TITLE: Electrical Safety

REFERENCE NUMBER: HSE

Issue Date: 2018

Version Number: 1

Prepared By: Umer Mehmood

Reviewed Electrical Manager : M. Shahbaz

Approved By HSE Manager: Furqan Shahid

PepsiCo Sundar Snacks Plant Issued: 2018

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 1 PRINCIPLE AND PURPOSE
2 SCOPE
3 TERMS & DEFINATIONS
4 RESPONSIBILITIES
5 PROCEDURE
6 REPORTING
7 RECORD KEEPING:
8 TRAINING
9 LEGAL AND POLICY FRAMEWORK
10 REFERENCES
11 MYEHS IMPLEMENTATION
12 CONFIDENTIALITY
13 RECORDS

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 1. PRINCIPLES AND PURPOSE:
The purpose of this procedure is to ensure that persons working at PepsiCo Sundar
Plant are, as far as reasonably practicable, safe from risk of injury caused by
electricity, electrical installations and associated entities.

2. SCOPE:
This procedure applies to PepsiCo Sundar Snacks Plant.

3. TERMS & DEFINATIONS:

3.1 Competent Person:

A person who has acquired through training, qualification or experience, the
knowledge and skills to carry out the task.

3.2 Electrical Work:

Connecting electricity supply wiring to electrical equipment or disconnecting
electricity supply wiring from electrical equipment.
Installing, removing, adding, testing, replacing, repairing, altering or maintaining
electrical equipment or an electrical installation.

However, the following are not ‘electrical work’:

 work that involves connecting electrical equipment to an electricity supply by
means of a flexible cord plug and socket outlet
 work on a non-electrical component of electrical equipment if the person
carrying out the work is not exposed to an electrical risk
 replacing electrical equipment or a component of electrical equipment if that
task can be safely performed by a person who does not have expertise in
carrying out electrical work (e.g. replacing domestic fuses or light bulbs)
 assembling, making, modifying or repairing electrical equipment as part of a
manufacturing process
 building or repairing ducts, conduits or troughs where electrical wiring is or will
be installed if:
 the ducts, conduits or troughs are not intended to be earthed
 the wiring is not energised, and
 the work is supervised by a licensed or registered electrical worker
 locating or mounting electrical equipment, or fixing electrical equipment in
place, if this task is not performed in relation to the connection of electrical
equipment to an electricity supply
 assisting a licensed electrician to carry out electrical work if:
 the assistant is directly supervised by the licensed electrician, and
 the assistance does not involve physical contact with any energised
electrical equipment
 carrying out electrical work, other than work on energised electrical
equipment, in order to meet eligibility requirements in relation to becoming a
licensed electrician.
Electrical work does not include work on electrical equipment that is operated by
electricity at extra-low voltage except:
 electrical equipment that is part of an electrical installation that is located in an
area in which the atmosphere presents a risk to health and safety from fire or
explosion
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  in relation to electrical equipment that is part of an active impressed current
cathodic protection system.

3.4 Live Electrical Work

Work on or near exposed and energised electrical conductors including the testing of
a live circuit.

3.5 Electrical Worker:

A person with a valid and appropriate electrical licence and qualification for the
electrical work being undertaken. The electrical licence must be applicable for the
jurisdiction in which the electrical work is being undertaken. An Electrical Worker’s
qualification must cover that type of specialised work being undertaken such as work
within a Hazardous Area.

3.6 Extra-low Voltage

Voltage that does not exceed 50 volts alternating current (50 V a.c.) or 120 volts
ripple-free direct current (120 V d.c.).

3.7 RCD – Residual Current Devices

A device that works by detecting a current leakage (often called an ‘earth leakage’).
When the RCD detects this current leakage, it turns off the power almost
immediately.

3.8 Safety Officer

A person who is competent to implement the control measures in an emergency,
rescue the worker who is carrying out the work and has completed an Electrical
Rescue & Resuscitation Course and has been assessed as competent within the
past 12 months.

4. ROLES & RESPONSIBILITIES

4.1. Sundar Management Team:

The Sundar Management Team is responsible for ensuring that all electrical
Installation, disconnection and termination at Sundar Plant is carried out by an
Electrical Worker in accordance with this procedure.

The Sundar Management is to ensure that:

(a) The requirements of this document are enforced with all employees
operating at the Sundar Plant premises, and
(b) All relevant employees are trained in its contents.

 Sundar Plant Management Team is responsible to provide adequate support

in the implementation of this Electrical Safety Program across the Sundar
Plant.
 Providing adequate resources & tools to the departments managers and
supervisors as required and to ensure an appropriate level of training is
provided.
 Sundar Management Team is responsible to ensure that this procedure is
correctly followed & implemented across the Sundar Plant.

