The invisible killer - electrical safety in the food and drink industry Jackie Wooldridge Head of Health & Safety 2 Sisters Food Group
A game of chance? - Introduction to electrical hazards 1. Take turns rolling the dice. The person who rolls a 6 first is the one who is injured following an accident involving electricity. 2. Discuss what happened and how the accident happened. Brainstorm different hazards and scenarios. 3. Select a person to feedback the accident circumstances to the rest of the group.
The hazards and effects of electricity Key electrical hazards are: Shock - passage of current through the body Fire - ignition of flammable materials from electrical arcing Blast and heat effects of short circuits
Why do electrical accidents occur? Most electrical accidents occur because people are working on or near equipment that is: Thought to be Dead Known to be Live but those involved do not have adequate training or appropriate equipment, or they have not taken adequate precautions
What do we need to focus on? 68% inadequate working practices 19% failure to maintain 13% miscellaneous
Why do electrical accidents matter in the food and drink industry? In the UK one in 50 electrical accidents at work results in a fatality, compared with one in 600 from other causes You re10 times more likely to die from an electrical incident than from an incident due to another cause The ratio of fatal to major and reportable injuries due to accidents caused by electricity
I ve had electric shocks and it didn t do me any harm.. Three important considerations current path duration and frequency amount of energy or current flow
Special considerations in the food and drink industry Sometimes wet environment Production pressures Lots of people interacting with equipment Complex, high energy systems
Whose time is up? The person who rolled a 6 in the last exercise should open envelope 1 in the centre of the table. All other delegates should choose one of the other envelopes. Open your envelope and read through the character notes but don t share with others on the table. You will be playing a character who was involved in an electrical accident Start the role play with envelope 1 and go through the envelopes in numerical order. Read out the information to all the other delegates
Whose time is up? Once you have completed the role play answer the following questions what was the immediate cause of the accident What were the root causes of the accident What controls could have been put in place to prevent that accident happening?
The invisible killer Electrical dvd Electrical guidance Operators toolbox talk Competency assessments Posters
Who is it aimed at? The food and drink industry Electrical workers Managers and supervisors Operatives
Availability and next steps Free of charge Launched Oct 13 Web site www.iosh.co.uk/electricalsafety Launch event 25 th Mar 14 A taster
The Food and Drink Group s hopes and aspirations The package will be well received It will be used to raise awareness Not replace training on local rules Perhaps it will save a life or two
Workshop the right controls You will find an envelope on your table On front is one of 10 electrical topics inside are some questions about that topic 25 minutes to review the control measures required in relation to the topic given 5 mins feedback per group Choose volunteer to feedback
Controls 1. Training & competence 2. Risk assessment 3. Electrical maintenance 4. Cleaning & shop floor controls 5. Right tools and equipment 6. Procedures & rules 7. Isolation & lock off 8. Live testing procedures 9. Electrical contractor controls 10. Electrical duty holder
Training & competence
Challenge Provide clarity on competency requirements to carry out electrical isolation and lock off Confirm what restrictions are applicable to multi skilled engineers and non electrical engineers Consider what competencies contractors must have Confirm who is authorised to carry out electrical isolation and lock off
Assessment process Create employees CV to include: Formal qualifications Experience Portfolio evidence Deliver specific training on the LV safety rules Undertake competence assessment with defined pass rate (80%) Pass for isolation and lock off procedure 100% Duty holder to issue with LV Certificate of competence
Competency Review Electrical Maintenance Assessment Questionnaire 1. What is electricity? A pressure difference Power in a circuit Resistance in a circuit A form of energy 2. An insulator increases current flow increases voltage allows current to flow prevents current flow
