Hazardous Areas Stanwell Power Station

Business Procedure
Hazardous Areas at Stanwell Power Station

Document Number HB625195
This document applies to the following sites:
All Sites
Rockhampton Office
Brisbane Office
Tarong Site
Barron Gorge Hydro PS
Kareeya Hydro PS
Mica Creek PS
Koombooloomba Hydro PS
Swanbank PS
Mackay Gas Turbine
Wivenhoe Small Hydro PS
Stanwell PS
Meandu Mine
Table of Contents
1.0
2.0
3.0
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.7.1
3.1.7.2
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13
3.1.14
3.1.15
4.0
4.1
5.0
6.0
7.0
Purpose ...................................................................................................................................... 2
Scope ......................................................................................................................................... 2
Hazardous Area Safe System of Work ...................................................................................... 2
Controls ...................................................................................................................................... 2
Classification Audits ................................................................................................................... 3
Risk Management ...................................................................................................................... 3
Managing Ignition Sources ......................................................................................................... 4
Competent Design ...................................................................................................................... 5
Authorised Modifications to Plant ............................................................................................... 5
General Hazardous Area Work .................................................................................................. 5
Electrical Work............................................................................................................................ 5
Electrical Installation Work ......................................................................................................... 6
Maintenance and Repair Work - Electrical ................................................................................. 6
Routine Inspections of Equipment - Electrical............................................................................ 6
Process for Managing Unrated Electrical Equipment................................................................. 7
Regular Auditing ......................................................................................................................... 7
Regular Cleaning ........................................................................................................................ 7
Maintaining a Hazardous Area Verification Dossier ................................................................... 7
Training and Authorisation of Workers ....................................................................................... 8
Maintaining a Hazardous Area Equipment Register .................................................................. 9
Signage ...................................................................................................................................... 9
Responsibilities........................................................................................................................... 9
Function Flowchart ................................................................................................................... 11
Review and Consultation .......................................................................................................... 12
Communication Plan ................................................................................................................ 12
References (Including Information Services) ........................................................................... 12
WRITTEN BY: ..................................

NAME: Peter Cox
Doc No: HB625195
ENDORSED/CHECKED BY: ..............................

NAME: James Oliver
Revision No: 8
APPROVED BY: ....................................
DATE: ........
NAME: Brad Perry
Revision Date: 10.09.2014
THIS DOCUMENT IS UNCONTROLLED IN HARD COPY FORMAT
Page: 1 of 19
8.0
9.0
10.0
10.1
10.2
10.3
Definitions ................................................................................................................................. 13
Revision History........................................................................................................................ 15
Attachments.............................................................................................................................. 16
Attachment A Routine Inspection and Cleaning SDs ........................................................... 16
Attachment B Managing Electrical Equipment in Hazardous Areas Guide ........................... 17
Attachment C - Approval & Certification Process Required for Electrical Work in Hazardous
Areas on Entity Works .............................................................................................................. 18
Attachment D - Electrical Maintenance and Repair Flowchart .............................................. 19
10.4
1.0
Purpose
Stanwell Power Station as an operating site within Stanwell Corporation Limited has obligations to
comply with WH&S and Electrical Safety Legislation, AS/NZS standards and codes of practice to
establish and maintain a safe and healthy workplace. The presence of flammable gases and
liquids and combustible dust may present a hazard to people, property and the environment.
Legislation places a responsibility on SCL and individuals to exercise a duty when designing,
constructing and operating facilities to ensure the safety of people, property and the environment.
SPS will have a documented safe system of work in relation to hazardous areas to ensure the
obligations of the Workplace Health and Safety Act and the Electrical Safety Act of Queensland
are met.
2.0
Scope
This procedure will outline the SPS safe system of work for managing hazards associated with
hazardous areas.
The identification of hazardous areas.
The identification of associated hazards and risks within the identified hazardous areas, with
specific consideration needs to be given to the non introduction of ignition sources.
The elimination of the risks where possible, if elimination is not possible, then the hierarchy of
controls shall be applied to reduce the risk as far as reasonably practicable.
The maintenance of control measures.
The review of the effectiveness of the applied control measures.
This procedure is to be used in conjunction with the Business Strategy Corporate Hazardous
Area Management (14/74811).
3.0
3.1
Hazardous Area Safe System of Work

Controls
The following controls exist within the fundamental elements and combine to become the defined
safe system of work that is being used by Stanwell Power Station to minimise the risks within
hazardous areas as far as reasonably practicable:
Classification Audits
Risk Management
Managing Ignition Sources
Competent Design
Authorised Modifications to Plant
General Hazardous Area Work
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Page 2 of 19
Electrical Work
Electrical Installation Work
Electrical Plant Modifications
Maintenance and Repair Work Electrical
Routine Inspections of equipment - Electrical
Process for Managing Unrated Electrical Equipment
Regular Auditing
Regular Cleaning
Maintaining a Hazardous Area Verification Dossier
Training and Authorisation of Workers
Maintaining a Hazardous Area Equipment Register
Signage
3.1.1
Classification Audits
Classification audits are required to identify where on plant there is a reasonable probability
that an explosive atmosphere may exist, so managers and personnel can implement
appropriate control measures.
SPS will conduct a hazardous areas classification audit of all site plant areas.
The audit shall identify the type of hazard and assess the probability of an explosive
atmosphere actually occurring.
AS/NZS 60079.10.1 for explosive gas atmospheres and AS/NZS 60079.10.2 for
combustible dust atmospheres shall be used for conducting the classification audits.
Hazardous areas shall be classified into specific Zones, depending on the nature of the
explosive atmosphere present i.e. flammable gases & liquids and combustible dusts.
Classification auditing shall be undertaken by a competent person in accordance with
AS/NZS 4761- Competencies for working with electrical equipment for hazardous areas.
SPS will keep a copy of the audit report/s in the site hazardous area verification dossier.
SPS will develop classification drawings for each separate classified area based on the
classification audit report.
3.1.2
Risk Management
SCL has a Corporate Risk Management Framework (13/575645) and this shall be used
when conducting any risk assessment process.
A risk assessment shall be performed and controls identified to ensure the risk is
managed to as low as reasonably practicable or where this cannot be achieved it must
be minimised to as far as reasonably practicable e.g. existing unrated electrical
equipment within defined hazardous areas.
When conducting risk assessments for combustible dusts AS/NZS 4745:2012 Code of
Practice for Handling Combustible Dusts shall be used for guidance to define the
hazards and establish the required controls.
When preparing task/job risk assessments e.g. work method statements it is expected
that the Managing Electrical Equipment in Hazardous Areas Guide table in attachment
B will be used to identify hazards and appropriate controls for the hazard/s.
SPS is on a pathway to achieve hazardous area compliance for all hazardous area
equipment and to achieve the target risk of as low as reasonably practicable.
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Risk
Time
Diminishing Risk Graph

