I&I NSW Technical Reference Electrical Engineering Management Plan

Transcription

1 Technical Reference Electrical Engineering Safety EES-001 I&I NSW Technical Reference Electrical Engineering Management Plan Coal Mine Health and Safety Act 2002 Coal Mine Health and Safety Regulation 2006 Occupational Health and Safety Act 2000 Occupational Health and Safety Regulation 2001 July 2009 (version 2) Page 1 of 74

2 Disclaimer The compilation of information contained in this document relies upon material and data derived from a number of third party sources and is intended as a guide only in devising risk and safety management systems for the working of mines and is not designed to replace or be used instead of an appropriately designed safety management plan for each individual mine. Users should rely on their own advice, skills and Experience in applying risk and safety management systems in individual workplaces. Use of this document does not relieve the user (or a person on whose behalf it is used) of any obligation or duty that might arise under any legislation (including the Occupational Health & Safety Act 2000, any other Act containing requirements relating to mine safety and any regulations and rules under those Acts) covering the activities to which this document has been or is to be applied. The information in this document is provided voluntarily and for information purposes only. The New South Wales Government does not guarantee that the information is complete, current or correct and accepts no responsibility for unsuitable or inaccurate material that may be encountered. Unless otherwise stated, the authorised version of all reports, guides, data and other information should be sourced from official printed versions of the agency directly. Neither Industry and Investment NSW, the New South Wales Government, nor any employee or agent of the Department, nor any author of or contributor to this document produced by the Department shall be responsible or liable for any loss, damage, personal injury or death howsoever caused. Users should always verify historical material by making and relying upon their own separate inquiries prior to making any important decisions or taking any action on the basis of this information. This publication contains information regarding occupational health, safety, injury management or workers compensation. It includes some of your obligations under the various workers compensation and occupational health and safety legislation that Industry and Investment NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate Legislation. This publication may refer to NSW Legislation that has been amended or repealed. When reading this publication you should always refer to the latest laws. Information on the latest laws can be checked at or contact (02) Page 2 of 74

3 PREFACE Electrical installations at mines are generally more complex than those found in most business and residential installations, also the mining industry is increasing consumption of electricity and its use of electrical technology with consequent increases in size (power rating) and complexity. With this comes a changing risk profile. To adequately manage the safety risks posed by electrical equipment and technology the hazards, risks and risk controls need to be thoroughly understood. This understanding must be at an engineering level hence mine Electrical Engineering Management Plan s are required to be designed, implemented and managed by a Manager of Electrical Engineering who is a qualified electrical engineer with relevant experience in the mining industry, the requirements as outlined below: For an underground mine it is expected the Manager of Electrical Engineering being a person who holds a certificate of competence to be a mine electrical engineer would be responsible for development, periodic review and day to day implementation of the Electrical Engineering Management Plan. For open cut and processing plant operations it is expected that a qualified electrical engineer being an electrical engineer with mining electrical engineering qualifications (Mine electrical engineers certificate of competence) or an electrical engineer with qualifications suitable for registration by the Institution of Engineers Australia will be responsible for the day to day implementation of the Electrical Engineering Management Plan. It is expected that these engineers would appear within the management structure required by the Coal Mine Health and Safety Act 2002 which requires the management structure to include competent people with appropriate electrical engineering competence and, specifically for underground mines, a competent person to perform the functions of the manager of electrical engineering.. It is expected that the management structure will clearly show that the Manager of electrical engineering (underground mine) or the qualified electrical engineer (open cut mine and/or processing plant) has a supervisory role over all persons involved in the selection and life cycle management of electrical powered plant and electrically controlled plant, including associated work practices. This managerial role should effectively supervise / oversee all decisions that can impact on electrical engineering safety at the operation, in particular those decisions made by other electrical engineers and electrical tradespeople doing work at or for the operation. This Technical Reference will be used by Mine Safety Operations to assess the effectiveness of coal operation Electrical Engineering Management Plans. This Technical Reference can also be used by coal operators as guidance to the content of an Electrical Engineering Management Plan. It also provides guidance on the electrical engineering content of the management structure for an operation. Use this Technical Reference to assess your Electrical Engineering Management Plan. John Francis Waudby Senior Inspector of Electrical Engineering Page 3 of 74

4 REVISIONS This is Version 2 of EES-001. This document has been revised as a result of changes to legislation applying to Coal Operations. In September 2008, the NSW Occupational Health and Safety Regulation 2001 were amended so that the whole of the regulation (with specific non-electrical matters exempted) applied to coal operations. Also the contents of EES-002 Control and Supervision of Electrical Work have been included. Editorial changes have also been made with the relevant legislation referenced (generally) at the beginning of each subsection and denoted by ACT or in the left hand margin. Information that can assist in interpretation and enhanced detail has been included at the end of each sub-section and is denoted by INFO in the left hand margin. Also provided as information are references to International Labour Office, Geneva, Draft code of practice on safety and health in underground coalmines, doc ref MESHCM/2006 this is indicated by ILO in the left hand margin, this applies to underground mines only. Refer to Appendix A for details of the changes. Page 4 of 74