4.2. Sundar EHS Manger/Officer:

 EHS Manager/ Officer is responsible for ensuring the implementation and
monitoring of Electrical Safety Program across the Sundar Plant by providing
adequate facilities & awareness to all employees / workers / contractors.

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  EHS Manager/ Officer is responsible to ensure tracking of Electrical Safety
Protocols according to standard requirements.
 EHS Manager/ Officer will ensure to conduct annual review with CU HSE
Manager & Sundar Management Team and share the updated version with all
stackholders.

4.3. Electrical Manager

 Electrical Manager is responsible to ensure the integrity of Electrical Safety
reommendations and action plan.
 Electrical Manager is responsible to maintained the record of all near-miss
and incidents & followup with team to complete action plan within time lines.

4.4 Electrical Artisan/ Supervisor:

 The Electrical Artisan/ Supervisor is responsible for maintaining a valid
electrical expertise appropriate for the scope of electrical work being
undertaken.
 The Electrical Artisan/ Supervisor is responsible for ensuring that all electrical
work undertaken by them is carried out in accordance with this procedure.
 The Electrical Artisan/ Supervisor is responsible for ensuring that electrical
installations are tested in accordance with the approved design specifications.

4.5. Department Managers:

Department Managers are responsible for ensuring that all electrical Installation,
disconnection and termination within their area of responsibility is carried out by an
Electrical Worker in accordance with this procedure.

4.6. Employees
 Relevent employess must adhere the all recommendation according to
electrical safety program and PPEs.
 They will respond in case of electrocution or short circuiting and share the
event report.

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 5. PROCEDURE

5.1 General Electrical Work

 All electrical work carried out at Sundar Plant must be conducted by an
Electrical Worker who is a suitably qualified and licenced electrician.
 All electrical work carried out at Sunadr Plant must comply with the requlatory
requirments and involve LESCO where required.

5.2 Test for Dead

 The safe work procedure ‘TEST FOR ‘DEAD’ BEFORE YOU TOUCH’ must
be applied at all times.
 Even if the electricity supply is believed to have been isolated, it must be
assumed that all conductors and electrical components are energised until
they have been proven de-energised.
 Testing for ‘dead’ must be undertaken as appropriate for the duration of the
electrical work. Testing is undertaken prior to touching, taking into account all
relevant factors including the nature of the conductor, nature of the isolation,
nature of work, if there has been a change or the area has been left idle
(unattended) for a period.
 The testing method (including the tester used) must be safe and
effective. The electrical worker carrying out the testing must understand
testing procedures and be competent in the use of the tester.
 Panel voltmeters should not be used as the only method of determining
whether an electrical part is de-energised.
 If voltage testers are used they should be tested for correct operation
immediately before use and again after use to confirm that the instrument is
still working. This check should be considered to be part of the ‘TEST FOR
‘DEAD’ BEFORE YOU TOUCH’ safe work procedure.
 If there are any exposed conductors in the immediate work area they should
be separated by design or segregated and protected with insulated
barricades, insulated shrouding or insulated material to prevent against
inadvertent or direct contact.

5.3 Electrical Cabinets

 Electrical Cabinets are maintained in accordance with recommended IP rating
and kept locked with access restricted to a Competent Person/ electrical
artisan.
 For new installations, install smoke detectors inside the main electrical
cabinets - areas with adequate existing protections do not need to be
upgraded - identify the main switches to disconnect the electrical cabinets,
and install adequate fire suppression devices against electrical fires.
 Ensure that all electrical equipment has the adequate labels and declarations
of conformity (including insulation or double insulation when required).

5.4 Live Electrical Work

 Ensure that work on or near exposed conductors that are or could be live is
not undertaken by our employees, or other people performing work for us by
ensuring all electrical circuits are correctly isolated before electrical work is
performed on them. Ensuring satisfactory precautions are made in case of
automatic sequence starting, fail-safe start-up systems, remote control
systems, emergency power supply system or other technology that may be
cause for a system over-riding a single isolation technique and physically
isolate circuits by applying a locking device such as a padlock wherever
possible.
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  All Electrical Workers required to work on or near electrical equipment must
Test for Dead to confirm they are de-energised prior to commencement of
work.
 Live electrical work is prohibited Sundar Plant other than testing and fault
finding when a risk assessment determines the risk to be low.

5.6. Testing and Fault Finding

 De-energised testing methods should be used before energised testing
methods
 Fault finding should first be attempted in a de-energised environment using
de-energised testing methods. If unsuccessful, energised testing methods
may be used subject to meeting the requirements of the Code of practice –
Managing Electrical Risks in the Workplace.