This graph is a visual representation of the risk carried depending on the controls in place whilst
transitioning to a risk position of as low as reasonably practicable.
The red section represents the level of risk associated with compliant electrical equipment and
minimal conditions of control to achieve the target risk.
The green section is the risk carried in addition to the target risk when there are increased
conditions of control and non compliant electrical equipment installed in the hazardous areas.
Therefore the level of risk on the left hand side is the current risk (minimised to as far as
reasonably practicable) and the level of risk on the right hand side is the target risk.
During the transition from current risk to target risk two key elements need to be in place.
1. Increased controls such as high frequency cleaning, high frequency inspections and external
auditing of controls;
2. A process to replace unrated electrical equipment with properly compliant equipment as soon
as practicable.
3.1.3
Managing Ignition Sources

Where possible equipment to be taken into a hazardous area shall be rated as explosion
protected and/or intrinsically safe. Non-sparking hand tools (e.g. beryllium) where applicable
shall be used. Prior to commencing hot work activities in a hazardous area, a Hot Work
Control Guide shall be completed.
The following equipment (not inclusive) may act as an ignition source, and as such, is NOT
permitted in a hazardous area unless under the controls nominated within a hot work control
guide or the equipment is appropriately rated for the hazardous area:
Combustion engines;
Mobile phones;
Hearing aids;
Key-ring torches;
Calculators;
Car keys with automatic door locking features;
Pagers;
Watches;
Transistor radios and communication radios;
Battery chargers with their control equipment and batteries being charged (unless
suitable for the hazardous area);
Lasers;
Low pressure sodium vapour discharge lamps;
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Nylon and other synthetic clothing; and other sources of static electricity;
Alloy tools, scaffolding or ladders striking rusty metal, or rusty tools striking a light alloy
could produce a thermite reaction and hence lead to an explosion in a hazardous area;
Battery operated vehicles (e.g. fork lifts), to be used in a hazardous area are to be in
accordance with AS 1915 Electrical apparatus for explosive atmospheres Battery
operated vehicles; and
Non-certified / non-explosion protected portable equipment e.g. welding equipment.
3.1.4
Competent Design
The design of plant and installations in which flammable and / or combustible materials are
handled or stored must consider minimising the likelihood and frequency of releases by one
or more of the following:
Replacing flammable products with non-flammable products;
Not having joints in pipework;
Using high integrity products for gaskets and glands;
By having areas ventilated;
Reducing inventories of flammable materials;
Ensuring ignition sources are controlled;
Ensuring life saving appliances and emergency control points are located in nonhazardous areas;
Determining the maximum allowable surface temperature for a particular area;
Determining the location of flammable gas detectors;
Determining gas groups;
Determining the types of release, duration and velocity; and
Defining the extent of flammable gas level from vents.
Any person performing hazardous area design work shall be a competent person in accordance
with AS/NZS 4761- Competencies for working with electrical equipment for hazardous areas.
3.1.5
Authorised Modifications to Plant

SCL has a project management and plant change process that ensures due diligence is
carried out when installing new or modifying existing plant. For more details on projects refer
to GenNet Our business Project Management and for more detail on plant change refer
to GenNet Our business Operations Operations Systems and Processes Plant
Change.
3.1.6
General Hazardous Area Work

General hazardous area work is work that is not electrical installation or maintenance &
repair work, such as mechanical work and cleaning activities.
Inspections are not considered a work activity for this procedure.
Workers shall complete Hazardous Area Awareness Training HS043, prior to performing
general hazardous area work;
A Hot Work Control Guide shall be completed for any work that has the potential to
introduce an ignition source into a hazardous area (refer to section 4.1); and
A Work Method Statement shall be required for all work performed in a hazardous area.
3.1.7
Electrical Work
SPS has electrical equipment within the works of an entity and electrical installation as
defined in the Electrical Safety Act 2002. The obligations of electrical workers are different
depending on where the equipment is located. For electrical installations their obligation is
to comply with the wiring rules and for entity works they follow the SPS hazardous area safe
system of work.
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For SPS, all electrical equipment within hazardous areas is considered works of an entity
with the exception of equipment located in the following buildings:
1. Flammable liquids store.
2. Laboratory.
3. Main store including the unleaded fuel bowsers.
4. Main workshop.
5. Waste transfer station.
3.1.7.1 Electrical Installation Work

All electrical installation work conducted within a hazardous area must be performed by an
authorised licenced electrical worker who has the appropriate EEHA competencies for the
work they are to perform.
All electrical installation work (including modifications) must be inspected upon completion
and an accredited auditor must audit the work and give clearance before connecting to a
source of supply.
All documentation associated with electrical installation work and modifications to
hazardous area equipment must be included in the Hazardous Area Verification Dossier.
The selection, installation and inspection of electrical equipment for use in hazardous areas,
shall be in accordance with the applicable Australian Standards.
3.1.7.2 Maintenance and Repair Work - Electrical

