricades containing live parts or exposed conductors operating at or over
600 volts nominal shall be kept locked or barricaded and a "Danger" sign
shall be hung in the immediate vicinity. The use of approved equipment such
as fuse-pullers, voltmeters, oscilloscopes, clamp on ammeters, hot sticks and
non-contact voltage testers while wearing the required PPE is not considered
"Prohibited Work" or "Restricted Work". Only devices designed for the
purpose of pulling fuses shall be used to remove and install fuses. The fuse
pullers shall be the appropriate size and style.
11.0 WORKING ON OR NEAR ENERGIZED EQUIPMENT
11.1 Any work to be performed on energized equipment must be approved, in
writing by the YERP HSE Manager. Contractors shall develop a written safe
work plan for any work to be performed on energized equipment. An
Electrical Hazardous Work Plan shall be included in the Contractor’s Safe
Working Plan that is submitted to YERP (see Attachment 2 – Electrical
Hazardous Work Plan).
Note: Work must be stopped and re-evaluated if it cannot be executed as planned or if conditions change.
Document No.:100-YER-PM-PPM-0228
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11.1.1 The written safe work plan must include a step-by-step out line of the
work to be performed and must include a sketch to facilitate technical
review.
11.1.2 The following documents, generated by the Contractor, are required:
•Electrical Hazardous Work Plan
• Hazard/Risk Analysis
•Approach distances to exposed energized conductors and circuit parts
11.2 The preferred approach to working on or near electrical equipment is to de-
energize and lock out the equipment before work begins. Personnel are deemed to be “Working Near Energized Electrical Equipment” (for purposes
of this procedure) when they perform any activity inside the Limited Approach
Boundary and the Restricted Approach Boundary or are inside the Arc Flash
Boundary (see Section 11.7). A Standby person shall be used if the circuits or
parts being worked on contain voltages greater than 50 volts.
Note: This includes persons working in electrical cabinets having energized conductors.
11.2.1 Standby Persons and other personnel who work on or near exposed
energized electrical conductors shall be trained in methods of release
of victims from contact with exposed energized conductors.
11.2.2 Standby Persons and other personnel who work on or near exposed
energized electrical conductors shall be trained in methods of first aid,
cardio pulmonary resuscitation (CPR) and other emergency
procedures.
11.3 At voltages of less than 24 volts, work on or near energized components may
be performed without special isolating equipment if a documented specific
Procedure has been written for the work to be done.
11.3.1 Shoring or grounding of low voltage circuits may result in electrical
burns or arcs with enough energy to ignite flammable vapors or dusts
and requires additional precautions to be taken.
11.4 Additional precautions shall be taken if the task involves any moving
machinery parts, other hazardous objects, or fall hazards.
11.5 Work on electrical equipment must be carefully planned and executed. All
sources of voltage must be identified and all sources 50 volts or greater must
be Locked, Tagged, Tried, and Tested. The following conditions must be met
before equipment is isolated for electrical work and work can begin:
11.5.1 Identify all possible sources feeding, supplying or controlling the
equipment. Single-Line Diagrams, Loops Sheets, Control Diagrams,
Electrical Schematics, etc. should be used in conjunction with
equipment
11.5.1.1 Labeling to identify all power sources. Vendor prints, status
boards, and job plans should be used where applicable or
provided.。