Allied Bakeries. The invisible killer electrical safety in the food and drink industry 25/03/2014

Transcription

1 Allied Bakeries The invisible killer electrical safety in the food and drink industry 25/03/2014 Health & Safety 2013/14

2 Introduction to Electrical Controls Mark Baker Company Electrical and Controls Engineering Manager

3 Agenda Introduction to Allied Bakeries A little about me! Electrical safety with in Allied Bakeries Our investment Journey

4 o We employee around 4,000 people across 20 sites Introducing Allied Bakeries o This year, we will produce: 511 m loaves of bread 268 m bread rolls 320 m crumpets 85 m English muffins 230 m pancakes o Annual Turnover c. 450m Bakery Depot Head office

5 We make over 57,000 deliveries a week, covering over 1 million km Transport fleet of 850 vehicles Introducing Allied Bakeries Orders come in on 24 hour and 48 hour lead times 65 million bread baskets delivered annually We deliver to 47 major customers groups and 16 convenience/wholesale buying groups as well as field sales

6 A little about me!

7 Mark Baker 1989 completed my Electrical Goodyear Wolverhampton 1994 Cargill Meats Senior Electrical Engineer 1998 Joined Allied Bakeries as Plant Engineering Manager West Bromwich 2004 Joined Central Engineering Team as Scada Systems Engineer 2008 Company Electrical and Controls Engineer (Company Electrical duty Holder)

8 Managing Electrical Safety

9 The elements of Electrical safety Plant & Equipment People Procedures ECOPs Business Standards Audits

10 Managing Electrical Safety Managing Electrical Safety Electrical Contractors and OEM Suppliers Plant and Equipment Procedures Audits AB Electrical Craft and Managers

11 Equipment 20Buildings 35 HV Systems 720 Mains Distribution Boards 17,991 Distribution Circuits 3642 Control Panels 1971 PLC Systems Biggest CC Link Network outside of Japan

12 People Company Structure Company Electrical Duty Holder 9 Bakeries 10 Depots Head Office 85 Electrical Contractors 9Site Authorised Persons 53 Craft 20 Electrically Trained Managers

13 Electrical Technician tool box Basic electrical core technical competency Behavioural skills Plant knowledge BS 7671 EAW Regulations

14 Procedures Electrical Permit to Work Sanction to Test Electrical Limitations of Access Lock off and Isolation Electrical Audit Process Panel Inspections Competency Interview Competency Test Panel Data Capture PPE and Equipment Issue of Panel Keys Panel Safe System of Work

15 Business Standards

16 Audits

17 People Audits Shift* Days Nights *Circle as appropriate Job Description.. Craftsman. Toolbox Audit Craftsmens Name. Date of audit.. Manager / Chargehand. No. Chargehand / Manager.. Checklist Correct isolation of all hazard sources? Work area kept tidy during work Personal Hygiene ie overalls, hats Is method of working safe? Correct permits being used? Is PP1 being used & signed off? SSOW's being used? Is one needed? Check Cross Skill Notebook content & use? Does engineering carry it? Correct lifting techniques Satisfactory Unsatisfactor y Comments Key Issues Inspect for: Condition of toolbox ( No tape or stickers on outside of box ) Condition of tools. ( No wooden handles allowed ) Cleanliness Contamination Oil / Grease / Blood / Other. Foreign matter. Ensure all small spares i.e. split pins / crimps etc are secured in a box or container Personal items, money, etc Ensure the Engineering handback blue book is present and being used Action Agreed Ratin g (1,2,3) Corrective Action Details Rectified by and date Tools - type and use of Voltage tester & proving unit used? Is it in tool box? PPE being used Audit visible machine condition Work inspected prior to test Work area tidy after completion All guards bolted in place Check for glass items in box, eg torches etc Check condition of drifts and chisels for burrs and remove as req'd Check that gloves are being carried in toolbox Other. Padlock removed Audited by (Manager) Rating Scores: 3 - An item that is in need of correction but which is not judged to be of a serious nature. 2 - An individual item which, if not controlled could pose a risk to product or process integrity and should be corrected at the earliest opportunity. 1 - Any one item that poses a serious risk to product or process integrity and should be corrected immediately.or a number of minor issues which show control of that category has been lost. This form is required for Monday Weekend Review