All electrical equipment maintenance and repair work conducted within a hazardous area
must be performed by an authorised licenced electrical worker who has the appropriate
EEHA competencies for the work they are to perform. Maintenance and repair work
includes;
Breakdown work;
Like for like equipment replacements of rated or unrated hazardous area equipment; and
Disconnect/reconnect of electrical equipment.
Where maintenance or repair work is undertaken for electrical equipment, a Hazardous
Area Maintenance and Repair Work Report is to be completed and added to the HAVD.
When conducting maintenance and repair work on entity works the Approval & Certification
Process Required for Electrical Work in Hazardous Areas on Entity Works guide in
attachment C shall be used. Firstly select the applicable situation on the table and then
implement the actions, gain approvals as necessary, perform tests, perform inspections and
audits as required for the work.
There is also a simplified version of this process in a flow chart in attachment D.
3.1.8
Routine Inspections of Equipment - Electrical

To ensure electrical installations and entity works are maintained in a satisfactory condition,
regular periodic inspections shall be conducted.
There will be a schedule in place to regularly inspect electrical equipment in hazardous
areas. The length of time between inspections shall not exceed 4 years.
Inspections must be performed by an authorised electrical person or authorised licenced
electrical worker who has the appropriate EEHA competencies for inspections.
All defects and non-compliant equipment are to be detailed on the inspection sheets.
Secondary work orders are to be raised for any rectification work identified from the
inspections.
The Service Definitions for the inspections are listed in attachment A.
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When performing routine inspection on entity works and on equipment which is unrated for
the hazardous area in which it is installed, the inspection is to specifically look at the
integrity of the equipment. The integrity of the equipment is a key control within the safe
system of work to manage the risk associated with unrated equipment until compliance is
achieved. Hence the inspections shall focus on the
IP rating e.g. IP5X for zone 22;
Integrity of seals;
Cable and gland integrity;
Mechanical protection;
Internal wiring integrity e.g. in local control panels;
Equipment mounting security;
Earth connections;
Corrosion; and
Dust build up.
3.1.9
Process for Managing Unrated Electrical Equipment

On electrical installation equipment the process shall be to have the equipment replaced
and installed as soon as practicable to the relevant Australian standards by an authorised
licenced electrical worker who is EEHA competent. The new equipment must be inspected
by a competent person and audited by an ESO accredited auditor prior to connecting to a
source of supply.
On entity works equipment, the process shall be to follow the Managing Electrical
Equipment in Hazardous Areas Guide TRIM Doc number 13/2197469 refer also to
attachment C. The flowchart in attachment D also provide guidance.
3.1.10
Regular Auditing
There will be regular audits conducted on classified hazardous areas for systems
compliance and to ensure effectiveness of conditions of control such as cleaning of
combustible dust plant areas.
The maintenance management system will be used to schedule these regular audits.
The time between audits will be no more than 12months.
3.1.11
Regular Cleaning
A program of increased cleaning will be implemented in combustible dust areas until all
equipment within the area is made compliant.
A program of inspections of the increased cleaning program will also be in place until all
equipment within the area is made compliant.
Once equipment in an area is compliant the cleaning and inspections can be less
frequent dependent on keeping dust levels to below 5mm thick.
Cleaning and inspections will be scheduled within the maintenance management system.
The Service Definitions for the cleaning are listed in attachment A.
3.1.12
Maintaining a Hazardous Area Verification Dossier

SPS will have a Hazardous Area Verification Dossier (HAVD) and have an appropriate
person ensure that it is kept up to date with relevant documentation.
The verification dossier will contain the following:
Identity of the legal owner of the facility (person in control of the electrical equipment).
Area classification drawings.
Classification reports and associated documents;
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Any risk assessments associated with hazardous areas(not Work Method Statements);
Certificates of conformity for all items of equipment installed in the hazardous areas.
Conformity Assessment Documents for uncertified or foreign equipment.
Location of each equipment item.
Calculations performed to verify compliance.
Records of electrical tests performed on installation or commissioning.
Inspection schedules.
Records of inspections performed, including faults and defects and their rectification.
Records of overhauls and repairs carried out by licenced repairers.
Records of any modifications made to equipment and justification for them.
Details of the competence of personnel working in hazardous areas.
Completed Hazardous Area Maintenance and Repair Work Reports.
The Verification Dossier is to be readily available to all persons required to enter and / or
work in the hazardous area(s).
The SPS Hazardous Area Verification Dossier:
Electronic version is in folder MIG/73441.
Hard copy version is located in annexe 2/3 level 4.
3.1.13
Training and Authorisation of Workers

There will be a process for training to authorise personnel to perform electrical work
within a Hazardous Area, in accordance with relevant Australian Standards.
All persons (including contractors) who are expected to, or who may enter a hazardous
area for any purpose, shall have first received appropriate training / instruction in relation
to the necessary precautions, particularly the need to ensure that no potential ignition
sources are taken into the hazardous area. Training shall be provided in accordance with
Hazardous Areas Awareness Training HS043 (13/1330264).
All Hot Work activities shall be performed using a Hot Work Control Guide.
Authorised electrical workers, technicians and engineers who install, maintain, inspect or
test electrical equipment in a hazardous area shall receive Hazardous Area Training 1
Installation and Maintenance of Electrical Equipment HS072 (13/1269196).
Refresher training shall be provided in accordance with Hazardous Area Training 1Installation and Maintenance of Electrical Equipment Refresher (13/1810710).
Persons who are required to carry out design for explosion protected and associated
electrical equipment in hazardous area installations shall receive Hazardous Area
Training 2 - Design of Electrical Installations (13/1779536).
Refresher training shall be provided in accordance with Hazardous Area Training 2 Design of Electrical Installations Refresher (13/1810435).
Persons who develop maintenance management programs for hazardous area
installations shall receive Hazardous Areas Training 3 - Maintenance Management of
Electrical Equipment (13/1797125).
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Page 8 of 19
3.1.14
Maintaining a Hazardous Area Equipment Register