5 CONTENTS PREFACE 3 REVISIONS 4 CONTENTS 5 Chapter 1 Establishment Title Purpose Scope Authority Definitions Applicable legislation Referenced Gazette Notices Referenced Standards and Guidelines Acronyms Other referenced legislation Who is affected by this Technical Reference? Electrical Installations Automotive Electrical Installations...13 Chapter 2 Health and Safety Management Systems and the Electrical Engineering Management Plan (EEMP) Introduction Occupational Health and Safety Management System...15 Chapter 3 Electrical Engineering Management Plan Objectives Management Structure Scope of an Electrical Engineering Management Plan Plant Safety Electrical Work and Practices Standards of Engineering Practice (SEP s) Compliance with AS/NZS 3000 and AS Electrical Plant used in Hazardous Zones Static Electricity Electrical Protection Earthing Switching Electrical Power Use of Portable Apparatus Specific Procedures Overhead Power Lines & Cables & underground (buried) cables Signage and Plans...46 Chapter 4 Electrical Engineering Management Plan, other management plans and regulatory requirements Relationship to other plans and requirements Electrical Engineering Management Plan and other management plans Electrical Engineering Management Plan and other coal mines regulations requirements Electrical Engineering Management Plan and OH&S regulations requirements Duties relating to contractors...55 Chapter 5 Maintenance of electrical installations & equipment...57 Chapter 6 Technical matters to consider for SEP s Control Circuits Electrical cord extension sets...60 Page 5 of 74

6 6.3 Safe access to electrical equipment Underground Installations...60 FEEDBACK SHEET...72 Chapter 7 I&I NSW Contact Details...74 Page 6 of 74

7 Chapter 1 Establishment 1.1 Title This is the DPI Electrical Engineering Safety Technical Reference Electrical Engineering Management Plan. 1.2 Purpose This Technical Reference is intended to provide a framework for DPI officers to assess coal operation Electrical Engineering Management Plans. It can also be used by coal operators as guidance material for implementing, managing or reviewing their Electrical Engineering Management Plan. This Technical Reference identifies issues required to be addressed to achieve safety measures equivalent or better than those expressed in electricity safety legislation. Some of the aspects included in this document may not be specifically nominated in the current climate of non-prescriptive legislation but are relevant and worthy of acceptance in an effort to protect people and property from harmful effects of electricity. This Technical Reference describes acceptable arrangements that can be tailored to suit the particular needs of an operation. It identifies some of the core hazards, risks and control measures relevant to electrical circuitry. It is intended to protect the safety of workers, others in the workplace and property. The outcomes sought to be achieved by this Technical Reference are to protect people and property from the hazards occurring during electrical equipment failures and include: Electrocution. Electric shock. Electrical burn injuries. Arc blast injuries. Injuries sustained through operation of the apparatus. Unintended operation of the apparatus. Ignitions of flammable mixtures of gas or dust. Fire 1.3 Scope This Technical Reference extends to all coal operations in New South Wales. The areas within a coal operation include general surface, treatment plants, underground outbye and underground hazardous zones. The Technical Reference deals with high voltage, low voltage, and extra low voltage equipment, it applies to mains supplied plant, privately owned generating plants, installations supplied by privately owned generating plant, self contained electrical apparatus and electric welding equipment (including the welding work circuit). This Technical Reference is supplemented by the following Technical References: Page 7 of 74

8 EES-003 NSW DPI Technical Reference - Practices for the Life-Cycle of Management of Explosion Protected Equipment EES-004 NSW DPI Technical Reference Practices for Portable Electrical Apparatus EES-005 NSW DPI Technical Reference - Electrical Protection and Earthing EES-006 NSW DPI Technical Reference - Removal and Restoration of Power 1.4 Authority This is an Electrical Engineering Safety Technical Reference and is recommended by Industry and Investment NSW. 1.5 Definitions Coal operation is defined in the Coal Mine Health and Safety Act 2002 and broadly includes underground mines, open cut mines, coal preparation plants and in some cases coal loading facilities. A document that specifies the boundaries of a coal operation should be referenced in the Electrical Engineering Management Plan. Competent person for any task means a person who has acquired through training, qualification, experience, or a combination of them, the knowledge and skills to carry out the task. Hostile operating environment means an operating environment at a place of work where an electrical article is in its normal use subjected to operating conditions that are likely to result in damage to the article and for example includes an operating environment that may: Cause mechanical damage to the article. Expose the article to moisture, heat, vibration, corrosive substances or dust that is likely to result in damage to the article. Employee means an individual who works under a contract of employment or apprenticeship. Employer means a person who employs persons under contracts of employment or apprenticeship. Note: in some chapters of the Regulation the term employer includes a selfemployed person in relation to duties to other persons. Manager of Electrical Engineering means a person listed in the management structure of an underground coal operation who is responsible for development, periodic review of, and review of the day to day effectiveness of the implementation of the Electrical Engineering Management Plan. Plant includes any machinery, equipment or appliance. Qualified Supervisor means an electrical tradesperson holding a Qualified Supervisor Certificate Electrical Work, issued by the Office of Fair Trading, that licenses the holder to supervise or carry out electrical wiring work without supervision. Residual current device (RCD) means a device to isolate supply to protected circuits, socket outlets or electrical equipment in the event of a current flow to earth which exceeds a predetermined value. The device should comply with AS/NZS3190 Voltage: Extra-low voltage Not exceeding 50 V a.c. or 120 V ripple free d.c. Page 8 of 74

