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EMIRATES ALUMINIUM
SMELTER COMPLEX
VENDOR OR SUBVENDORS NAME REVISION DATE VENDORS APPROVAL NAME
Purchase Order No. & Title TK 4842 - Phase 1 Extension 220kV GIS
VDR Codes
This review does not relieve the vendor of his 5 AS BUILT CERTIFIED
responsibility for errors in design and detailing as
detailed in his contract. 6 CANCELLED
3.5 Work with hazardous substances. Exposure that could result in acute or Injuries of human body parts Complete and document hazard communications 4 2 8 Avoid skin contact and inhalation local ABB SM 1 4
chronic effects. training for employees. potential.
Follow operation instruction.
Ensure relevant PPE is used.
3.6 Use of tools Crush, knock, strike, shear, etc. Injuries, damage to equipment an/or parts. Use proper tools that have been inspected Only 5 2 10 All tools must be inspected on a Supervisor, 1 5
qualified and trained employees are allowed to work. quarterly basis and prior to use Commissioning,
by the employee. local ABB, local
Personnel
4.3 Is there a description of the circuit Unknown aspects of circuits can lead Electrocution, death, severe electrical burn. Single line must be available for review and use, 5 3 15 Continuous interface with site local ABB SM 1 5
or equipment at the job location? to electrocution Damage to equipment and injury of worker updates required must be reviewed and approved. management and client.
4.4 Is there a detailed job description Encountering energized equipment Electrocution, death, severe electrical burn. All work planned for the day must be reviewed and 4 3 12 Ensure that site management local ABB SM 1 4
of planned work? thought to be dead. Damage to equipment and injury of worker risks assessed, detailed job plan must be updated and installation crew interface
daily. daily.
4.5 Can you justify why equipment Electrocution, death Violation of ABB Electrocution, death, severe electrical burn. Work on energized circuits must be prevented and 5 4 20 Only those employees qualified Supervisor, 1 5
cannot be de-energized or the job policy Damage to equipment and injury of worker when necessary a comprehensive review of the scope to work on energized circuits will Commissioning,
deferred until the next scheduled of the job and safety precautions must be employeed. do so and a job hazard local ABB
outage? Use ABB 7-Steps. assessment will be completed
for each task.
4.6 Were required electrical safety Failure to recognize or understand Electrocution, death, severe electrical burn. An assessment of electrical hazards relative to 3 3 9 A job hazard assessment is 1 3
analyses performed? risks. Damage to equipment and injury of worker ongoing work and adjacent work must be included in required for each task and must
the job hazard assessment. be signed by each employee.
4.7 Were proper tools and equipment Untested tools used conducting Electrocution, death, severe electrical burn. Only tools with a current certificate of testing will be 4 2 8 Only use tools that are Supervisor, 1 4
used? current. Damage to equipment and injury of worker used for high voltage work. appropriate for the task and Commissioning,
have a current certificate of local ABB
testing.
4.8 Staging and installing equipment Crush, knock, strike, shear, etc. Injuries, damage of equipment and machine No transport and lift above persons. 5 2 10 Inform personal about working Supervisor, local 1 5
parts. Crane be qualified and a lift plan current. activity. Follow operation Personnel
All llifting equipment must have a current annual instruction.
inspection and inspected daily. Defect lifting equipment to be
Equipment to be secured against turn over. marked and secured against
Ensure relevant PPE is used. reuse.
Discuss communication between
cranedriver and rigger before
lifting activity.
4.9 Installation of GIS parts Crush, knock, strike, shear, etc. Injuries of human bodyparts, damage of Only qualified and trained employees are allowed to 4 2 8 Inform personal about working Supervisor, local 1 4
equipment and machine parts. work. activity. Follow operation Personnel
Relevant PPE to be used. instruction.
Use the insulated tools when working on or near Only use approved tools and
energized equipment. equipment.
4.11 Filling equipment with SF6 gas Displacement of air by SF6 gas Risk of asphyxiation Only qualified and trained employees are allowed to 5 1 5 Warn employee by using Supervisor, local 1 5
work. warning signs. Personnel ,
Relevant PPE to be used. Follow operation instruction. customer
Use the correct tools. Prohibit unauthorized entry.
Use only closed cycle system with work SF6 gas.
Generally provide a good air supply of the work space.
Ventilate all basement areas to ensure that a buildup
fo SF6 in lower areas is prevented.
Eating, drinking and smoking in the work area are
prohibited.
4.12 Filling equipment with SF6 gas Exposure to high pressure release Injuries of human bodyparts, damage of Only qualified and trained employees are allowed to 4 2 8 Warn workplace by caution Supervisor, local 1 4
equipment and machine parts. work. label. Personnel
Relevant PPE to be used. Inform personal about working
Use the correct tools. activity.
For filling of equipment follow operation instruction and Check the quality of the
gas layout. pressure hoses.
4.13 Evacuate SF6 gas. Release to the environment Adverse impact to the environment. Only qualified and trained employees are allowed to 4 2 8 Follow operation instruction. Supervisor, local 1 4
work. Inform personal about working Personnel
Relevant PPE to be used. activity.
Use the correct tools.
Use recycling equipment to recycle SF6 and ensure
that charging operations stop when any leak of SF6 is
observed.
4.14 Evacuate SF6 gas. Eliminate air by SF6 gas Risk of suffocation Only qualified and trained employees are allowed to 3 1 3 Warning Workplace by caution Supervisor, local 2 6
work. label. Contaminated objects with Personnel
Relevant PPE to be used. SF6 gas to be separately
Use the correct tools. disposed. Consider operating
Use only closed cycle system with work SF6 gas. instruction.