SPS will have a register of all electrical equipment items installed in hazardous areas
(14/132200).
The equipment register shall be kept with the site HAVD (MIG73441).
The equipment register shall be updated with any changes to equipment installed in
hazardous areas.
The equipment register shall include the following details for each item:
Tag ID / KKS;
Item Description;
Item Location;
Protection Type;
Manufacturers Name;
Model Number;
Serial Number;
Certifying Authority;
Last Inspection Date;
Zone; and
Classification Drawing Number.
o
o
o
o
o
o
o
o
o
o
o
3.1.15
Signage
Hazardous areas shall be clearly defined and marked / signed in accordance with AS 1319 Safety Signs for the Occupational Environment.
Signage for a hazardous area shall:
Identify the nature / type of hazardous area (e.g. gas or dust hazardous area); and
Specify requirements / precautions whilst in the hazardous area (e.g. signage is to
identify equipment which is not permitted in the hazardous area).
4.0
Responsibilities
Person Conducting a Business or Undertaking (PCBU):
Sections 32 to 38 of the WH&S Regulation 2011 outlines the requirements for eliminating or
minimising risk so far as is reasonably practicable by identifying the hazards, managing the risk,
applying hierarchy of control measures and maintaining and reviewing the nominated control
measures.
Section 51 of the WH&S Regulation 2011 states that a PCBU must manage risks to health and
safety associated with a hazardous atmosphere at the workplace.
Section 355 of the WH&S Regulation 2011 relates to specific controls around fire and explosion. A
PCBU must ensure ignition sources are not introduced into hazardous areas.
Section 29 of the Electrical Safety Act 2002 states that the duty of an Electrical Entity is to ensure
that its works are electrically safe and operated in a way that is electrically safe. It is the
responsibility of the PCBU for the Electrical Entity to ensure, the Entity meets its obligations under
the act.
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Section 30 of the Electrical Safety Act 2002 states that the duty of PCBU is to conduct the
business in a way that is electrically safe. This means that equipment is electrically safe, electrical
work is performed safely and ensuring all people and property are electrically safe for any
equipment and electrical work on that equipment that is not part of entity works.
Person in Control of Electrical Equipment in Relation to the Electrical Safety Act
At SPS this is the Site Manager as defined in the Legacy Corporate Authority to Work Electrical
Safety Standard.
Section 38 of the Electrical Safety Act 2002 states that the person in control of electrical
equipment must ensure the electrical equipment is electrically safe.
At SPS the nominated person in control of electrical equipment shall be the person for both the
entity works and the electrical installation as defined in the Electrical Safety Act 2002.
Electrical Workers
The licensed electrical worker is responsible for ensuring compliance to the wiring rules when
performing work on an electrical installation under section 70 of the Electrical Safety Act 2002.
Note: As the works of an entity is not considered an electrical installation (as defined within the
act), the licensed electrical worker needs to ensure the safe system of work that has been
established by the Entity, in relation to its obligations, under the acts and regulations, are met
when performing electrical work on works of an entity.
Electrical Contractors
When performing electrical work on entity works the electrical contractor will comply with the
safe work system established by the entity. This means that for the electrical work they have
conducted they will inspect, test and commission the equipment to verify that the electrical
equipment is suitable for service and can be operated safely when initially installed or altered in
accordance with the procedures established by the entity.
Electrical contractors performing electrical work on an electrical installation have an obligation
under Section 70 of the Electrical Safety Act 2002 to be in compliance with the wiring rules.
Hazardous Area Technical Person
This role is to provide expert knowledge and guidance to manage safe work in hazardous areas.
At SPS this role is performed by the Electrical Systems Technologist Compliance.
The role shall perform the following duties:
Determine the frequency of periodic inspections and the grade of inspections.
Ensure that the HAVD is kept up to date.
Maintain the hazardous area equipment register for the site.
Check that skilled personnel are receiving appropriate training and refresher training.
Check that documentation is being completed correctly and added to the HAVD.
Provide adequate technical support to the skilled personnel.
Conduct audits and inspections and produce reports so that the state of the electrical
installation is known.
Check on effectiveness of controls implemented under conditions of control documents.
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4.1
Function Flowchart
The following flowchart outlines the process of determining controls for activities within
hazardous areas.
Entry required into a classified hazardous area
Perform the activity( i.e. inspections)

and ensure ignition sources are left
outside the hazardous area.
No
Is the entry for a work

activity?
Yes
Identify hazards and

controls for the
work
Perform the work following controls on

WMS and ensure ignition sources are left
outside the hazardous area.
Prepare WMS using

guide in attachment
B
No
Does the work involve hot work or

introducing an ignition source into
a hazardous area?
General
Type of work to be
performed
Electrical
Is the work electrical

installation work or work on
an electrical installation?
No
The work is electrical

maintenance or repair work
on entity works.
Yes
Yes
Ensure there is a
hot work control
guide are in place.
Implement controls on WMS

and perform electrical work
following Australian Standards.
Implement controls on WMS

and perform electrical work
following SPS safe work process
refer to attachments B, C&
D for further details.
Perform work following controls

on WMS and HWCG.
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5.0
Review and Consultation