9 Low voltage Exceeding extra-low voltage, but not exceeding 1000 V a.c. or 1500 V d.c. High voltage Exceeding low voltage. Information Note - For underground mining applications, voltages of 1000 V a.c. and 1100 V a.c. have been commonly used in a similar manner to voltages of 415 V a.c. and 550 V a.c. (low voltage). Previous legislation required that voltages exceeding 1200 V a.c. not be applied to certain types of apparatus (explosion protected, mobile, portable, or motors smaller than 15Kilowatts). From this there is a common and accepted practice of considering high voltage to be greater than 1200 V a.c. in underground mining applications and associated surface applications. Where a coal operation chooses to not use accepted (mining and non-mining industry) high voltage practices on circuits whose nominal voltage exceeds 1000 V and is less than 1200V, this must be supported by a risk assessment and nominated controls, including specific procedures to prevent electric shock, arcing and failure of explosion protection. Underground coal operations use mining machinery powered at 3.3 kv. High voltage practices and procedures must be used on these circuits, it is not acceptable to plug and unplug restrained plugs at 3.3kV, without effecting proper isolation. Proper isolation does not rely on a contactor as the sole power conductor opening device. For high voltage distribution systems a permit to work system must be used and records kept. 1.6 Applicable legislation The Occupational Health and Safety Act 2000 The Occupational Health and Safety Regulation 2001 The Coal Mine Health and Safety Act 2002 The Coal Mine Health and Safety Regulation Referenced Gazette Notices Gazette Notice for Retention of Notifications Gazette Notice for Specification of Plant that can be used in a Hazardous Zone Gazette Notice for the conditions of use of non-explosion protected plant in a hazardous zone Gazette Notice for considering certain workshops to be licensed Gazette Notice for the specification of requirements to be licensed as a cable repair workshop 1.8 Referenced Standards and Guidelines AS/NZS 1020 The control of undesirable static electricity AS Safety in welding and allied processes - Electrical AS/NZS 1802 Electric cables - Reeling and trailing - For underground coal mining purposes Page 9 of 74

10 AS/NZS 1972 Electric cables - Underground coal mines - Other than reeling and trailing cables AS/NZS : Electrical equipment for coal mines - Introduction and maintenance - For hazardous areas AS/NZS 2381 Series - Electrical equipment for explosive gas atmospheres - Selection, installation and maintenance AS/NZS 3000: Electrical installations (known as the Australian/New Zealand Wiring Rules) AS 3007 Series - Electrical installations - Surface mines and associated processing plant AS/NZS3019 Electrical installations - Periodic verification AS/NZS 3190: Approval and test specification - Residual current devices (current-operated earth-leakage devices) AS Series - Safety of machinery AS/NZS 4240 Remote controls for mining equipment AS 4242 Earth-moving machinery and ancillary equipment for use in mines - Electrical wiring systems at extra-low voltage AS/NZS 4761 Series - Competencies for working with electrical equipment for hazardous areas (EEHA) - Competency Standards AS/NZS 4801 Occupational health and safety management systems - Specification with guidance for use AS/NZS 4871 Series - Electrical equipment for coal mines, for use underground - General requirements AS Safety of machinery - Electrical equipment of machines AS Series - Functional safety of electrical/electronic/programmable electronic safety- related systems AS Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems Australian Standards Handbook, HB187 Guide to selecting a safe multimeter Australian Standards Handbook, HB , Handbook: High voltage mining equipment for use underground NSW Minerals Industry Safety Handbook EES-003 NSW DPI Technical Reference - Practices for the Life-Cycle of Management of Explosion Protected Equipment EES-004 NSW DPI Technical Reference - Practices for Portable Electrical Apparatus EES-005 NSW DPI Technical Reference - Electrical Protection and Earthing EES-006 NSW DPI Technical Reference - Removal and Restoration of Power MDG 15 Technical References for Mobile and Transportable Equipment for Use in Mines MDG 25 Guideline for Safe Cutting and Welding Operations at Mines MDG 40 Guideline for Hazardous Energy Control (Isolation or Treatment) Page 10 of 74

