ELECTRICAL SAFETY PROCEDURE - Tetra Pak · electrical equipment and of all the inherent electrical...

Procedure ID: Electrical Safety Procedure Johnny Srader Created Date: 3/27/2015, updated: 04/27/2015

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ELECTRICAL SAFETY PROCEDURE


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Table of Contents

1 PURPOSE ............................................................................................................................................................... 3

2 PROGRAM COMPLIANCE ....................................................................................................................................... 3

3 SCOPE ................................................................................................................................................................... 3

4 DEFINITIONS ......................................................................................................................................................... 3

5 RESPONSIBILITES ................................................................................................................................................... 3

6 ELECTRICA HAZARDS ............................................................................................................................................. 4

7 TRAINING .............................................................................................................................................................. 4

8 PORTABLE ELECTRICAL EQUIPMENT & EXTENSION CORDS .................................................................................... 5

9 REQUIREMENTS FOR TEMPORARY WIRING ........................................................................................................... 7

10 WET OR DAMP LOCATIONS ............................................................................................................................... 8

11 WORKING ON DE-ENERGIZED EQUIPMENT ....................................................................................................... 8

12 WORKING ON OR NEAR ENERGIZED EQUIPMENT .............................................................................................. 9

13 PERSONAL PROTECTIVE EQUIPMENT............................................................................................................... 10

14 EQUIPMENT LABELING .................................................................................................................................... 13

15 WORKING SPACE AROUND ELECTRICAL EQUIPMENT ...................................................................................... 13

16 CONTRACTORS ................................................................................................................................................ 15

17 APPENDICES .................................................................................................................................................... 16

APPENDIX A: ELECTRICAL WORK HAZARD CATEGORIES .............................................................................................. 17

APPENDIX B: ELECTRICAL PPE REQUIREMENTS ........................................................................................................... 18

APPENDIX C: ELECTRICAL WARNING LABELS ............................................................................................................... 19

APPENDIX D: ENERGIZED WORK PERMIT .................................................................................................................... 20

APPENDIX E: ELECTRICAL SAFETY CHECKLIST .............................................................................................................. 21

APPENDIX F: ENERGIZED CIRCUIT RISK ASSESSMENT .................................................................................................. 25


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1 PURPOSE

This program establishes minimum standards required to prevent hazardous electrical exposure to personnel while ensuring compliance with regulatory requirements applicable to electrical systems. Working on equipment in a de-energized state is required unless de-energizing is impractical. This program is designed to help ensure that energized electrical work at Tetra Pak facilities and customer sites is performed safely by qualified workers, who are trained and provided with the appropriate safe work procedures, protective equipment and other controls. The program is intended to protect employees against electrical shock, burns and other potential electrical safety hazards as well as comply with regulatory requirements.

2 PROGRAM COMPLIANCE

2.1 All Tetra Pak Inc. employees and contractors shall comply with the requirements of this policy.

2.2 Violation of this policy will result in will result in progressive disciplinary action in accordance with Tetra Pak policy.

2.3 A printed copy of this policy shall be made available to all Tetra Pak Inc. employees and their authorized representatives.

3 SCOPE

3.1 This program applies to all North American Tetra Pak properties and customer sites, for work performed by its employees regardless of job site location.

3.2 This includes contractors working at Tetra Pak facilities that do not have a Tetra Pak approved Electrical Safety Program.

3.3 Tetra Pak Inc. field service employees will comply with customer-specific procedures where their requirements are stricter than this policy.

3.4 This policy shall be effective June 15, 2015.

4 DEFINITIONS

4.1 Non-Qualified Worker – employees that do not have full knowledge of the operation of electrical equipment and of all the inherent electrical hazards.

4.2 Qualified Worker – employees that are knowledgeable of the electrical equipment on which they will work, inherent electrical hazards and how avoid them.

5 RESPONSIBILITES

5.1 OHS Officer

5.1.1 Evaluate work being performed and determine compliance with this program.

5.1.2 Coordinate training required by this policy and maintain training records.

5.1.3 Periodically review and update this written program.


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5.1.4 Coordinate and maintain documentation for training required by this policy.

5.2 Supervisors, Line Managers, and Functional OHS Leads

5.2.1 Promote electrical safety awareness for all employees.

5.2.2 Ensure employees comply with all provisions of the electrical safety program.

5.2.3 Ensure employees receive training appropriate to their assigned electrical tasks and maintain documentation of such training.

5.2.4 Develop and maintain a list of all qualified workers under their supervision. Ensure employees are provided with and use appropriate protective equipment.

5.3 Employees

5.3.1 Follow the work practices described in this document, including the use of appropriate protective equipment and tools.

5.3.2 Attend all training required relative to this program.

5.3.3 Immediately report any concerns related to electrical safety to supervision.

5.4 Building Managers

5.4.1 Ensure electrical work permits are completed for energized electrical work that is conducted at Tetra Pak Inc. locations.

5.5 Project Managers and Site Responsible

5.5.1 Ensure employees comply with the requirements of this policy at customer and project sites.

5.5.2 Ensure electrical work permits are completed for energized electrical work conducted on customer and project sites.

6 ELECTRICAL HAZARDS

6.1 Electrical shocks and burns: These can occur when an electric current passes through the body. This can happen when touching an energized part. If the electric current passes across the chest or head, death can result. Severe burns can occur at high voltages.

6.2 Arc-flash burns: These can occur if a conductive object gets too close to a high-amp current source or by equipment failure (for instance, while opening or closing disconnects). The arc

can heat the air to temperatures as high as 35,000o

F, and vaporize metal in the equipment. The arc flash can cause severe skin burns by direct heat exposure and by igniting clothing.

6.3 Arc-blast impacts: The heating of air and vaporization of metal creates a pressure wave that can damage hearing and cause memory loss (from concussion) and other injuries. Flying metal parts from the blast are also a hazard.