This Document is required to be reviewed, as a minimum, every 3 years.
6.0
Communication Plan
This document will be communicated to affected employees through information sessions at team
meetings, through the site electrical safety committee meetings and incorporated into the
hazardous area awareness and the EEHA training and refresher packages.
7.0
References (Including Information Services)

13/1330264
Hazardous Areas Awareness Training
13/1269196
Hazardous Area Training 1-Installation and Maintenance of Electrical

Equipment HS072
13/1810710
Hazardous Area Training 1-Installation and Maintenance of Electrical

Equipment Refresher
13/1779536
Hazardous Area Training 2 - Design of Electrical Installations
13/1810435
Hazardous Area Training 2 - Design of Electrical Installations Refresher
13/1797125
Hazardous Areas Training 3 - Maintenance Management of Electrical

Equipment
13/1269696
HEHI Hot Work - HS021
14/13767
Hazardous Area Maintenance and Repair Work Report
13/2198197
Hazardous Area Classification Report - Coal Handling Plant
13/2188564
Hazardous Area Classification Report - Liquids and Gasses
13/2197876
Hazardous Area Classification Schedules for Coal Handling Plant Materials
13/2198200
Hazardous Area Classification - Stanwell Power Station Coal Dust Risk

Assessment & HAC Report
13/2197871
Hazardous Area Classification Schedules - Coal Handling Plant
13/2188358
Hazardous Area Classification Schedules - Liquids and Gasses
13/2188563
Hazardous Area Classification Schedule of Materials - Liquids and Gasses
14/132200
MIG/73441
621013 series
Hazardous Area Equipment List

Electronic Hazardous Area Dossier - SPS
Combustible Dust Classification Drawings
621018 series
Flammable Liquids Classification Drawings
621020 series
Flammable Gas Classification Drawings
T-2681 to T-2685
Hazardous Area Inspection Sheets
QLD WH&S Regulations 2011

QLD Electrical Safety Act 2002
QLD Electrical Safety Regulation 2013
AS 1319:1994
Safety Signs for the Occupational Environment
AS 1915:1992
Electrical apparatus for explosive atmospheres Battery operated

vehicles
AS/NZS 3000:2007
Wiring Rules
AS/NZS 3800:2012
Electrical equipment for explosive atmospheres Repair and overhaul
AS/NZS 4761.1:2008
Competencies for working with electrical equipment for hazardous areas

(EEHA)
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8.0
AS/NZS 60079 Series
Electrical apparatus for explosive atmospheres
HB 13:2007
Electrical equipment for hazardous areas TAFE NSW Technical and

Further Education Manufacturing and Engineering Education Services
Division
Definitions
Area:
A three-dimensional region or space.
Certificate of
Conformity:
A certificate that has been issued for a piece of equipment that provides proof
that it meets manufacturing standards acceptable in Australia.
Classification
Drawings:
Drawings showing the extent of the classified hazardous area. They also have
details of the hazardous material, zone, temperature class and apparatus
group.
Classification of
Hazardous Areas:
Is a method of analysing and classifying the environment where an explosive

atmosphere is present or is expected to be present
Combustible dust:
Dust that can burn or glow in air and could form explosive mixtures with air at
atmospheric pressure and normal temperatures. Combustible dusts include
dusts, fibres and flyings.
Competent
person:
A person who has through a combination of training, education and

experience, acquired knowledge and skills enabling that person to perform
correctly the specified task.
Dust:
Small solid particles in the atmosphere which settle out under their own
weight, but which may remain suspended in air for some time.
EEHA:
Electrical Equipment in Hazardous Areas
Electrical
Equipment:
Means any apparatus, appliance, cable, conductor, fitting, insulator, material,

meter or wire that is used for controlling, generating, supplying, transforming
or transmitting electricity at a voltage greater than extra low voltage or
operated by electricity at a voltage greater than extra low voltage.
Electrical
Installation:
A group of electrical equipment items that are permanently electrically

connected together and can be supplied with electricity. This does not include
items that are works of an entity.
Electrical Risk:
In relation to a person, the risk to the person of death, shock or injury from
electricity or in relation to property, the risk to the property of damage caused
by electricity.
Electrically Safe:
Means that persons and property are free from electrical risk
Electrical Work:
Means connecting or disconnecting electricity supply wiring to electrical

equipment or manufacturing, constructing, installing, removing, adding,
testing, replacing, repairing, altering or maintaining electrical equipment or an
electrical installation.
Electrical
Installation Work:
Means electrical work associated with an electrical installation, but does not
include testing, repairing or maintaining equipment included in the electrical
installation or electric line wok associated with the electrical installation.
Entity Works:
Means the electrical equipment and electric line associated equipment

controlled or operated by the entity to generate, transform, transmit or supply
electricity. SCL generating equipment is deemed to be entity works under this
definition.
Explosive
atmosphere:
Mixture with air under atmospheric conditions, of flammable materials in the

form of gas, vapour, mist, dust or fibres in which, after ignition, combustion
spreads throughout the unconsumed mixture.
Explosion
protection:
Specific measures applied to electrical equipment to avoid ignition of a

surrounding explosive atmosphere.
Doc No: HB625195
Rev: 8
Rev Date: 10.09.2014
Page 13 of 19
Flammable gas or
vapour:
Gas or vapour which, when mixed with air in certain proportions, will form an
explosive gas atmosphere.
Flammable liquid:
Any Class 3.1 or Class 3.2 liquid having a flashpoint of not more than 61 C.
Flammable
material:
Gas, vapour, liquid, dust or solid which can react continuously under
appropriate concentration conditions with atmospheric oxygen and which may
therefore sustain fire or explosion when such reaction is initiated by a suitable
spark, flame or hot surface.
NOTE: Many liquids and solids, though regarded as flammable, nevertheless do not normally burn.
The application of heat to such materials serves to release vapour, which may burn with
atmospheric oxygen. The heat of the subsequent reaction serves to release further vapour for
combustion. Flame may propagate throughout suspensions of dusts by this mechanism.
Free from
electrical risk:
Means that the electrical risk to a person or property has been eliminated, so
far as reasonably practical or if not able to eliminate the electrical risk then the
risk has been minimised so far as is reasonably practicable.
Flyings:
Airborne particles.
HAVD:
Hazardous Area Verification Dossier.
Hazardous area:
An area in which an explosive atmosphere is present or may be expected to