11 MDG 5002 Guideline for the use of remote controlled mining equipment Underground metalliferous mines. ILO MESHCM/2006 Draft code of practice on safety and health in underground coalmines WTIA TN 7-98 Health and Safety in Welding Workcover Code of Practice for Overhead Power Lines. 1.9 Acronyms AS Australian Standard AS/NZS Australian New Zealand Standard CMHS Coal Mine Health and Safety CMHSA Coal Mine Health and Safety Act 2002 CMHSR Coal Mine Health and Safety Regulation 2006 ECSA Electrical (Consumer Safety) Act 2004 EEMP Electrical Engineering Management Plan ELV Extra Low Voltage EPL Explosion protection level (refer AS/NZS ) Ex Explosion protected IEC International Electrotechnical Commission ILO International Labour Office MEMMES Mining Electrical & Mining Mechanical Engineers Society (Engineers Australia) NECA National Electrical and Communications Association of Australia OH&S Occupational Health and Safety OHSR Occupational Health and Safety Regulation 2001 (as amended) SEP Standard of Engineering Practice SIL Safety Integrity Level WTIA Welding Technology Institute of Australia 1.10 Other referenced legislation The Electricity (Consumer Safety) Act 2004 The Home Building Act ELECTRICITY SAFETY LEGISLATION The industries that provide electricity, construct and maintain the equipment that conveys electricity and supply electrical articles are highly regulated in Australia and around the world because of the potential for electricity to injure and kill people and to destroy property. The legislation that regulates electricity safety in NSW, the Electricity (Consumer Safety) Act 2004, is administered by the Minister for Fair Trading. Page 11 of 74

12 The Electricity (Consumer Safety) Act 2004 meets its consumer protection objectives by requiring, encouraging and promoting the supply of safe electrical articles (consumer appliances) and safe practices for electrical wiring work. It aims to do this in all situations whether at home or in commercial, industrial or agricultural environments. Electrical installations at mines are excluded from the application of the Electricity (Consumer Safety) Act The approach taken by mining industry regulators is based on a requirement for Mine Safety Management Plans to incorporate an Electrical Engineering Management Plan (EEMP) that provide for an equivalent or better safety outcome. The EEMP should specify risk controls that meet the objectives and targets for electrical engineering safety set by Industry and Investment NSW and meet the expectations of legislation and are consistent with non-mining workplaces and guidance material provided by Industry and Investment NSW Who is affected by this Technical Reference? All operators of coal operations in New South Wales where there is an electrical installation that is connected to the network of an electricity supply authority or where there is an electrical installation with the source of electricity is a stand-alone power system such as photovoltaic cells (solar panels), wind or water turbines, diesel or petrol generators. All individuals, unincorporated businesses and corporations involved in utilizing electricity at NSW coal operations including those who design, install and implement electrical safety systems and those who commission, test, operate and maintain the systems Electrical Installations OHSR, Clause, 33(1) Definition electrical installation For the purposes of this technical reference, the following definition of an electrical installation is designed to remain consistent with the Electricity (Consumer Safety) Act 2004 and includes coal mines. For the purposes of this Technical Reference an electrical installation 1 is the fixed electrical wiring and associated equipment in a place that conveys, controls or uses electricity, at low voltage or above, from a source of electricity to the points where the wiring terminates. It also includes the electrical wiring and associated equipment utilizing trailing cables, reeling cables and flexible feeder cables. All intrinsically safe equipment and circuits normally supplied via the mains is considered to be part of an electrical installation. Electrical installations can be indoors, outside, above or below ground. The source of electricity may be either the transmission or distribution lines of a distribution network service provider or a stand-alone power system (which falls within the ambit of AS 4509) which is owned or operated by the user of an installation. An electrical installation commences at the end of the network operator s electricity distribution line. In the case of an electrical installation connected to the grid this will be the point of supply as determined by the local electricity supply authority 2. When an electrical installation has a stand-alone power system as its sole source of electricity the electrical installation commences at the system output terminals. This 1 The term electrical installation is defined in the Electricity (Consumer Safety) Act For more information refer to the network operators Standard Form of Customer Connection Contract Page 12 of 74

13 Technical Reference also applies to the generating equipment, even though it is not part of the defiined electrical installation. Termination points of an electrical installation include power points (electrical socket outlets) into which electrical articles can be plugged, and the termination of electrical wiring to which electrical articles can be fixed, whether permanently or temporarily Automotive Electrical Installations Automotive wiring systems and equipment on vehicles and other mining machinery is not considered as an electrical installation, however it is expected that the life-cycle management of such wiring and systems is addressed in the coal operation EEMP and that persons working on such wiring systems and equipment are deemed competent to do so. Page 13 of 74