Competence matrix Low Voltage Electrical Safety Competence Matrix Example Last updated: 25th May 10 1st Name Last Name Training Date Competent Person Training test Authorisations Requested Authorisations Recommended Other Comments Assessment Date Chris Williams 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 LV2 subject to audit on 1st permits William Williams 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Alan Smith 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Andrew Jones 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Stephen Jolly 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Sam Smith 08/03/2010 09/03/2010 No exam certs, suggest apply to C&G for Pass LV1,2,3,4,5,6,7,8,9 LV1,2,3,4,5,6,7,8,9 copies Ian Anderson 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Adam Opel 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15, LV1,2,3,4,5,6,7,8,9,10,11,12,13,14,15 Artie Catch 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,7,8,9 LV 1,8,9 LV 8 restrictions to be for self isolation for low power 240V circuits associated with instrumentation. Peter Power 08/03/2010 09/03/2010 Pass LV1,2,3,4,5,6,7,8,9 LV1,3,4,5,6,7,9 Assessed for LV2 but requires further mentoring and monitoring Reference LV1 LV2 LV3 LV4 LV5 LV6 LV7 LV8 LV9 LV10 LV11 LV12 LV 13 LV14 LV15 Specification and Competence Designated Competent Person - Authorised to carry out isolation procedures for own work only. Designated Competent Person - Authorised to carry out isolation procedures for own work and work by other operatives and contractors. Dead work - Install, repair, inspect, test and connect electrical circuit conductors and electrical equipmwnt, ensuring that they conform to the relevant regulations Issue LV Permits to work Receive LV permits to work Issue sanction for work near live conductors Receive sanction for work near live conductors Special circumstances - Proving circuit conductors or Electrical Equipment dead, an assumption shall be made that they are still live before testing Special circumstances - Work in the vicinity of live LV conductors - Removal/replacement of Fuse Bridges Special circumstances - Work in the vicinity of LV conductors - Testing and running adjustments under a live testing testing risk assessment check Special circumstances - Work in the vicinity of live LV conductors - Work on large storage Battery systems Special circumstances - Work in the vicinity of LV conductors - Work under a sanction for work near Live conductors Access to LV switch rooms Issue Electrical Substation Access Permit Restricted Competency - insert note in comments box
Risk assessment of electrical panels What should be covered? Exposure to direct contact (IP2X) Network labelling Operating identifications Access, egress and lighting Operation of isolator Panel wiring Power of panel Panel security Are all the components in the panel finger safe (IP2x) and adequately shrouded? Are live incoming tails completely shrouded? Check supply cable from gland position to isolator is via the shortest suitable route Where the supply cable takes a route through the panel, is it separated from all other cables of different voltages and current? Check warning labels and panel reference are in place, legible and easily seen. Check condition of panel components e.g. lamps, bulbs and control labelling Check the panel is lockable (normally by key plus tool).
Outcome from risk assessment Categorise control panels HIGH RISK PANEL UNAUTHORISED ACCESS PROHIBITED Only 24v DC controls in this panel RISK ASSESSMENT & SANCTION OR SSOW REQUIRED PRIOR TO PANEL ACCESS All or some elements of this panel are not finger safe High incident energy panel (? 100amps upstream fuse) When isolated some supplies remain live WARNING Unauthorised access prohibited Panel in accordance with IP2X standards at time of classification only PANEL INSPECTION AND RISK ASSESSMENT REQUIRED PRIOR TO WORK COMMENCING
HIGH RISK PANEL UNAUTHORISED ACCESS PROHIBITED RISK ASSESSMENT & SANCTION OR SSOW REQUIRED PRIOR TO PANEL ACCESS All or some elements of this panel are not finger safe High incident energy panel (? 100amps upstream fuse) When isolated some supplies remain live Bus bars Perspex cover provided but NOT finger safe
Risk assessment live work 1 2 3 Live Testing Risk Assessment Checklist Is the live work No DEAD necessary? WORK Yes ONLY Equipment checked & in No good condition? Yes See Guidance Upstream fuse notes for number greater than references 100A? 10 4 5 No Work at height required? No Is the location a hazardous zoned area? Yes SANCTION FOR WORK NEAR LIVE CONDUCTORS OR APPROVED SSOW REQUIRED 11 No 6 Instruments, tools leads checked. OK? No Take corrective action 12 Yes 7 Is the Equipment Finger safe? No Take corrective action 12 Yes 8 Access/Space Lighting & Environ. OK? No Take corrective action 12 9 Yes Implement Safe Work