6.4 Falls: Electric shocks and arc blasts can cause falls, especially from ladders or unguarded scaffolding. Always use proper personal protective equipment (PPE) when working at heights.

7 TRAINING


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Workers near energized, or potentially energized electrical circuitry of fifty (50) volts to ground or greater, shall be trained in energized electrical safe work practices and procedures and retrained as necessary.

7.1 Qualified Workers

To be qualified workers, employees must receive training in avoiding the electrical hazards associated with working on or near exposed energized parts prior to performing energized electrical work. Such training will be provided when the employee is initially assigned to the job and refresher training will be provided every three years or when conditions change. The following items are to be included in the training of qualified workers:

7.1.1 On-the-job training with a qualified worker.

7.1.2 The Lockout/Tagout Training Program including safe work practices required to safely de- energize electrical equipment.

7.1.3 Universal electrical safety procedures.

7.1.4 Skills and techniques necessary to distinguish exposed live parts from other parts of electric equipment.

7.1.5 Skills and techniques necessary to determine the nominal voltage of exposed live parts.

7.1.6 The approach distances and the corresponding voltages to which the qualified worker will be exposed.

7.1.7 Selection and use of proper work practices, PPE, tools, insulating and shielding materials and equipment for working on or near energized parts.

7.1.8 Ability to recognize signs and symptoms of electric shock, heart fibrillation, electrical burns, and proper first aid protocols for these conditions. They must have the following training:

7.1.8.1 Basic Cardio Pulmonary Resuscitation (CPR);

7.1.8.2 Automatic External Defibrillator (AED); and

7.1.8.3 Contacting emergency personnel and basic first aid

7.2 Non-qualified Worker

General electrical safety awareness training is required for non-qualified workers who will assist qualified workers, use electrically-powered tools, or perform maintenance or serving of electrically-powered machines or equipment.

7.3 Training must be completed prior to assignment of duties that are covered by this policy. Retraining will be required whenever an employee shows lack of the necessary knowledge or skills to safely work on or around electrical systems.

7.4 Documentation of all training, including on-the-job training delivered by qualified workers, shall be maintained by the OHS Officer.

8 PORTABLE ELECTRICAL EQUIPMENT & EXTENSION CORDS


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The following requirements apply to the use of cord-and-plug-connected equipment and flexible cord sets (extension cords):

8.1 Extension cords may only be used to provide temporary power.

8.2 Portable cord-and-plug-connected equipment and extension cords must be visually inspected before use on any shift for external defects such as loose parts, deformed and missing pins, or damage to outer jacket or insulation, and for possible internal damage from pinched or crushed outer jacket.

8.3 Defective cord or cord-and-plug-connected equipment must be removed from service and no employee may use it until it is repaired and tested to ensure it is safe for use.

8.4 Extension cords must be of the three-wire type. Extension cords and flexible cords must be designed for hard or extra hard usage (for example, types S, ST, and SO). The rating or approval must be visible.

8.5 Job-made extension cords are forbidden per the electrical code.

8.6 Personnel performing work on renovation or construction sites using extension cords or where work is performed in damp or wet locations must be provided with, and must use, a ground fault circuit interrupter (GFCI).

8.7 All portable equipment must be handled in a manner that will not cause damage. Flexible electric cords connected to equipment may not be used for raising or lowering the equipment.

8.8 Extension cords must be protected from damage. Sharp corners and projections must be avoided. Flexible cords may not be run through windows or doors unless protected from damage, and then only on a temporary basis. Flexible cords may not be run above ceilings or inside or through walls, ceilings or floors, and may not be fastened with staples or otherwise hung in such a fashion as to damage the outer jacket or insulation.

8.9 Cords must be covered by a cord protector or tape when they extend into a walkway or other path of travel to avoid creating a trip hazard.

8.10 Extension cords used with grounding-type equipment must contain an equipment-grounding conductor (i.e., the cord must accept a three-prong, or grounded, plug).

8.11 Attachment plugs and receptacles may not be connected or altered in any way that would interrupt the continuity of the equipment-grounding conductor. Additionally, these devices may not be altered to allow the grounding pole to be inserted into current connector slots. Clipping the grounding prong from an electrical plug is prohibited.

8.12 Flexible cords may only be plugged into grounded receptacles. The continuity of the ground in a two-prong outlet must be verified before use. It is recommended that the receptacle be replaced with a three-prong outlet. Adapters that interrupt the continuity of the equipment-grounding connection may not be used.

8.13 All portable electric equipment and flexible cords used in highly conductive work locations, such as those with water or other conductive liquids, or in places where employees are likely to contact water or conductive liquids, must be approved for those locations.


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8.14 Employee's hands must be dry when plugging and unplugging flexible cords and cord-and-plug-connected equipment if energized equipment is involved.

8.15 If the connection could provide a conducting path to employees hands (for example, if a cord connector is wet from being immersed in water), the energized plug and receptacle connections must be handled only with insulating protective equipment.

8.16 Locking type connectors must be properly locked into the connector.

8.17 Lamps for general illumination must be protected from breakage, and metal shell sockets must be grounded.

8.18 Temporary lights must not be suspended by their cords unless they have been designed for this purpose.

8.19 Portable lighting used in wet or conductive locations, such as tanks or boilers, must be operated at no more than 12 volts or must be protected by a GFCI.

8.20 Extension cords are considered to be temporary wiring, and must also comply with the section on “Requirements for Temporary Wiring” in this program.

9 REQUIREMENTS FOR TEMPORARY WIRING

Temporary electrical power and lighting installations of 600 volts or less, including flexible cords, cables and extension cords, may only be used during and for renovation, maintenance, repair, or testing of equipment. The duration for temporary wiring used for decorative lighting for special events and similar purposes may not exceed 90 days. The following additional requirements apply:

9.1 Ground-fault protection (e.g., ground fault circuit interrupters or GFCIs) must be provided on all temporary-wiring circuits, including extension cords, used on construction sites.