14 Chapter 2 Health and Safety Management Systems and the Electrical Engineering Management Plan (EEMP) 2.1 Introduction ACT CMHS Act, Section 23(3) (e) Contents of health and safety management system. CMHSR, Clause 13(1) (e) Additional components of health and safety management system OHSR, Clause 41(1) (a) Electricity particular risk control measures OHSR, Clause 41(1) (2) Electricity particular risk control measures OHSR, Clause 64(1) Electricity particular risk control measures Electrical Engineering decisions are critical to attaining safe production at mine sites. To achieve safety these decisions must be of the highest quality. A model for making these quality decisions is the Minerals Industry Risk Management Model (MIRM Model). MIRM has two main elements: these are the management system and the work process factors. The management system incorporates the management and electrical engineering framework for the design and operation of the site. The electrical engineering framework is the legislative requirement for an EEMP. As such it supplies the inputs to the daily work processes to achieve safe production within a controlled work environment by competent people, fit for purpose equipment and safe work practices. This is expressed in the diagram below (refer: Engineering & Management Framework The quality of the decision depends on the quality of the engineering and management process that designs, purchases, installs, commissions, operates, maintains (including repair and overhaul), modifies, trains, standardizes and otherwise defines the nature of the day-today work process. To do this the management system has to be defined and formally documented so that the quality of key decisions is not left to chance. (Refer to Page 14 of 74

15 Australian/New Zealand Standard AS/NZS 4801:2001 Occupational health and safety management systems specification with guidance for use) All of the above must be present and effective at every stage of the equipment and mines life cycle and must be effectively supported by the organisational culture. If any element is deficient or there is ineffective support from the organisational culture safe production is left to chance. The EEMP is an element of the Health and Safety Management System and must be developed, implemented and periodically reviewed through consultation with a qualified electrical engineer, and for underground mines the Manager of electrical Engineering. The key point is that the EEMP should clearly establish links to the Health and Safety Management System, other mandatory management plans and business management systems and vice-versa. 2.2 Occupational Health and Safety Management System The Occupational Health and Safety Management System must be consistent with AS AS 4801 POLICY Health and Safety Management System Leadership and Commitment The Health and Safety Management System should clearly establish leadership and commitment to Electrical Engineering Safety through the EEMP AS 4801 PLANNING Health and Safety Management System Planning Identification of Hazards, Risk Assessment and Control of Risks OHSR, Clause 9 Employer to identify hazards OHSR, Clause 10 Employer to assess risks CMHSR, Clause 13(e) (v) Additional components of health and safety management system electrical engineering management plan electrical safeguards for electrical and nonelectrical hazards These requirements should be specifically addressed for Electrical Engineering Safety matters. The OHSR requires hazards relating to a number of elements for Electrical Engineering Safety to be identified, and the risks from those hazards assessed. The legislation also specifies certain electrical engineering safety risk controls to be implemented and in certain circumstances the use of a functional safety approach. Also refer to section ILO MESHCM/2006 Section 5.1 Hazards and health, p16-17 ILO MESHCM/2006 Section 18.1 Electricity, Hazards description, p Health and Safety Management System Legal and other Requirements These requirements should be specifically addressed for Electrical Engineering Safety matters. Non-Electrical Engineering Safety matters should encompass people doing electrical work, for example hazardous substances. This may require specific elements to be integrated in the EEMP or require specific electrical input via the Health and Safety Page 15 of 74

16 Management System e.g. hazardous substances such as asbestos or PCB s may only be encountered when doing electrical work, as such the most appropriate place to address this aspect is within the EEMP Health and Safety Management System Objectives and targets Electrical Engineering Safety objectives are specified in the legislation. These objectives must be addressed in the EEMP and referenced in the Health and Safety Management System. Specific targets should be nominated for each of the objectives Health and Safety Management System Management Plans CMHSR, Clause 13(1) (e) Additional components of health and safety management system An EEMP must be developed, implemented and maintained. The EEMP is a plan within the Health and Safety Management System and must be developed, implemented and periodically reviewed in consultation with a qualified electrical engineer. For an underground mine it is expected that the Manager of Electrical Engineering would be responsible for development, periodic review and day to day implementation of the EEMP. For open cut and processing plant operations it is expected that an electrical engineer with a coal mine electrical engineer certificate of competence or qualifications suitable for registration by the Institution of Engineers Australia would be responsible for development, periodic review and day to day implementation. The duties of the person appointed to the specified function of a qualified electrical engineer should make provision for overall supervision of standards for the installation, commissioning, maintenance and repair of electrical plant and installations and overall supervision of all electrical engineers and/or qualified tradespersons at the mine to ensure safety of the electrical installation and plant AS 4801 IMPLEMENTATION Health and Safety Management System Structure and Responsibility - Resources These requirements should be specifically addressed for Electrical Engineering Safety matters within the Health and Safety Management System and they must be sufficient to give effect to the EEMP. Each operation should have a documented management structure detailing positions, incumbents, responsibility and accountability for all of the elements of the EEMP. Purchasing and hiring of electrical equipment is a particularly important issue. The Health and Safety Management System must make provision for electrical equipment only being acquired after consultation with the qualified electrical engineer. Purchasing and hiring of equipment with electrical components is generally done by nonelectrical people. The Health and Safety Management System through the EEMP must consider electrical engineering aspects at the specification phase and be part of the EEMP. Where equipment is acquired that has electrical components for power, control or provision of safeguards then processes requiring review and acceptance (sign off) by a qualified electrical engineer must be used. ILO MESHCM/2006 Section (a) Electricity Hazard control General provisions appointment and resourcing for electrical work, p121 Page 16 of 74