Electrical maintenance Fixed electrical testing PAT testing look at frequency for equipment in harsh wet environments Planned maintenance earth bonding Thermographic imaging Design of panels
Cleaning & shop floor controls Bagging protection from water ingress RCD s (in testing) Bonding Awareness for operatives IP rating Maintenance Scales moveable equipment Good installation standards earths Specification and design of panels PAT testing - frequency
The right - Tools & equipment GS 28 voltage tester & proving unit Extendable barriers 1000v screw driver and plier set & gloves Insulated matting
The right - Tools & equipment Breaker MCB Fuse Caution notices Plug Light switch
Electrical safety rules & guidance Principal requirements: DEAD WORKING Special Procedures circumstances: batteries, LIVE WORKING substation access etc. Approved tools & equipment Authorisation Electrical safety rules Electrical safety Guidance COMPETENCE & RESPONSIBILITIES PROCEDURES Low voltage PTW Electrical live working RA & sanctions
Isolation & lock off 1. Electrical 2. Procedure to be followed 3. Test for dead 4. Permit if isolate for others
Step 1 IDENTIFY, ISOLATE AND MAKE DEAD From all points of supply by means described in the explanatory notes. Isolation & reinstatement must always be in agreement with users. Step 2 APPLY CAUTION NOTICES Apply caution notices to all points of isolation Step 3 PREVENT RE -ENERGISATION By locks, retention of fuses and links or other means described in the explanatory notes Step 4 PROVE DEAD Using an approved voltage indicator, check all poles of supply. Prove Dead at the point of work. Check voltage indicators before and after test. Step 5 POST DANGER NOTICES & OTHER PRECAUTIONS TO ADJACENT LIVE EQUIPMENT Identify adjacent live equipment in the work zone and prevent access. Apply danger notices. Step 6 ISSUE PERMIT TO WORK If required by the safety rules.
Low voltage permit to work (dead) 1. EQUIPMENT & TASK INFORMATION The following equipment has been made safe /is considered safe to carry out work as detailed below: Equipment Description:...... Equipment Location:...... Supplies Isolated At:...... Caution notices displayed at:...... Danger notices displayed at:...... Work to be carried out:......... Note: this permit does not absolve the persons to whom it is issued from exercising due caution in cooperating with safety procedures applicable to the task. All other equipment outside the scope of this permit should be considered potentially dangerous unless stated otherwise elsewhere. 2. SPECIFIC PRECAUTIONS TO BE TAKEN............ This Permit Is Valid Until:... (Date)... (Time)... 3. ISSUE BY DESIGNATED COMPETENT PERSON Signed:... Print Name:.Date:..Time:.. DESIGNATED COMPETENT PERSON 4. RECEIPT BY COMPETENT PERSON I have read and understand the above. I have confirmed to my own satisfaction that the supplies referred to in this permit have been made dead. I will return this permit to the issuer on completion/suspension or at the expiry of the validity period. Signed:... Print Name:.Date:..Time:.. COMPETENT PERSON 5. HAND BACK BY COMPETENT PERSON Work in the above location has ceased and the area cleared. The status of the equipment is as follows: Work complete, tools and materials removed, covers and barriers replaced. Work incomplete, reinstated and operational. Work incomplete, NOT operational, safety precautions applied. Signed:... Print Name:.Date:..Time:.. COMPETENT PERSON
Live work (including testing) 1. Not acceptable to undertake manipulation of cables live 2. Testing is defined as live work 3. Authorised to do this 4. Extra precautions in wet environments 5. Rubber mats/barriers etc 6. PPE gloves and glasses 7. Individuals authorised to do this work 8. High power panels require sanction 9. Classification pf panels
Note 1 Is the Live work necessary? - If the answer is no then dead working is essential. Whether the risk assessment is in a generic or written form, the following applies in all cases. Live working can only be permitted where: - (a) it is unreasonable in all the circumstances for it to be carried out dead; and (b) it is reasonable in all the circumstances for it to be carried out while the equipment is live; and (c) suitable precautions (including where necessary, the provision of suitable protective equipment) are taken to prevent injury. Note 2 Equipment examined and in good condition? The rules state that no live work shall be permitted where there are any doubts about the safety of cables and electrical equipment being worked upon or adjacent to those being worked upon. Note 3 Upstream Fuse less than 100A? It can be assumed that where the upstream protective device is a