9.2 In general, all equipment and tools connected by cord and plug must be grounded. Listed or labelled double insulated tools and appliances need not be grounded.

9.3 Feeders must originate in an approved distribution center, such as a panel board, that is rated for the voltages and currents the system is expected to carry.

9.4 Branch circuits must originate in an approved power outlet or panel board.

9.5 Neither bare conductors nor earth returns may be used for the wiring of any temporary circuit.

9.6 Receptacles must be of the grounding type. Unless installed in a complete metallic raceway, each branch circuit must contain a separate equipment-grounding conductor, and all receptacles must be electrically connected to the grounding conductor.

9.7 Flexible cords and cables must be of an approved type and suitable for the location and intended use. They may only be used for pendants, wiring of fixtures, connection of portable lamps or appliances, elevators, hoists, connection of stationary equipment where frequently interchanged, prevention of transmission of noise or vibration, data processing cables, or where needed to permit maintenance or repair. They may not be used as a substitute for the fixed wiring, where run through holes in walls, ceilings or floors; where run through doorways,


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windows or similar openings; where attached to building surfaces; or where concealed behind building walls, ceilings or floors.

9.8 Suitable disconnecting switches or plug connects must be installed to permit the disconnection of all ungrounded conductors of each temporary circuit.

9.9 Lamps for general illumination must be protected from accidental contact or damage, either by elevating the fixture or by providing a suitable guard. Hand lamps supplied by flexible cord must be equipped with a handle of molded composition or other approved material and must be equipped with a substantial bulb guard.

9.10 Flexible cords and cables must be protected from accidental damage. Sharp corners and projections are to be avoided. Flexible cords and cables must be protected from damage when they pass through doorways or other pinch points.

10 WET OR DAMP LOCATIONS

Work in wet or damp work locations (i.e., areas near water or other liquids) should not be performed unless it is absolutely critical. Electrical work should be postponed until the liquid can be cleaned up. The following special precautions must be incorporated while performing work in damp locations:

10.1 Remove standing water before beginning work. Work is prohibited in areas where there is standing water;

10.2 Keep electrical cords away from standing water;

10.3 Do not use electrical extension cords in wet or damp locations;

10.4 Place a dry barrier over any wet or damp work surface; and

10.5 Only use electrical cords that have GFCIs;

11 WORKING ON DE-ENERGIZED EQUIPMENT

11.1 Assume all electric circuits are energized unless each involved worker ensures they are not. Every circuit and conductor must be tested every time work is done on them. Proper PPE must be worn until the equipment is proven to be de-energized:

11.2 The procedure to verify conditions for electrically safe work are as follows:

11.2.1 Identify all sources of power to the equipment. Check applicable up-to-date drawings, diagrams, and identification tags.

11.2.2 Remove the load current, and then open the disconnecting devices for each power source.

11.2.3 Where possible, visually verify that blades of disconnecting devices are fully open or that circuit breakers are turned off.

11.2.4 Apply lockout/tagout devices in accordance with a formal, written policy.


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11.2.5 Test each phase conductor or circuit part with an adequately rated voltage detector to verify that the equipment is de-energized. Test each phase conductor or circuit part both phase-to-phase and phase-to-ground. Check the voltage detector before and after each test to be sure it is working.

11.2.6 Properly ground all possible sources of induced voltage and stored electric energy (e.g., capacitors) before touching. If conductors or circuit parts that are being de-energized could contact other exposed conductors or circuit parts, apply ground-connecting devices rated for the available fault current.

11.2.7 Always refer to Lockout/Tagout Procedures when available.

11.3 The process of de-energizing is "live" work and can result in an arc flash due to equipment failure and should be performed in accordance with Section 12 "Working On or Near Energized Equipment."

12 WORKING ON OR NEAR ENERGIZED EQUIPMENT

12.1 Only a qualified worker is allowed to work on energized circuits.

12.2 Working on live circuits means actually touching energized parts. Working near live circuits means working close enough to energized parts to pose a risk even though work is on de-energized parts. Common tasks where there may be a need to work on or near live circuits include:

12.2.1 Taking voltage measurements

12.2.2 Opening and closing disconnects and breakers

12.2.3 Racking breakers on and off the electrical busbars

12.2.4 Removing panels and dead fronts

12.2.5 Opening electric equipment doors for inspection

12.3 Standard written procedures and training should be adopted for common tasks. For instance, when opening and closing disconnects, use the left-hand rule when possible (stand to the right side of the equipment and operate the disconnect switch with the left hand).

12.4 Energized electrical work permit for 240 Volts or higher

12.4.1 If live parts are not placed in an electrically safe condition, work to be performed shall be considered energized electrical work and shall be performed by written permit only.

12.4.2 A copy of the Tetra Pak Energized Electrical Work Permit can be found in the Appendix of this document. The intent of this permit is to ensure that all appropriate safety precautions are taken prior to starting energized electrical work.

12.4.3 Work related to testing, troubleshooting, and voltage measuring may be completed without a permit provided appropriate safe work practices and PPE are used.

12.4.4 The permit must be originated by the qualified worker.

12.4.5 Energized Work Permits shall be submitted to the appropriate supervisor for each facility.


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12.4.6 The permit must be posted in an appropriate location where the energized work is taking place for the duration of the task.