Before commencing any testing or fault finding in an energised environment:

 identify exposed conductive parts that could become energised while using
test instruments
 use temporary or fixed barriers to prevent electrical workers from
inadvertently contacting exposed conductive parts
 use only appropriate insulated and rated tools, test instruments and test
probes
 carry out checks to ensure that the test instruments to be used are
appropriate and functioning correctly
 use only appropriately rated PPE
 use a safety observer, if required by the risk assessment conducted for the
work
 ensure that only authorised persons may enter the immediate area where the
work is to be carried out
 carry out a regular review of the work situation to ensure that no new hazards
are created during the process.
 When testing or fault finding is completed, circuits and equipment must be
restored to a safe condition. For example, disconnected conductors should be
reconnected and left in a safe state, covers replaced, and accessories and
equipment properly secured.
 Procedures involving coordination, such as procedures related to switching
circuits or equipment on and off during the fault finding or testing process,
must be implemented and maintained at all times.

5.7. New Installations

 Where cables are not connected to a power source and/or the field end is not
terminated they must be suitable protected and be made electrically safe by
use of an insulated connector, terminator or electrical insulation tape.
 Where cables are connected to a power source and the field end is not
terminated they must be suitable protected and be made electrically safe by
use of an insulated connector or terminator in the event they become live.
 If the cables are left longer than 1 shift they must be appropriately identified at
each end.

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 5.8. Temporary Removal of Plant and Equipment
 For temporary removal of plant and equipment where cables are connected to
a power source the power source must be isolated and locked out to ensure
that the cable is not live in accordance with the PepsiCo Sundar Lockout and
Danger Tag Procedure.

5.9. Permanent Removal of Plant and Equipment

 Where plant and equipment is to be removed permanently, the cables shall
be removed back to the fuse holders or circuit breaker in the distribution
board at the time that the plant and equipment is removed.
 In circumstances where it is likely that the same cabling routing will be
required in future (As determined in consultation with the Electrical/
Maintenance Manager) or there are unused cores in a multi-core cable some
cores of which are still in use, the cabling may be left in place and terminated
at both ends and clearly identified.

5.10. Scrapping/Dumping of Electrical Equipment

 Workers who scrap or dump electrical equipment must ensure that any
electrical supply cord is cut off to prevent unauthorised use and that the item
is disposed of in a manner to discourage retrieval.

5.11. Pre-existing Redundant Cabling:

 Where pre-existing redundant cabling is identified that does not comply with
the requirements of this procedure, action should be taken to make it
compliant, either by addressing immediately or by raising a work order for it to
be addressed.

6. REPORTING:
Employees are responsible to immediately report to site management any
incidents involving Electricity that result in accident as well as any near-miss
incidents that could have resulted in an accident. Such incidents must be
reported according to the PepsiCo EHS Standard 01 – EHS Event Reporting
and Investigation, which must include investigation and corrective action
directed to prevent recurrence.

7. RECORD KEEPING:
Sundar Plant will follow Document Control and Records Management
Procedure. In addition, the following records, at a minimum maintained for at
least five years unless otherwise directed in the PepsiCo Record Retention
Policy:
 Risk Assessment
 Electrical Permit to Work
 Electrical safe work practices/SOP
 Preventive maintenance and inspection record
 Employee training record

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 8. TRAINING:
 All personnel involved with the implementation of any portion of this standard
are trained on the overall requirements of the standard and to gain the
knowledge (such as regulatory requirements) and skills necessary for the
safe and comprehensive performance on their assigned duties.
 Refresher training will be provided semi-annually to all relevant employees.
 Training sessions will be organized for all relevant new and transferred
employees related to electrical hazards.

9. LEGAL AND POLICY FRAMEWORK

 PepsiCo Global Environment, Health and Safety Management System
(GEHSMS)
 OHSAS 18001: 4.3.1 (Hazard Identification, Risk Assessment and
Determining Controls); 4.3.2 (Legal and Other Requirements); 4.4.2
(Competence, Training and Awareness); 4.4.3 (Communication, Participation
and Consultation); 4.4.6 (Operational Control); 4.5.1 (Performance
Measurement and Monitoring)

10. REFERENCES:
 PepsiCo EHS Standard – 56 Electrical Safety
 PepsiCo EHS Standard 01 – EHS Event Reporting and Investigation
 OHSAS 18001
 PepsiCo EHS Standard 04- Management of Change - Vsn.2
 PepsiCo EHS Standard 10 - EHS Risk Management V3 FINAL

11. myEHS IMPLEMENTATION

PepsiCo Sundar plant downloaded all the updated standards from myEHS
and uploaded spill incidence reports accordingly.

12. CONFIDENTIALITY

Non Confidential

13. RECORDS

Document Revision History

Document Version
Date Revision Detail Author By
No Number

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