conventional fuse or fast acting fixed pattern circuit breaker at a rating less than 100 amperes and the voltage is at 400 volts 3 phase and below then the incident energy levels will be limited. This does not mean to say that flash burn injury cannot be totally discounted and severe burns can still be experienced particularly at the hands which will usually be closer to a possible arc when testing live circuits. Note 4 Work at height required? Working at height whilst carrying out live work is always subject to a Sanction for Work near Live Conductors Certificate. Note 5 Is the location a hazardous area? Live testing is not permitted in a hazardous zoned area and will be subject to a Sanction for Work near Live Conductors. Note 6 Instruments, leads & tools checked. OK? Only approved tools and instruments may be used but their condition must be checked especially test leads. Note 7 Is the Equipment Finger Safe? This is defined as no exposed live parts that can be accessed by solid objects greater than 12.5mm as defined by IP rating IP2X. You must check the integrity of finger safe equipment in case it has been removed or has been replaced incorrectly. If the equipment is not finger safe, can corrective actions been taken to shroud live parts to prevent inadvertent contact. Note 8 Access/space, lighting & environment ok? The work area should be clearly defined with barriers and with a good means of escape and illumination. A hostile or wet environment will significantly increase the risk and severity of electric shock and the area must be made safe from spillages and tripping hazards. Note 9 Dead Work Only. Note 10 Sanction for Work Near Live Conductors Required. Refer to the Electrical Duty Holder. Note 11 Take Corrective Actions. Note 12 Implement Safe Work. Implement safe working and make sure that any special equipment and PPE is properly used and maintained. Keep the duration of all LIVE work to a minimum and ensure that suitable accompaniment provided?
Sanction for work near live conductors
Contractors Induction Training on your rules JIB card http://www.jib.org.uk/ecs-card-scheme-faqs.aspx Authorisation
Duty holder 1. Appointed in writing 2. Training & authority 3. Control all Low Voltage operations, maintenance and new works 4. Ensure that employees and contractors are competent 5. Appoint Responsible Engineers for the authorisation of contractors as Competent Persons. 6. Approve specific tools, equipment & PPE. 7.Highlight any significant deficiencies in writing 8. Keep a master record of all Competent Persons.
Controls required 1. Training, competence & authorisation 2. Risk assessment 3. Electrical maintenance 4. Cleaning & shop floor controls 5. Right tools and equipment 6. Procedures & rules 7. Electrical isolation & lock off 8. Live testing procedures 9. Electrical contractor controls 10. Electrical duty holder
What do we need to focus on? 68% inadequate working practices 19% failure to maintain 13% miscellaneous
What you can do now! Inspect and classify panels according to their potential risk Make sure shrouding is in place if not implement programme to replace/upgrade WHEN THE PANEL IS DEAD Only allow electricians access to high risk panels Review competence of your employees undertaking electrical work qualifications, experience, self assessment (including multi-skilled) use templates to document Based on above assessments define type of electrical work each individual can undertake Ask about the competence of the electrical contractors you use Review the live work you undertake is there anything obviously unnecessary? Carry out dynamic risk assessments for engineering and electrical tasks Ensure all panels/substations locked Show isolation and lock off DVD to those undertaking electrical work NICEIC Make sure have correct type of lock off devices for your circumstances Use caution and danger notices
Conclusions Developing the rules helps give clarity Things which were once acceptable can be challenged as part of the process To implement properly requires an improvement plan It is a journey..
Other resources Electrical safety dvd Safety Media 99.00 http://www.safetymedia.co.uk/cgibin/sh000003.pl?refpage=http%3a%2f%2fwww%2esafetymedia%2eco%2euk%2facatalog%2fdv ds%2ehtml&wd=electrical%20safety&shop=%20&pn=safety_products_electrical_safety_dvd_ 167%2ehtml%23aESDVD1#aESDVD1 NICEIC Safe isolation procedures dvd 10.00 http://www.niceicdirect.com/epages/nicshop.sf/en_gb/?objectpath=/shops/nicshop/products/dv D6 Fluke electrical testing DVD Joint Industry Board electrical competency scheme (ecs) http://www.jib.org.uk/ecs1.htm Reece Safety, Manchester Isolation and lock out web site http://www.reecesafety.co.uk/fuse%20lockouts.htm