be present, in quantities such as to require special precautions for:
any access or activity that presents an ignition source;
the construction, installation, testing, inspection and use of electrical
equipment;
installing mechanical equipment. (There are no standards yet that
directly govern the installation of mechanical equipment within a
hazardous area i.e. air compressors, conveyor systems).
Hot work:
Welding, thermal, friction or oxygen cutting, grinding, heating and other fireproducing or spark-producing operations that may increase the risk of fire or
explosion.
Ignition source:
Source of energy, which may comprise of naked flames, sparks or hot

surfaces / particles, sufficient to ignite an explosive atmosphere.
Examples of typical sources of ignition from electrical systems and apparatus
include:
electrical arcing / sparking when circuits are switched by devices such
as motor contactors, auxiliary relays, switches and contacts; and
Hot surfaces produced by motors, relay coils, transformers, ballasts,
hot joints, cables, light globes, etc.
Intrinsically safe:
a device termed intrinsically safe is designed to not contain any components

that produce sparks or which can hold enough energy to produce a spark of
sufficient energy to cause an ignition.
Service
Definitions (SDs):
An automatically generated work request from the maintenance management

system.
Thermite reaction:
An aluminothermic reaction in which aluminium metal is oxidised by the oxide

of another metal, most commonly iron oxide.
Wiring rules:
Means: AS/NZS 3000:2007 - Wiring Rules

Note Section 7.7 of the wiring rules outlines the requirement to comply with
the relevant AS/NZS hazardous area standards for classification, equipment
selection, installation and competency.
Worker:
A person who carries out work in any capacity for a business or undertaking.
Zone 0:
An area in which an explosive gas atmosphere is present continuously, or is

present for long periods. Examples may include the vapour space of vented
vessels, vapour space of vented storage tanks and immediately adjacent to a
continuous source of release.
Doc No: HB625195
Rev: 8
Rev Date: 10.09.2014
Page 14 of 19
9.0
Rev. No.
Zone 1:
An area in which an explosive gas atmosphere is likely to occur in normal

operation. Examples may include where pumps are liable to leak under normal
conditions, or where vents, relief valves or sample points are likely to release
vapour into the atmosphere.
Zone 2:
An area in which an explosive gas atmosphere is not likely to occur in normal

operation and if it does occur it will exist for a short period only. Examples
may include where vessels, pumps, compressors and pipes containing
flammable gases and liquids are constructed and maintained to prevent
leakage under normal operating conditions.
Zone 20:
An area in which combustible dust, as a cloud, is present continuously or

frequently, during normal operation, in sufficient quantity to be capable of
producing an explosive concentration of combustible dust mixed with air, and /
or where layers of dust of uncontrollable and excessive thickness can be
formed.
Zone 21:
An area not classified as zone 20 in which combustible dust, as a cloud, is

likely to occur during normal operation, in sufficient quantities to be capable of
producing an explosive concentration of combustible dust mixed with air.
Zone 22:
An area not classified as zone 21 in which combustible dust clouds may occur
infrequently, and persist for only a short period, or in which accumulations or
layers of combustible dust may be present under abnormal conditions and
give rise to combustible mixtures of dust in air. Where, following an abnormal
condition, the removal of dust accumulations or layers cannot be assured then
the area is to be classified zone 21.
Revision History
Rev. Date Revision Description
0-7
8
10.09.2014
Doc No: HB625195
Author
Legacy Hummingbird versions
P Cox
Document revised and updated
P. Cox
Rev: 8
Endorse/Check
Approved By
J. Oliver
B. Perry
Rev Date: 10.09.2014
Page 15 of 19
10.0 Attachments
10.1
Attachment A Routine Inspection and Cleaning SDs
Periodic Electrical Equipment Inspection SDs

SD Number
Description
Frequency
(Weeks)
Compliance
SD
Responsible
Group
1150 - SI34000
U1 IGNITION GAS HAZARDOUS AREA INSPECTIO
208
T5E
1150 - SI34001
208
T5E
1150 - SI34002
208
T5E
1150 - SI34003
208
T5E
1150 - SI34010
LPG IGNITION GAS HAZARDOUS AREA INSPECTIO
208
T5E
1265 - SI44500
HAZARDOUS AREA CHECKS - TOOL STOR
208
T5E
2030 - SI51000
HAZ AREA - FLAM GAS/LIQ STORE, FUEL BOWS
208
T5E
2030 - SI51005
HAZ AREA - SOLVENT ROOM AND DECANTING RO
208
T5E
1105 - SI29520
TRAIN R1 R3 HAZARDOUS AREA INSPECTIONS
208
T5E
1105 - SI29522
SLOT BUNKER HAZARDOUS AREA INSPECTIONS
208
T5E
1105 - SI29524
BUNKER BUILDINGS HAZARDOUS AREA INSPECTIONS
208
T5E
1130 - SI32020
U1 H2 SYSTEM HAZARDOUS AREA INSPECT
208
T5E
1130 - SI32021
208
T5E
1130 - SI32022
208
T5E
1130 - SI32023
208
T5E
1130 - SI32030
H2 SUPPLY AREA HAZARDOUS AREA INSPECTION
208
T5E
2030 - SI51000
MISCELLANEOUS HAZARDOUS AREA INSPECTIONS
208
T5E
Compliance
SD
Responsible
Group
CSC
Routine Cleaning SDs