Ensure that supply ventilation is used in the work area. Follow operation instruction.
Ventilate cavities and more deeply lying areas. Prohibit unauthorized entry.
Eating, drinking and smoking in the work area are
prohibited.
4.15 Evacuate SF6 gas. High pressure Injuries of human bodyparts, damage of Only qualified and trained employees are allowed to 3 2 6 Warn workplace by caution Supervisor, local 1 3
equipment and machine parts. work. label. Personnel
Relevant PPE to be used. Inform personal about working
Use the correct tools. activity.
Check the quality of the
pressure hoses.
5.3 Can you justify why equipment Violation of ABB policy and high Severe injury or death Work on energized circuits must be prevented and 5 4 20 Only those employees qualified Commissioning, 1 5
cannot be de-energized or the job potential for contacting energized when necessary a comprehensive review of the scope to work on energized circuits will local ABB SM
deferred until the next scheduled circuits. of the job and safety precautions must be employeed. do so and a job hazard
outage? Use ABB 7-Steps. assessment will be completed
for each task.
5.4 Were required electrical safety Failure to recognize or understand Damage to equipment and injury of worker An assessment of electrical hazards relative to 3 3 9 A job hazard assessment is 1 3
analyses performed? risks. ongoing work and adjacent work must be included in required for each task and must
the job hazard assessment. be signed by each employee.
5.5 Were proper tools and equipment Untested tools used cinducting Damage to equipment and injury of worker Only tools with a current certificate of testing will be 4 2 8 Only use tools that are 1 4
used? current. used for high voltage work. appropriate for the task and
have a current certificate of
testing.
5.6 Was the necessary PPE FR Clothing required to prevent burn Injuries, damage of equipment and machine Arc flash analysis must be completed to determine 4 2 8 Wear FR rated clothing 1 4
determined? from arc flash. parts. appropriate PPE. appropriate for the potential
energy present.
5.7 Visual check of equipment. Crush, knock, strike, shear, etc. Injuries Only use tested and relevant accessories (e.g. ladder 3 3 9 Working at height use relevant Commissioning, 1 3
and steps). safety equipment. local Personnel
Follow commissioning instruction.
5.8 Manual check of equipment. Crush, knock, strike, shear, etc. Injuries, damage of equipment and machine Only qualified and trained employees are allowed to 3 3 9 Inform personal about working Commissioning, 1 4
parts. work. activity. local Personnel
Relevant PPE to be used. Secure and label danger area.
Use the correct tools.
Follow commissioning instruction.
5.9 Installation HV Test equipment, Lifting of heavy test equipment, Injuries, damage of equipment and machine Only qualified and trained employees are allowed to 5 1 5 Working only with work permits HV Test engineer 1 4
site preparation and organisation working in hights . parts. work. for all personell as safety Client's Test
for HV Test. Follow the Safety Instruction for HV Test on site (ABB instruction 1HC0081057 says engineers
Document 1HC0081057)
5.10 HV testing Electrical shock. Injuries, damage of equipment and machine Only qualified and trained employees are allowed to 5 2 10 Follow operation manual and HV Test engineer 1 5
parts. work. testing instruction 1HC0081057 Client's Test
Relevant PPE to be used. Inform personal and site about engineers
Use the correct tools. testing activity.
Secure and label testing and danger area. During testing prohibit
unauthorized entry.
Ensure the five electrical safety
rules are followed.
5.11 Test of secondary equipment. Crush, knock, strike, shear, etc. Injuries, damage of equipment and machine Only qualified and trained employees are allowed to 3 3 9 Inform personal about testing Commissioning, 1 3
parts. work. activity. local Personnel
Relevant PPE to be used. During testing prohibit
Use the correct tools. unauthorized entry.
Follow commissioning instruction.
Secure and label danger area.
Severity
3 1 2 2 3 3
2 1 1 2 2 3
1 1 1 1 2 2
1 2 3 4 5
Likelyhood
SEVERITY
Description Score Definition
Fatal Injury 5 Multiple or single fatality per event
A major fracture of any bone
Loss of limb or eye
Severe Injury 4 Lost of sight or hearing (permanent)
Acute illness requiring medical treatment
Any injury requiring > 30 days off work
Fracture of the hand, wrist, or ankle
Unconsciousness
Major Injury 3 Major burn
Amputation of fingers or toes
Loss of sight or hearing (temporary)
Any injury leading to 3-30 days off work
Fracture of digits
Strains, scratches, cuts and abrasions
Minor burn
Minor Injury 2 General discomfort
Minor occupational related illness
Occupationally induced allergic reaction
Any injury resulting in < 3 days off work
Superficial Injury 1 Very minor or superficial injury where First Aid may be required but no lost
LIKELYHOOD
Description Score Definition
Event is likely to occur if controls are not adequate
Highly likely 5
Possible weekly frequency of occurrence
Likely 4 Event is likely to occur at least once a month
Possible 3 Event could occur at least once every year
Unlikely 2 Expected to occur every few years
Remote 1 Very rare event likely only every 10 years
Risk Factor = 6, 5, 4,
3, 2 or 1 No additional controls are required;
LOW Consideration may be given to a more cost effective solution or improvement that imposes no additional cost burden;
Monitoring is required to ensure that the controls are maintained.