12.5 Approach distances to exposed energized parts

12.5.1 Prohibited Area – considered the same as being in contact with energized parts. Any energized work must have a justified reason and must only be entered by qualified workers. The following are required to enter:

12.5.1.1 Qualified electrical training

12.5.1.2 Energized electrical work permit

12.5.1.3 Risk assessment for live electrical work

12.5.1.4 Use of arc-rated PPE per the requirements of the arc hazard analysis of the electrical equipment

12.5.2 Restricted Area – may only be entered by qualified workers. The following are required to enter:

12.5.2.1 Energized electrical work permit

12.5.2.2 Use of arc-rated PPE per the requirements of the arc hazard analysis of the electrical equipment

12.5.2.3 Ensure no part of the body enters the Prohibited Area

12.5.3 Limited Area – may be entered by a non-qualified worker if escorted by a qualified worker. The qualified worker must instruct the non-qualified worker on the hazards of the energized equipment.

12.5.4 Arc Flash zone – the area around the electrical equipment where a worker can receive a second degree burn if an electrical arc flash were to occur.

12.6 Limiting access to equipment

12.6.1 Barricades shall be used in conjunction with safety signs to prevent or limit access to work areas containing live parts. Conductive barricades shall not be used where they might cause an electrical hazard. Barricades shall be placed no closer than the Limited Approach Boundary.

12.6.2 If signs and barricades do not provide sufficient protection, an attendant will be assigned to warn and protect pedestrians. The primary duty of the attendant shall be to keep a non-qualified worker out of the work area where an electrical hazard exists. The attendant shall remain in the area as long as there is a potential exposure to electrical hazards.

12.7 Elevated working surfaces, such as scaffolds, and vehicle or mechanical equipment capable of having parts of its structure elevated shall be located at least 10 feet plus 4 inches for every additional 10 kV above 50 kV from overhead power lines. Power lines shall be deenergized and grounded if these clearances cannot be maintained.

13 PERSONAL PROTECTIVE EQUIPMENT

13.1 General requirements


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13.1.1 Employees working in areas where there are potential electrical hazards must be provided with and use personal protective equipment (PPE) that is appropriate for the specific work to be performed.

13.1.2 The electrical tools and protective equipment must be specifically approved, rated, and tested for the levels of voltage to which an employee may be exposed.

13.1.3 Each Tetra Pak Inc. location shall provide electrical protective equipment (Arc Flash Gear) required by this program. Such equipment shall include, at minimum, 8 calorie rated Arc Flash apparel, eye protection, head protection, hand protection, insulated footwear, and face shields where necessary.

13.2 Personal Protective Equipment

13.2.1 Class E hard hats meeting the requirements of ANSI Z89.1 shall be used where there is potential for head injury from electric shock or burns due to contact with live parts or from flying objects resulting from an electrical explosion.

13.2.2 Eye and face protection meeting the requirements of ANSI Z87.1 and ASTM F2178 shall be used when there is a potential for an arc blast. Additional illumination may be needed when using tinted face shields for protection during electrical work.

13.2.3 Hand protection, consisting of rubber insulating gloves worn underneath leather protection gloves, shall be used when working with exposed energized parts greater than 50 Volts.

13.2.3.1 Rubber insulting gloves shall meet the requirements of ASTM D120;

13.2.3.2 An air test must be performed on rubber insulating gloves before each use and must be tested by the manufacturer at least once every 6 months; and

13.2.3.3 Protective leather gloves shall meet the requirements of ASTM F696.

13.2.4 Dielectric overshoes meeting the requirements of ASTM F1116 and F1117 shall be used where protection against step and touch potential is required. Insulated soles shall not be used as primary electrical protection.

13.2.5 PPE shall be maintained in a safe, reliable condition and be inspected for damage before each day's use and immediately following any incident that can reasonably be suspected of having caused damage.

13.3 Flame-Resistant Apparel & Under layers

13.3.1 Flame-resistance (FR) apparel shall meet the requirements of F1506. FR hoods shall also meet the requirements of ASTM F2178 for eye and face protection.

13.3.2 FR apparel shall be visually inspected before each use.

13.3.3 FR apparel that is contaminated or damaged shall not be used. Protective items that become contaminated with grease, oil flammable liquids, or combustible liquids shall not be used.

13.3.4 The apparel manufacturer’s instructions for care and maintenance of FR apparel shall be followed.

13.3.5 When the apparel is worn to protect an employee, it shall cover all ignitable clothing and allow for movement and visibility.


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13.3.6 FR apparel must cover potentially exposed areas as completely as possible. FR shirt sleeves must be fastened and FR shirts/jackets must be closed at the neck.

13.3.7 Non-melting, flammable garments (i.e. cotton, wool, rayon, silk, or blends of these materials) may be used as under layers beneath FR apparel.

13.3.8 Fibers that can melt such as acetate, nylon, polyester, polypropylene, and spandex shall not be permitted in fabric under layers next to skin. (Small amounts of elastic used on non-melting fabric underwear or socks shall be permitted).

13.3.9 FR garments worn as outer layers over FR apparel must also be made from FR material. Flash suits must permit easy and rapid removal by the user.

13.4 Rubber insulating equipment

13.4.1 Rubber insulating equipment includes protective devices such as gloves, sleeves, blankets, and matting.

13.4.2 Rubber insulating blankets, covers, line hoses, and sleeves meeting the requirements of ASTM D1048-1051 may be used as additional protection against electrical hazards working near exposed energized parts.

13.4.3 Insulating equipment must be inspected for damage before each day’s use and immediately following any incident that can reasonably be suspected of having caused damage.

13.4.4 Insulating equipment found to have defects that might affect its insulating properties must be removed from service until testing indicates that it is acceptable for continued use. No repairs to rubber insulating equipment shall be attempted.

13.4.5 Rubber insulating equipment must be tested according to the schedule supplied by the manufacturer or at least every 6 months.

13.4.6 Rubber insulating equipment must be stored in an area protected from light, temperature extremes, excessive humidity, ozone, and other substances and any conditions that may cause damage.