17 ACT Health and Safety Management System Structure and Responsibility - Responsibility and Accountability CMHS Act, Section 37(4) & (5) Operator must prepare management structure CMHSR, Clause 44 Contents of management structure For an underground mine, the Manager of Electrical Engineering is responsible for the development, periodic review of, and review of the day to day effectiveness of the implementation of, the EEMP. For open cut and processing plant operations, an electrical engineer with a coal mine electrical engineer s Certificate of Competence, or registered on the National Professional Engineers Register (administered by Engineers Australia) would be responsible for the development, periodic review of, and review of the day to day effectiveness of the implementation of, the EEMP. These persons should be the nominated management representative with defined roles, responsibility and authority for ensuring the EEMP is established, implemented and maintained and shall have responsibility for reporting on performance. The EEMP should identify the types of electrical work at the coal operation for which an electrical worker must be authorised and appointed. In each case the EEMP should specify the minimum qualification, skills and experience that would be required to enable a person to do the work safely. AS 3007 refers to ordinary persons, instructed persons and skilled persons and requires that these persons can only have access to electrical installations that are appropriate for their level of knowledge and experience appointments and authorizations should reflect this. The CMHSR clause relating to Appointment of People does not specifically require the assessing and recording of the competence of electrical persons however it would be prudent to implement these requirements for electrical persons Health and Safety Management System Structure and Responsibility - Training and competency OHSR, Clause 41(1)(c) Electricity particular risk control measures CMHSR, Clause 19(1)(a) Electrical engineering management plan The EEMP shall identify the training needs for Electrical Engineering Safety matters to be addressed within the Health and Safety Management System. The regulation is quite specific about requirements for electrical work. The EEMP must make provision for the installation, commissioning, maintenance and repair of electrical plant and installations being undertaken only by a qualified electrical engineer or qualified tradesperson or people under the supervision of a qualified electrical engineer or qualified tradesperson. Further, the OHS Regulation is specific about requirements for training of persons entering an area in which electrical installations are located. The EEMP should include measures for establishing competencies for electrical work. Competencies are regarded as qualifications, skills and experience. Levels of supervision may vary according to the complexity of the task, the level of risk associated with a task and the levels of competency (qualification, skill or experience) of the person doing the work. The EEMP should include measures to ensure that apprentices and trainees are supervised and only perform activities assigned to their current competence level. The EEMP encompasses ALL electrical equipment installed and used at a coal operation that is under the control of Page 17 of 74

18 the coal operator. The EEMP should specify types of work where specific training and instruction is required, for example High Voltage work. For underground mines this would incorporate the National Competency Standards for working on hazardous area equipment (Refer to AS/NZS 4761) ILO MESHCM/2009 Section (e), p120 specify training, qualification and experience of electrical workers Health and Safety Management System Consultation, Communication and Reporting The Health and Safety Management System shall provide for Electrical Engineering Safety matters to be addressed. This may be via EEMP specific requirements. It is expected that significant consultation will be required as part of the EEMP in particular in relation to electrical work and where actions by non-electrical people such as mining engineers, mechanical engineers and purchasing officers can influence the acquisition of fit for purpose equipment electrical engineering aspects of equipment acquisition must be considered at the specification phase and be part of the EEMP. Consultation must occur when: Changes that may affect health, safety or welfare are proposed to the: - Work premises - Systems or methods of work - Plant or substances used for work Assessing the risks to health and safety arising from work Decisions are made about the measures to be taken to eliminate or control those risks Introducing or altering the procedures for monitoring risks Decisions are made about the adequacy of facilities for employee welfare Decisions are made about the procedures for consultation Note 1: For more details about the obligations to consult refer to the Workcover Guideline: Occupational Health and Safety Consultation. Note 2: Electrical Engineering Safety must be a specified element within the above points Health and Safety Management System Documentation The EEMP shall provide specific Electrical Engineering Safety content. The regulation has specific requirements that must be addressed Health and Safety Management System Document and Data Control OHSR, Clause 41(5) Electricity particular risk control measures It is expected that all documents and data requirements within the EEMP will utilise the Health and Safety Management System documentation and data control system. It is important to ensure that changes to any electrical circuit are documented and managed under the management system s document control arrangements. If this is not done there is often an increase in risk to persons fault finding on electrical equipment and installations, all energy sources may not be identified and experience has shown that circuits can remain energised and be a source of electric shock to unsuspecting mine workers. With the use of software based control of machinery, comes the need to control the software versions and any changes to code. Software management for safety related applications Page 18 of 74