2030 - 51063
CLEANING - COAL DISTRIBUTION SYS - 12MTH
Frequency
(Weeks)
52
2030 - 51040
CLEANING - COAL DISTRIBUTION SYS - 2WKLY
CSC
2030 - 51051
CLEANING - COAL DISTRIBUTION SYS - 3MTHL
12
CSC
2030 - 51061
CLEANING - COAL DISTRIBUTION SYS - 6MTHL
24
CSC
2030 - 51041
CLEANING - COAL DISTRIBUTION SYS - MTHLY
CSC
2030 - 51112
CLEANING - BOILER HOUSES - 12 MTHLY
52
CSC
2030 - 51110
CSC
2030 - 51111
12
CSC
2030 - 51106
CLEANING - BOILER HOUSES - MTHLY
CSC
2030 - 51023
CLEANING - BOILER HOUSES - WKLY
CSC
2030 - 51103
CLEANING - FDR & SHUTTLE LVLS - 12 MTHLY
52
CSC
2030 - 51046
CLEANING - FDR & SHUTTLE LVLS - 2 WKLY
CSC
2030 - 51038
CLEANING - FDR & SHUTTLE LVLS - 2 WKLY
CSC
2030 - 51102
CLEANING - FDR & SHUTTLE LVLS - 3 MTHLY
12
CSC
2030 - 51101
CLEANING - FDR & SHUTTLE LVLS - MTHLY
CSC
SD Number
Description
The frequency of these SDs is currently under review as part of the conditions of control to reduce the level of risk
carried as there is unrated electrical equipment installed in these areas.
Note: Cleaning inspections SDs are to be created and implemented.
Doc No: HB625195
Rev: 8
Rev Date: 10.09.2014
Page 16 of 19
10.2
Attachment B Managing Electrical Equipment in Hazardous Areas Guide
The purpose of this guide is to provide information to workers to assist with the preparation of Work
Method Statements in relation to managing unrated electrical equipment in Hazardous Areas during the
interim period until compliance of each hazardous area is achieved.
Hazard Identification and Control

Hazard
1. Unrated electrical
equipment
2. Personnel performing
inspections and
maintenance and
repairs in hazardous
areas with unrated
electrical equipment.
3. Personnel performing
electrical fault finding in
hazardous areas with
unrated electrical
equipment
4. Personnel entering a
hazardous area to
inspect the area or
operate equipment
Doc No: HB625195
Control
a) Equipment manuals
b) Documented Periodic close inspections
c) IP Ratings of equipment
d) Routine plant inspections and mechanical maintenance
Examples:
Mechanical valve and connections repairs maintenance for gas systems
Housekeeping
Fuel sources isolated when not in use
e) Documented routine maintenance
f) Sample testing of key electrical aspects (earth bonding and equipotential bonds etc.)
g) Hazardous Area Dossier updated and maintained
h) Plant protection, automated control and alarming
i) Physical location and guarding from damage
a) Periodic plant inspections performed
b) IP Ratings of equipment
c) Personnel complete hazardous area training as specified by AS/NZS 4761
d) Signage
e) Locks where applicable
f) WMS incorporate risks associated with activities e.g. may require the use of a hot
work control guide.
g) Use the Approval & Certification Process Required for Electrical Work in Hazardous
Areas
a) Periodic plant inspections performed
b) IP Ratings of equipment
c) Personnel complete hazardous area training as specified by AS/NZS 4761
d) Signage
e) Corporate Fault Finding Procedure
f) WMS incorporate risks associated with activities e.g. may require the use of a hot
work control guide.
g) Plant operating procedures/instructions
a) Equipment manuals
b) Periodic plant inspections performed
c) Periodic electrical equipment inspections and maintenance
d) IP Ratings of equipment
e) Trained and authorised to perform these tasks as part of the plant familiarisation and
authorisation process (i.e. as per ATW authorisation process, PT training)
f) Signage
g) Locks where applicable
h) WMS incorporate risks associated with activities
i) Documented plant operating procedures/instructions
j) Hazardous area rated tools and equipment used
Rev: 8
Rev Date: 10.09.2014
Page 17 of 19
10.3
Attachment C - Approval & Certification Process Required for Electrical

Work in Hazardous Areas on Entity Works
Situation
Actions by Qualified Electrical Worker for Electrical Equipment in

Hazardous Areas
Unrated equipment is
damaged.
Hazardous Area Safe System of Work Implemented

Repair if possible or replace equipment with like for like component.
Complete mandatory testing, perform close inspection and fill out
Electrical Safety & Test Report and update HAVD
Determine components that require replacement.
Determine if like for like component/s can be obtained.
If like for like component/s can be obtained then obtain and repair
equipment as necessary.
Determine component/s Part/s that require replacement.
If like for like component/s cannot be obtained then determine if
alternate component/s Part/s can be used.
If alternate components/parts are available then seek approval from an
RPEQ Electrical to use them for repairs.
If RPEQ approves use of alternate components/parts, obtain
components/parts and repair equipment as necessary.
Included in the final hazardous area audit for the particular area.
unserviceable
i.e.
Components require
replacement.
(like
for
like
parts
available)
unserviceable
i.e.
Components
OR
Parts
requires
replacement.
(like
for like parts not
available)
10
AS3000
mandatory
tests &
ESTR
required
Hazardous
Area
Equipment
Certificate
required
Audit
required by
an
accredited
hazardous
area
auditor
No
Yes if
circuit
integrity is
altered.
No
No
No
Yes if
circuit
integrity is
altered.
No
No
Yes
Yes if
circuit
integrity is
altered.
No
Yes
disconnected to allow
workshop repairs and
then reconnected on
plant.