13.5 Insulated tools and materials

13.5.1 Only insulated tools and equipment shall be used within the Limited Approach Boundary of exposed energized parts.

13.5.2 Insulated tools shall be rated for the voltages on which they are used.

13.5.3 Insulated hand tools shall be used when working inside of Restricted Areas and must be rated for the voltage of electrical equipment. These tools must meet the requirements of ASTM F1505-07 or IEC 900 Standards for Insulated Hand Tools. Tools and handling equipment should be replaced if the insulating capability is decreased due to damage.

13.5.4 Fuse or fuse holder handling equipment, insulated for the circuit voltage, shall be used to remove or install a fuse if the fuse terminals are energized.

13.5.5 Ropes and hand-lines used near exposed energized parts shall be nonconductive. Portable ladders used for electrical work shall have nonconductive side rails.

13.6 Other precautions


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13.6.1 When working on de-energized parts, but still inside the flash protection boundary for any existing nearby live exposed parts, the following precautions shall be taken:

13.6.2 For all Tetra Pak Machines that consist of systems of 600 volts or less, the flash protection boundary is 4 feet, based on an available bolted fault current of 50 kA (kiloamps) and a clearing time of 6 cycles (0.1 seconds) for the circuit breaker to act, or any combination of fault currents and clearing times not exceeding 300 kA cycles (5000 ampere seconds).

13.6.3 If the parts cannot be de-energized, barriers such as insulated blankets must be used to protect against accidental contact or PPE must be worn.

13.6.4 Workers shall not reach blindly into areas that might contain exposed live parts.

13.6.5 Workers shall not enter spaces containing live parts unless illumination is provided that allows the work to be performed safely.

13.6.6 Conductive articles of jewellery and clothing (such as watchbands, bracelets, rings, key chains, necklaces, metalized aprons, cloth with conductive thread, metal headgear, or metal frame glasses) shall not be worn where they present an electrical contact hazard with exposed live parts.

13.6.7 Conductive materials, tools, and equipment that are in contact with any part of an employee’s body shall be handled in a manner that prevents accidental contact with live parts. Such materials and equipment include, but are not limited to long conductive objects such as ducts, pipes, tubes, conductive hose and rope, metal-lined rules and scales, steel tapes, pulling lines, metal scaffold parts, structural members, and chains.

13.6.8 When an employee works in a confined space or enclosed spaces that contain exposed live parts, the employee shall use protective shields, barriers or insulating materials as necessary to avoid contact with these parts. Doors, hinged panels, and the like shall be secured to prevent them from swinging into employees.

14 EQUIPMENT LABELING

14.1 Switchboards, panel boards, industrial control panels, and motor control centers shall be field marked to warn workers of potential electric shock and arc flash hazards.

14.2 Markings (labels) shall be located so they are visible to the worker before examination, adjustment, servicing, or maintenance of the equipment.

14.3 The DANGER label should remind a qualified worker, who intends to open the equipment for analysis or work, of the following:

14.3.1 Electric arc flash and shock hazard exists

14.3.2 To turn off all power before opening

14.3.3 To follow all requirements of NFPA 70E for safe work practices and wear appropriate personal protective equipment (PPE) for the specific hazard

15 WORKING SPACE AROUND ELECTRICAL EQUIPMENT


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15.1 Sufficient access and working space shall be provided and maintained around all electric equipment to permit ready and safe operating and maintenance of such equipment. Enclosures that house electric apparatus and are controlled by lock and key shall be considered accessible to qualified workers.

15.2 Working space for equipment operating at 600 volts, nominal, or less to ground and likely to require examination, adjustment, service or maintenance while energized shall comply with the following dimensions:

15.2.1 Three (3) feet for 0-150 Volts

15.2.2 Three (3) feet for 151-600 Volts where exposed live parts on one side and no live or grounded parts on the other side of the working space, or exposed live parts on both sides effectively guarded by suitable wood or other insulating materials. Insulated wire or insulated bus bars operating at not over 300 volts to ground shall not be considered live parts.

15.2.3 Three and one-half (3.5) feet for 151-600 volts where exposed live parts on one side and grounded parts on the other side. Concrete, brick, or tile walls shall be considered as grounded surfaces.

15.2.4 Four (4) feet for 151-600 Volts where exposed parts are on both sides of the work space with the operator between.

15.3 Working space shall not be required in the back or sides of assemblies, such as dead-front switchboards or motor control centers, where all connections and all renewable or adjustable parts, such as fuses or switches, are accessible from locations other than the back or sides. Where rear access is required to work on non-electrical parts on the back of enclosed equipment, a minimum horizontal working space of 762mm (30 in) shall be provided.

15.4 Smaller working spaces can be permitted where all non-insulated parts operate at not greater than 30 Volts RMS, 42 Volts peak, or 60 Volts direct current (DC).

15.5 In existing buildings were electric equipment is being replaced, working clearance specified in Section 15.2.3 shall be permitted between dead-front switch boards, panel boards, or motor control centers located across the aisle from each other where conditions of maintenance and supervision ensure that written procedures have been adopted to prohibit equipment on bother sides of the aisle from being open at the same time. Qualified workers who are authorized will service the installation.

15.6 The width of the working space in front of the electrical equipment shall be the width of the equipment or 750 mm (30 in), whichever is greater. In all cases, the work space shall permit at least a 90 degree opening of equipment doors or hinged panels.

15.7 The workspace shall be clear and extend from the grade, floor, or platform to the height 2.0m (6 ½ ft) or the height of the equipment whichever is greater. Within the height requirements of this section, other equipment that is associated with the electrical installation and is located above or below the electrical equipment shall be permitted to extend not more than 150 mm (6 in) beyond the front of the electrical equipment.


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15.8 Working space required by this policy shall not be used for storage. When normally enclosed live parts operating at 50 volts or more are exposed for inspection or service, the working space, if in a passageway or general open spaced shall be suitably guarded.

15.9 Access and entrance to working space

15.9.1 At least one entrance of sufficient area shall be provided giving access to the working space around electric equipment.