18 Electrical Audits Sites Audit each other! Site Audit Date Electrical Audits Complete Electrical Audit Total No of Faults Electrical Audits Snags Outstanding Cat 1 Cat 2 Cat 3-4 Glasgow 23/01/2013 Yes Gateshead 15/02/2013 Yes Belfast 30/03/2013 Yes Liverpool 10/06/2013 Yes Stockport 07/07/2013 Yes Stoke 09/10/2013 Yes West Brom 01/04/2013 Yes Stevenage 10/05/2013 Yes Cardiff 10/10/2013 Yes London 22/11/2013 Yes Orpington 01/12/2013 Yes

19 Electrical Panel Audits Panel Rating Panel Energised Personal Protection IP2x IP2x + Perspex Guard Non IP2x Non IP2x Permit For Access Panel Locked

20 Panel Colour Coding

21 How does it all fit together?

22 The Right to work on our systems is? The Right Skills Gives you the Keys Understand and achieve the Standards To our Systems!! ECOPs Certification

23 Our Investment Journey

24 ABF on our investment We continued our capital investment programme to upgrade and modernise the bakeries. The new bread line at our Stockport bakery came on stream in September 2012 and in April this year we opened a new bread line at Walthamstow creating one of the most advanced bakeries in the UK. At West Bromwich another new bread line completed commissioning during the autumn of This is the final stage of a five year investment journey at West Bromwich, which will leave the site as one of the biggest and most modern in the world

25 Our Challenge! On our Investment journey, how do we incorporate the right Electrical Design and Electrical safety into our major investment programme?

26 Engineering Director s Electrical Design Challenges I don t know what I want but I know what I don t want but Ill know what I want when I see it Electricians Grrrr!!!! No armoured Cables no Basket Containment no Cable Tray and.. no Unistrut Best of Luck You just need to get the right density of smoke down the right pipe and make sure you connect the overflow!

27 Allied Bakeries Strategic investment Glasgow Stockport West Bromwich West Bromwich Rolls Stevenage Walthamstow 27

28 Our Challenge? Electrical Design Install and Commission Maintain 28

29 Electrical Design Containment Runs Control Panel & Systems Access Plant and System Isolation IP Rating Cable Protection Power Factor Correction Atex Factors Electrical Design Safety System Rating System Redundancy Lighting of Plant Metering E-Stop Zoning Harmonics Surveys 29

30 Installation and Commissioning Panel Colour Coding System Functionality Checklists Panel Testing System Isolator Tests Contractor Audits Field Wiring Tested System Crash Tests and Recovery Install and Commission Job Audits Stage 1 Sign off Area Control and Request for Access I/O Testing Panel Energise Procedure Permits Contractor Competency Plant and System Isolation 30

31 On going Maintenance Fixed Installation Electrical Testing Planned Preventative Maintenance Maintenance Distribution System Maintenance Thermography 31

32 Other Challenges!!!

33 Project Challenges Stockport Bakery

34 Stockport 11000v Network Upgrade 3km of cable laid and road excavated Allied Bakeries Stockport ENW Cromwell Rd Substation ENW Horsfield Way Sub Station

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36 Project Challenges London Bakery

37 New Switch installed behind the existing 1. Application for increased capacity and substation relocation October Final relocation of HV Substation March Months later!!

38 Easement City of London electrical supply 4 x 66,000 volt cables 900mm below ground

39 Project Challenges West Brom Bakery

40 Electrical Services Moves West Brom West Brom Substation is in the middle of the factory 21 Main Supply Cables running through the Project area 15 shutdowns Electrical Supplies to the following Boiler House Compressor House Muffin Plant Tray Wash Tray Feed Despatch VMU

41 Area effected Sub Station

42 Electrical Services Relocation

43 Existing Cable Routes

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45 Some thoughts to share.. 1. Don t jump process especially when you are in a hurry 2. Develop realistic standards, systems and processes 3. Build a competent organisation 4. Pick the right contractors 5. Manage with rigor, its your neck on the block 6. Trust the numbers they seldom lie 7. Makes decisions when you have to, however difficult 8. Have the courage to lead

46 And Remember It is not as easy as it looks It will take longer than you think It will cost more than you estimated If anything can go wrong it will

47 Thanks for Listening! Health & Safety 2013/14