19 should be managed within the document control system or as a specific program within the Electrical Engineering Management Plan Health and Safety Management System Hazard Identification, Risk Assessment and Control of Risks OHSR, Clause 9 Employer to identify hazards OHSR, Clause 10 Employer to assess risks CMHSR, Clause 13(e) (v) Additional components of health and safety management system electrical engineering management plan electrical safeguards for electrical and non-electrical hazards The EEMP shall provide specific Electrical Engineering Safety content. In addition to this general requirement for hazard identification and risk assessment, electrical safeguards for electrical and non-electrical hazards need to be subject to the functional safety method of establishing appropriate safety integrity levels (SIL) or equivalent (categories as used in AS4024). These functional safety requirements for electrical safeguards should be specifically addressed either in the Health and Safety Management System or the EEMP. The method of establishing appropriate SIL s or Categories for electrical safeguards should be specifically addressed either in the Health and Safety Management System or the EEMP. The EEMP should include provisions to ensure purchasing arrangements require the design of safety related parts and functions for plant to conform to a Safety Requirements Specification, which includes SIL or Category classification Health and Safety Management System Emergency Preparedness and Response The EEMP shall provide specific Electrical Engineering Safety content and shall cover the treatment of electric shock victims, the treatment of electrical burns, responses as a result of an electrical fire and electrical related responses to other emergency situations e.g. mine winders, explosions, machinery accidents etc. Liaison with electricity network providers will be an important element. The legislation is quite specific in the particular Electrical Engineering Safety matters that have to be addressed in the event of an emergency or similar situation AS 4801 MEASUREMENT AND EVALUATION Health and Safety Management System General The EEMP shall address calibrating, maintaining and storing of equipment used to monitor or measure effectiveness of risk controls related to Electrical Engineering Safety. Procedures developed for monitoring of performance, effectiveness and conformance to requirements of the EEMP shall be part of the Health and Safety Management System or referenced in the Health and Safety Management System as part of the EEMP Health and Safety Management System Incident Investigation, Corrective and Preventative Action OHSR, Clause 64(a4) Electricity particular risk control measures - Electrical installations and articles found to be unsafe Page 19 of 74

20 The EEMP shall provide specific Electrical Engineering Safety input to the Health and Safety Management System. In addition the OHSR requires specific actions for unsafe electrical equipment Records and records management OHSR, Clause 65 Maintenance of records - electricity CMHSR, Clause 19(1) (r) (ii) Electrical engineering management plan The EEMP shall provide specific Electrical Engineering Safety input to the Health and Safety Management System. The legislation specifies particular records to be kept with regard to electrical installations. This process is similar to the requirements for the non-mining industry. The process has to comply with section 6 of AS/NZS 3000: 2000 Electrical Installation. N.B. Operations should be considering reference to AS/NZS 3000:2007 instead of AS/NZS 3000:2000 if the requirements of the AS/NZS 3000:2007 provide for a higher level of safety Records are to be kept for the life of the installation. An EEMP should specify the form to be used for reporting safety and compliance tests. INFO Gazette Notice for Retention of Notifications INFO There are no specified notification forms gazetted at this time Health and Safety Management System Audit The EEMP shall be part of the audit program AS 4801 MANAGEMENT REVIEW The EEMP shall be part of the management review program. Development, implementation and periodic review shall be done through consultation with the qualified electrical engineer. Page 20 of 74

21 Chapter 3 Electrical Engineering Management Plan 3.1 Objectives CMHSR, Clause 13(e) Additional components of health and safety management system electrical engineering management plan A document that specifies the boundaries of a coal operation should be referenced in the EEMP. The purpose of the EEMP is to give effect to the Health and Safety Management System with regard to the following objectives: To prevent injury to people from sources of electrical energy. To prevent uncontrolled fires where electrical energy is the ignition source. To prevent initiation of gas or coal dust explosions by electrical energy. To prevent unintended operation of plant. To provide electrical safeguards for electrical and non-electrical hazards with an appropriate safety integrity level. (Note: The legislation does not use the term safety integrity level) To generally provide the means by which the safety of electrical plant is managed including requirements of the Act and this Regulation and relevant plant safety requirements under the Occupational Health and Safety Regulation With regard to electrical safeguards, the OHSR has particular requirements. OHSR, Clause 92(1) & (2) Emergency stops and warning devices particular risk control measures Emergency stop devices are required to be designed so that they are not affected by electrical or electronic circuit malfunction. A systematic functional safety approach that identifies the amount of risk control required to be delivered by the emergency stop and assignment of appropriate SIL (or Category as per AS4024.1) to deliver that risk control, may bring the risk of malfunction to a level that is ALARP. The EEMP must also encompass the life cycle of electrical plant and installations and electrical engineering practices at the coal operation. It is expected the EEMP would be fully integrated with the Health and Safety Management System and utilise the processes and procedures within that system. It is also expected that the EEMP will provide inputs to or provide for elements of other management plan requirements and non-clause 19 matters. Some systems will already be implemented at mines such as maintenance management systems. The EEMP should provide input into the maintenance management system and utilise the system elements such as work orders, defect reporting and management. How this is achieved is mine specific and is likely to vary from site to site. The key point is that the EEMP should clearly establish links to the Health and Safety Management System, other mandatory management plans and business management systems and vice-versa. 3.2 Management Structure CMHSR, Clause 44 Contents of management structure Page 21 of 74