15.9.2 Where the location permits a continuous and unobstructed way of exit travel, a single entrance to the working space shall be permitted.

15.9.3 Where the depth of the working space is twice that required by Section 15.2, a single entrance shall be permitted. It shall be located so that the distance from the equipment to the nearest edge of the entrance is not less than the minimum clear distance specified in Section 15.2 for equipment operating at that voltage and in that condition.

15.9.4 Illumination shall be provided for all working spaces about service equipment, switchboards, panel boards, or motor control centers installed indoors. Additional lighting outlets shall not be required where the work space is illuminated by an adjacent light source. In electrical equipment rooms, the illumination shall not be controlled by automatic means only.

15.9.5 The minimum headroom of working spaces about service equipment, switchboards, panel boards, or motor control centers shall be 2.0 m (6-1.2 ft). Where the electrical equipment exceeds 2.0 m (61/2 ft) in height, the minimum headroom shall not be less than the height of the equipment.

15.9.6 All switchboards, panel boards, distribution boards, and motor control centers shall be located in dedicated spaces and protected from damage. Exception: Control equipment that by its very nature or because of other rules of the standard must be adjacent to or within sight of the operating machinery shall be permitted in those locations.

15.10 When a qualified worker is working in the vicinity of overhead lines, whether in an elevated position or on the ground, they may not approach or take any conductive object without an approved insulating handle closer to exposed energized parts than

15.10.1 For 300 Volts or less: avoid contact

15.10.2 For over 300V, but not over 750V: 1 ft. 0 in. (30.5 cm)

15.10.3 For over 750V, but not over 2kV: 1 ft. 6 in. (46 cm)

15.10.4 For over 2kV, but not over 15kV: 2 ft. 0 in. (61 cm)


15.10.6 For over 37kV, but not over 87.5kV: 3 ft. 6 in. (107 cm)

15.10.7 For over 87.5kV, but not over 121kV: 4 ft. 0 in. (122 cm)


16 CONTRACTORS


16

16.1 Contractors shall comply with all of the requirements of this policy.

16.2 Employees hiring contractors shall ensure that contractors are aware of the requirements of this policy.

16.3 Tetra Pak Inc. Site Representatives shall ensure that contractors comply with the requirements of this policy at customer and project sites.

16.4 Tetra Pak Inc. building managers shall ensure that contractors comply with the requirements of this policy at Tetra Pak Inc. buildings.

17 APPENDICES

17.1 Appendix A: Electrical Work Hazard Categories

17.2 Appendix B: Electrical PPE Requirements

17.3 Appendix C: Electrical Warning Labels

17.4 Appendix D: Energized Work Permit

17.5 Appendix E: Electrical Safety Checklist

17.6 Appendix F: Energized Circuit Risk Assessment

18 REFERENCES

18.1 Occupational Safety and Health Administration (OSHA), 29 CFR 1910 Subpart S: Electrical Safety Standard

18.2 OSHA, 29 CFR 1910.147: Control of Hazardous Energy (Lockout/Tagout)

18.3 National Fire Protection Association (NFPA), Standard 70: National Electrical Code (NEC), 2011

18.4 NFPA, Standard 70E: Electrical Safety in the Workplace, 2012


17

APPENDIX A: ELECTRICAL WORK HAZARD CATEGORIES

Item Tasks Performed Within the ARC Flash

Boundary Hazard/Risk

Category

PPE Needed

1

Circuit breaker (CB) or fused Switch operation with covers on

0

Non melting or untreated natural fiber clothing, long sleeve shirt, pants, safety glasses or goggles, hearing protection (ear canal inserts), leather gloves.

2 Opening hinged covers (to expose bare, energized electrical conductors and circuit parts)

0 Same as item 1

3

Starter operation with enclosure doors opened

1

Arc rated long sleeve shirt and pants (at least 4 cal/cm

2), hard

hat, safety glasses or goggles, arc rated face shield, hearing protection (ear canal inserts), heavy duty work gloves, leather work shoes.

4

Perform infrared thermography and other non- contact inspections outside the restricted approach boundary

1

Same as item 3

5

CB or fused switch with covers off

1

Same as item 3 except gloves must be rubber and properly rated with leather protectors

6 Removal of bolted covers (to expose bare, energized electrical conductors and circuit parts)

1 Same as item 3

7

Work on energized electrical conductors and circuit parts, including voltage testing

2

Same as Category 1 plus: 8

cal/cm2

clothing (long sleeve shirt and pants or coveralls), Arc rated face shield and arc rated balaclava, and rubber gloves properly rated with leather protectors

8 Remove or install CBs or fused switches 2 Same as item 7

9

Work on energized electrical conductors and circuit parts of equipment fed directly by a branch circuit of the panel board.

2

Same as item 7

10 Work on control circuits with energized electrical conductors and circuit parts >120V exposed.

2

Same as item 7

11 Application of temporary protective grounding equipment, after voltage test

2

Same as item 7


18

APPENDIX B: ELECTRICAL PPE REQUIREMENTS


19

APPENDIX C: ELECTRICAL WARNING LABELS

The following label shall be affixed to industrial control panels (every enclosure that may contain exposed energized conductors or components):

The following is an example of a label to be affixed next to the main disconnect of a typical Tetra

Pak machine of 400VAC after arc flash hazard analysis has been completed:

.