Reconnect equipment after repairs.
unserviceable
i.e.
equipment requires
replacement.
Compliant equipment
is available for the
transition period (This

Determine equipment that requires replacement.
If like for like component/s cannot be obtained and alternate
component/s not available.
If alternate equipment is available then seek approval from an RPEQ
Electrical to use it for repairs.
If RPEQ approves use of alternate equipment, obtain equipment and
replace equipment as necessary.
Included in the final hazardous area audit for the particular area.
Yes
Yes if
circuit
integrity is
altered.

Repair if possible or replace equipment with like for like component.
Electrical Safety & Test Report and update HAVD.
Obtain a certificate for any new equipment and include in HAVD.
No
Yes if
circuit
integrity is
altered.

Replace only with appropriately certified equipment.
Obtain a certificate for any new equipment and include in HAVD.
No
is
treated
as
a
replacement only since it is
inserted into a remaining
non-compliant hazardous
area circuit)
Approval
by RPEQ
Electrical
Correctly
equipment
damaged
rated
is
Correctly
equipment
unserviceable
rated
is
Correctly
rated
equipment
is
disconnected to allow
workshop repairs and
then reconnected on
plant.

Reconnect equipment after repairs.
(New) Installation.
New equipment and
circuit installed into a
hazardous area

Install only appropriately certified equipment.
Ensure an accredited auditor audits the electrical installation work
before connection to a source of supply.
Obtain a certificate for the new equipment and include in HAVD.
Compliant Hazardous
Area
As per Act, Regulation, AS/NZS etc.
Doc No: HB625195
Rev: 8
Yes if
circuit
integrity is
altered.
Yes
(Refer s5.1 of
ASNZS
60079.14)
No
Yes
(Refer s5.1 of
ASNZS
60079.14)
No
No
No
Yes
No
Yes
No
No
Yes
Yes to
indicate that
maintenance
has been
performed.
Yes
Yes
Yes
Yes
Rev Date: 10.09.2014
Page 18 of 19
No
(this is
awaiting
clarification)
10.4
Attachment D - Electrical Maintenance and Repair Flowchart
Electrical maintenance or repair work to be

performed on Entity Works in a hazardous
area.
Fill out a Hazardous Area Maintenance & Repair work Form
No
Does the
equipment
require
replacement?
No
Yes
Is the equipment to be worked

on rated for the hazardous area?
No
Yes
Conduct repair,
perform safety tests
& detailed
inspection.
Is like for like

equipment
available?
No
Yes
Yes
Can the
equipment be
repaired?
Does the
equipment
require
replacement?
No
Select appropriately
rated equipment
No
Yes
Is like for like

equipment
available?
Can the
equipment be
repaired?
Yes
Conduct repair,
& detailed
inspection.
Yes
Follow plant change
process to obtain
approval for use.
Replace equipment,
& detailed
inspection
Replace equipment,
& detailed
inspection
Replace equipment,
perform safety tests &
detailed inspection
Forward all completed test reports, forms

and certificates to the Hazardous Area
Technical Person.
After review the Hazardous Area Technical Person will add paperwork to the HAVD
Equipment can now be energised

Notes: For new installation work on an electrical installation or entity works:
Only certified equipment is to be installed by an EEHA competent licenced electrical worker.
On completion of the installation work it is to be tested and a detailed inspection conducted.
An ESO acredited auditor must audit the work before connecting it to a source of supply.
All test sheets, inspection sheets, certificates of conformity, audit reports, etc must be added to the HAVD.
If the work is a disconnect/ reconnect only, fill out a Hazardous Area Maintenance & Repair Work Form then
conduct the work, perform safety tests & detailed inspection and add all completed test reports and forms to
HAVD .
Doc No: HB625195
Rev: 8
Rev Date: 10.09.2014
Page 19 of 19

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Hazardous Areas Stanwell Power Station

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Business Procedure

Hazardous Areas at Stanwell Power Station

Barron Gorge Hydro PS

Mackay Gas Turbine

Wivenhoe Small Hydro PS

WRITTEN BY: ..................................

ENDORSED/CHECKED BY: ..............................

APPROVED BY: ....................................

NAME: Brad Perry

Revision Date: 10.09.2014

THIS DOCUMENT IS UNCONTROLLED IN HARD COPY FORMAT

The identification of hazardous areas.

The maintenance of control measures.

The review of the effectiveness of the applied control measures.

Hazardous Area Safe System of Work

Doc No: HB625195

Rev Date: 10.09.2014

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Doc No: HB625195

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Diminishing Risk Graph

Managing Ignition Sources

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Authorised Modifications to Plant

General Hazardous Area Work

Doc No: HB625195

Rev Date: 10.09.2014

THIS DOCUMENT IS UNCONTROLLED IN HARD COPY FORMAT

3.1.7.1 Electrical Installation Work

3.1.7.2 Maintenance and Repair Work - Electrical

Routine Inspections of Equipment - Electrical

Doc No: HB625195

Rev Date: 10.09.2014

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Process for Managing Unrated Electrical Equipment

Maintaining a Hazardous Area Verification Dossier

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Training and Authorisation of Workers

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Maintaining a Hazardous Area Equipment Register

Doc No: HB625195

Rev Date: 10.09.2014

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Determine the frequency of periodic inspections and the grade of inspections.

Ensure that the HAVD is kept up to date.

Maintain the hazardous area equipment register for the site.

Provide adequate technical support to the skilled personnel.

Check on effectiveness of controls implemented under conditions of control documents.

Doc No: HB625195

Rev Date: 10.09.2014

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Entry required into a classified hazardous area

Perform the activity( i.e. inspections)

Is the entry for a work

Identify hazards and

Perform the work following controls on

Prepare WMS using