22 The Coal Mine Health and Safety Regulation 2006 require competent electrical engineers to be nominated in the management structure. The management structure for a coal operation must relate to the EEMP and identify competent engineers to give effect to the EEMP. Where the coal operation has underground hazardous areas, the EEMP should assign specific competency requirements for persons involved in supervision, installation, use and maintenance of electrical explosion protected equipment. Each operation should have a documented management structure detailing positions,, responsibility and accountability for all of the elements of the EEMP. The name of a person filling a position in the management structure must be contained in a register kept at the mine. For an underground mine it is expected the Manager of Electrical Engineering would be responsible for development, periodic review and day to day implementation of the EEMP. For open cut and processing plant operations it is expected that an electrical engineer with qualifications suitable for registration by the Institution of Engineers Australia, or an electrical engineer that has a NSW Mines Electrical Engineers Certificate of Competence, would be responsible for day to day implementation. INFO Guidance Note GN-002 NSW DPI Guidance Note on Management Structure 3.3 Scope of an Electrical Engineering Management Plan This includes both regulatory (mandatory) requirements and other matters that should be included. The mandatory requirements are specified in the regulations, primarily under clauses 13 and 19, however other mandatory requirements are found in other more general clauses and in the Occupational health and Safety Regulation The requirements are grouped into categories that do not necessarily follow the numbering of the clauses and subclauses. The Occupational Health and Safety Regulation have specific electrical requirements in: Part 4.2 Work premises, Division 3 Electricity, clauses 40 and 41 Part 4.3 Use of places of work, Division 8 Electricity, clauses 63, 64 and 65 Part 7.7 Electrical work, clauses 205, 206, 207 and 208 The definition of an electrical installation is the same as in the Electricity (Consumer Safety) Act. With the addition that it includes electrical equipment at a coal operation. A particularly important part of the OH&S Regulation is Chapter 5, Plant Safety. All electrical equipment is covered by these requirements. For this reason EEMP requirements outlined below start with Plant Safety. Particular electrical details of the plant safety requirements are included in each of the requirements. ILO MESHCM/2006 Section (c) A list of coal face equipment to be kept, including that not in use. 3.4 Plant Safety OHSR, Chapter 5 Plant safety Chapter 5 of the OH&S Regulation has extensive requirements for plant safety. This applies to ALL plant (equipment, apparatus, tools, machinery etc). It requires a life-cycle approach to Page 22 of 74

23 ILO the safety of plant. Responsibilities of persons dealing with any aspect of plant are prescribed. Information flow for life-cycle management of the safety is important. Certain plant must be registered. All electrical powered equipment and electrically controlled equipment is covered by these requirements and they need to be integrated within the EEMP. The EEMP will need to have arrangements whereby checks are made to establish that designers, suppliers, manufacturers, trade agents and hirers of plant have fulfilled their obligations. Also, the coal operator needs to be sure that their obligations have been fulfilled, such as a coal operator who contracts out the design of plant must ensure that the person who is engaged to design the plant is provided with all relevant information about matters relating to the plant that may affect health and safety. All people and organisations in the supply chain have responsibilities. An end user should be able to establish that any foreseeable hazards that may arise during the life-cycle have been identified, risks assessed, risks eliminated or controlled, information has been provided and plant is not used in conditions likely to give rise to electrical hazards. This extends to ALL types of plant. For example a designer of an electrical control system for a processing plant is required to comply with these requirements in relation to the control system and the equipment being controlled as far as it can be affected by the control system. MESHCM/2006 Section 19.3 Machinery and plant (equipment) Underground face equipment, and continuous mining and coal-cutting machines Explosion protection, installation of methane monitors, light and remote control, p INFORMATION RELATING TO PLANT SAFETY The information must be able to establish full compliance with legislation. As such Chapter 5 of the OH&S Regulation must be extensively referenced in plant specifications, SEP s and checklists used within the auspices of the EEMP. The information must encompass: All available information concerning health and safety about the plant provided by the manufacturer. The purpose for which the plant is designed. Testing or inspections to be carried out on the plan. Installation, commissioning, operation, maintenance, inspection, cleaning, transport, storage and, if the plant is capable of being dismantled, dismantling of the plant. Systems of work necessary for the safe use of the plant. Knowledge, training or skill necessary for persons undertaking inspection and testing of the plant. Emergency procedures. Any document relating to the testing and inspection of the plant. Each operation should have certain equipment dossiers or safety files including: HV Installation Dossier. Hazardous Area Equipment Dossiers. Underground Mobile Apparatus Dossiers. Mine Winding System Dossiers (Safety File). Radio Controlled Equipment Dossier (This to include operating frequencies, control of surface operations, testing of transmitters). Safety File for any apparatus identified as requiring a SIL. Page 23 of 74