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APPENDIX D: ENERGIZED WORK PERMIT

For Applications of 240 volts or greater

1. Work Location:

2. Work order/project #:

3. Description of the work to be done:

4. Check the following considerations when they apply:

Work is within the restricted approach boundary and there is a work plan

Work is within the prohibited approach boundary, it is very hazardous and there is a work plan

Request to shut down equipment was made

Conducted a shock hazard analysis

Shock protection boundaries have been determined

Flash hazard analysis has been made and the results are known

Flash protection boundary has been determined

Personal protective equipment including tools needed for the job have been determined and

are available

Non-qualified workers are restricted from the work area

Safe work practices that need to be employed have been considered

Job can be done safely

(Signature, Electrically Qualified Worker) (Date)

(Signature, Immediate Supervisor) (Date)


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APPENDIX E: ELECTRICAL SAFETY CHECKLIST

Electrical Safety Checklist

TRAINING ITEM YES N/A

COMMENTS

SCOPE AND TRAINING 1. All employees who work on, near or with premises wiring, wiring for

connections to supply, other wiring, and installation of optical fiber cable along with electrical conductors have been trained as either qualified or non-qualified workers.

0 0

2. Non-qualified workers have been trained in and are familiar with any electrically related safety practices not covered by this standard but necessary for their safety.

0 0

3. Qualified worker trained in and familiar with: a) Skills and techniques necessary to distinguish exposed

live parts from other parts of electric equipment. 0 0

b) Voltage determination. 0 0 c) Clearance distances that must be maintained. 0 0 d) Training conducted has been specific to the hazards to

which the employee may or will be exposed and their particular job duties.

0 0

SELECTION AND USE OF WORK PRACTICES 1. Work practices used to prevent electric shock and other injuries

address de-energized parts which may be energized. 0 0

2. Work practices used to prevent electric shock and other injuries address exposure to energized parts.

0 0

3. Procedure provided for work on or near exposed de-energized parts includes:

a) Written procedures specific to the equipment or worksite. 0 0 b) De-energizing equipment. 0 0 c) Application of locks and tags. 0 0

4. Working on or near exposed energized parts: a) All employees near enough to be exposed to a hazard

have been trained, and are aware of the practices that must be followed to protect them from the hazard.

0 0

b) Only qualified workers work on energized parts. 0 0 c) Overhead lines de-energized and grounded prior to

working near them or other protective measures used. 0 0

d) Non-qualified workers working near overhead lines are aware that they may not come approach, or use conductive objects closer than, 10 feet for lines up to 50 kV, or 10 feet plus 4 inches for every 10 kV over 50 kV.

0 0

e) Qualified workers have a working knowledge of the allowable approach distances of this program.

0 0

f) Vehicle and mechanical equipment operators understand that they must maintain:

i) A clear distance of 10 feet plus 4 inches for every 10 kV over 50 kV while working near energized overhead lines.

0 0

ii) A clear distance of 4 feet plus 4 inches for every 10 kV over 50 kV while in transit.

0 0

iii) Insulating barriers are used and installed as required.

0 0

iv) Insulated aerial lift operated by a qualified worker must comply with the separation distances.

0 0


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v) Employees standing on the ground understand they may not contact the vehicle unless using protective equipment rated for the voltage or the equipment located so no un-insulated part can provide a conductive path to persons on the ground.

0 0

g) Illumination is provided at all worksites to assure safe work.

0 0

h) Protective shields and barriers provided and used for work in confined spaces to prevent contact with exposed energized parts.

0 0

i) All conductive materials such as pipes, rods, etc. are handled so as to prevent contact with exposed energized parts.

0 0

j) Conductive articles of clothing and jewellery such as watches, rings, etc. are not worn if they might contact exposed energized parts unless rendered nonconductive.

0 0

k) Portable ladders with nonconductive side rails are used when working near or on exposed energized conductors.

0 0

l) Housekeeping conducted only when exposed energized parts may not be contacted. Barriers provided and nonconductive cleaning materials used.

0 0

m) Only qualified workers allowed to by-pass electrical interlocks on temporary basis while they work on equipment.

0 0

USE OF EQUIPMENT

1. Portable electric equipment such as cord-and-plug connected equipment, including flexible cords:

a) Handled in a manner to avoid damage. 0 0 b) Not used to raise or lower equipment. 0 0

c) Not fastened with staples or hung so as to damage insulation.

0 0

d) Visually inspected before each use on each shift. 0 0

e) Defective items removed from service and not used until rendered safe.

0 0

f) Plugs and receptacles mate properly. 0 0

g) Flexible grounding-type cords have a grounding conductor.

0 0

h) Grounding plug not defeated. 0 0

i) Adapters which interrupt grounding continuity not used. 0 0

j) Approved equipment used for work in conductive work locations (e.g. wet locations, etc.).

0 0

k) Locking-type connectors are properly secured after connection.

0 0

ELECTRIC POWER AND LIGHTING CIRCUITS

1. Only load rated switches or circuit breakers used as disconnecting means.

0 0

2. Circuits not manually reenergized until it is determined that it is safe to do so.

0 0

3. Over-current protection of circuits not modified. 0 0

TEST INSTRUMENTS AND EQUIPMENT


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1. Used by qualified workers only. 0 0

2. Visually inspected before use. 0 0

3. If circuit tested is over 600 volts, nominal, test instrument tested for proper operation before and immediately after the test.

0 0

4. Test instrument rated for the circuit to be tested and appropriate for the environment.

0 0

5. Electrical equipment capable of igniting flammable or ignitable materials not used if present in the worksite.

0 0

SAFEGUARDS FOR PERSONNEL PROTECTION

1. Protective equipment used when there is exposure to potential electrical hazards.

0 0

2. Protective equipment maintained in safe and reliable condition and tested and inspected as required.

0 0

3. Protective equipment protected from damage during use. 0 0

4. Approved electrically rated hardhats used as needed to protect head from electric shock or burns.

0 0

5. Safety glasses or goggles used as needed to protect eyes or face when there is a danger of arcs, flashes or flying objects.

0 0

6. Approved gloves worn that are appropriate for the hazard present 0 0

7. Insulated tools or handling equipment used when conductors may be contacted.

0 0

8. Insulated fuse handling equipment used to remove or install fuses when terminals are energized.

0 0

9. Ropes and handholds used near energized parts are nonconductive and are protected from moisture.

0 0

10. Protective shields, barriers or insulating materials are used to protect employees working near exposed energized parts.

0 0

ALERTING TECHNIQUES

1. Safety signs and tags used when necessary to warn employees about electrical hazards.

0 0

2. Barricades used with safety signs when necessary to prevent or limit employee access to work areas with non-insulated energized conductors or parts.

0 0

3. Attendants stationed as needed to warn when signs or barricades are not sufficient to prevent unauthorized access.

0 0

Name of Trainer: Date:

Employee Name Employee Name Employee Name

APPENDIX F: ENERGIZED CIRCUIT RISK ASSESSMENT

Actions Required for Risk Assessment:

1. Identifying and analyzing electrical hazards 2. Identifying tasks to be performed 3. Documenting hazards associated with each task 4. Estimating the risk for each hazard/task pair 5. Determining the appropriate protective measures needed to adequately reduce the level of risk.

Assessed by: (1) Approved by: (2) Approver’s Title and Company: (3) Location: (4)

Task: (5)

Item

Hazard (6)

Persons

Affected (7)

Risk

Level (8)

Preventative Control Measures (9)

Residual Risk

Assessment (10)

1 Electrical Shock possible

2 Arc Flash possible

3 Multiple sources of electricity are in the panel.

4 Each disconnect for each source of electricity to this panel not identified by location

5 Qualified worker not available

6 Arc Flash boundary violated

7 Shock boundaries are violated

8 No qualified AED, CPR, or First Aid worker available.

9 Proper PPE not being used

10 Non-qualified workers are not staying behind the Limited Approach Boundary?

11 Non-qualified workers are needed inside the Limited Area without training

12 Work must be performed with live circuit.

13 Connections in the panel are loose.

14 The equipment is not properly grounded.

15 The machine located in a moist area or is there a possibility of it becoming moist or wet.

16 Proper lighting is not available at or in the panel to be able to properly perform the task required.

Risk Assessment Completed by: (11) Date: (12)

Reviewed by: (13) Date: (14)

Completing the Risk Assessment

This form is recommended to be used for all electrical work both at Tetra Pak facilities and at customer facilities unless the customer demands that we use their forms. It is strongly suggested that you use it for all new assessments, and when existing assessments are being substantially revised.

(1) Assessed by: Insert the name of the assessor. For all electrical assessments they must be done only by qualified

workers.

(2) Approved by: Insert the name of the person who reviews and approves this Risk Assessment. This can be a Tetra Pak manager or a customer manager or customer’s responsible person for safety.

(3) Approver’s Title and Company: Insert the title of the person who is approving the RA and who they work for.

(4) Location: Insert all details of where the task is taking place (i.e. customer, customer location, type of machine, line

number, or serial number if needed to identify the equipment).

(5) Task: Give a brief description of what needs to be done. Use this area to state why it is necessary to do this task with the electricity energized.

(6) Hazard: List all of the hazards. The list that is available is not necessarily an all inclusive list. These are common

hazards that you may or may not have with this task and there may be others also. Remember to look at hazards that may not be immediately obvious.

(7) Persons Affected List all persons who could be harmed with each hazard. Do not forget to take into consideration all of

the personnel in the area other than Tetra Pak persons.

(8) Risk Level: The simplest form of risk assessment is to rate the remaining risk as high, medium or low, depending on how likely the activity is to cause harm and how serious that harm might be.

The risk is LOW - if it is most unlikely that harm would arise under the controlled conditions listed, and even if exposure occurred, the injury would be relatively slight.

The risk is MEDIUM - if it is more likely that harm might actually occur and the outcome could be more serious (e.g. some time off work, or a minor physical injury.

The risk is HIGH - if injury is likely to arise (e.g. there have been previous incidents, the situation looks like an accident waiting to happen) and that injury might be serious (broken bones, trip to the hospital, loss of consciousness), or even a fatality.

(9) Preventative Control Measures: List the measures that you will use to limit the risk or preferably eliminate the risk to all

persons affected by the hazard. Preventative measures include not only PPE and the proper tools, but could include training or the use of qualified workers to perform the task. You may need to list an action plan also to lower the risk to a reasonable level.

(10) Residual Risk Assessment: This column is extremely important. This will determine if the Risk Assessment is

completed for each hazard that is listed. The options for this column are:

T = trivial risk. Use for very low risk activities to show that you have correctly identified a hazard, but that in this particular circumstance, the risk is insignificant.

A = adequately controlled, no further action necessary. If you control measures lead you to conclude that the risk is low, and that all legislative requirements and Tetra Pak safety requirements have been complied with then insert A in this column.

N = not adequately controlled, actions required. Sometimes, particularly when setting up new procedures or adapting existing processes, the risk assessment might identify that the risk is high or medium when it is capable of being reduced by methods that are reasonably practicable. In these cases, an action plan is required. The plan should list the actions necessary, who they are to be carried out by, a date for completing the actions, and a signature box for the assessor to sign off that the action(s) has been satisfactorily completed. Some action plans will be complex documents; others may be one or two actions that can be completed with a short timescale.

(11) Risk Assessment Completed by: This is where the person who completed the Assessment places their

signature when they are satisfied that the assessment is complete and will be approved.

(12) Date: This is the date that the person signed the Assessment. Insert date that assessment form is completed. The assessment must be valid on that day, and subsequent days, unless circumstances change and amendments are necessary.

(13) Reviewed by: This is where the Safety Responsible for Tetra Pak would sign that they reviewed the

assessment.

(14) Date: This is the date that Safety Responsible signs off on the Risk Assessment. All RAs should be reviewed and filed by the Safety Responsible. If the RA is not effective there needs to be feedback to all that were involved in the assessment.

ELECTRICAL SAFETY PROCEDURE - Tetra Pak · electrical equipment and of all the inherent electrical...

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