Introduction to Electrical Controls - IOSH

Health & Safety 2013/14                         

Allied Bakeries

The invisible killer – electrical safety in the food and drink 

industry

25/03/2014

Mark Baker

Company Electrical and Controls Engineering Manager 

Introduction to Electrical Controls

Agenda

• Introduction to Allied Bakeries

• A little about me!

• Electrical safety with in Allied Bakeries

• Our investment Journey

BakeryDepot

Head office

o We employee around 4,000 people across 20 sites

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

Introducing Allied Bakeries

• We make over 57,000 deliveries a week, covering over         1 million km

• Transport fleet of 850 vehicles

• 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

Introducing Allied Bakeries

A little about me!

Mark Baker

• 1989 completed my Electrical apprenticeship @ 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)

Managing Electrical Safety

The elements of Electrical safety

PeoplePlant &Equipment

Audits

BusinessStandards

Procedures ECOPs

Audits

ProceduresP

lant

and

Equ

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ent

Ele

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al C

ontra

ctor

s an

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EM

Sup

plie

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AB

Ele

ctric

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ager

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Managing Electrical Safety

Managing Electrical Safety

720 Mains Distribution Boards17,991 Distribution Circuits

Equipment

20Buildings

35 HV Systems

3642 Control  Panels

1971 PLC SystemsBiggest CC Link Network outside of Japan

People

Company Structure

Head Office

9 Site Authorised

Persons85 Electrical Contractors

20 Electrically Trained Managers

Company Electrical Duty Holder

10 Depots

9 Bakeries

53 Craft

Electrical Technician tool box

Basic electrical core technical competency

Behavioural skills

EAW RegulationsBS 7671

Plant knowledge

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 DataCapture

PPE andEquipment

Issue of Panel Keys

Panel Safe System of

Work

Business Standards

Audits

People Audits

Toolbox AuditCraftsmens Name………………………………. Date of audit.…………………….

Manager / Chargehand……………………….… No.

Key Issues Action AgreedRatin

g (1,2,3)

Corrective Action Details Rectified by and date

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

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.

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.

Shift* Days Nights *Circle as appropriate

Job Description.………………………………….

Craftsman……………………………….

Chargehand / Manager……………………………..

Checklist Satisfactory Unsatisfactory Comments

Correct isolation of all hazard sources?Work area kept tidy during work

Personal Hygiene ie overalls, hatsIs 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

Tools - type and use ofVoltage tester & proving unit used? Is it in tool box?PPE being used

Audit visible machine conditionWork inspected prior to testWork area tidy after completion

All guards bolted in place

Padlock removed

Audited by (Manager)…………………………………………………

This form is required for Monday Weekend Review

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 80 0 17 63

Gateshead 15/02/2013 Yes 214 0 98 116

Belfast 30/03/2013 Yes 36 0 23 13

Liverpool 10/06/2013 Yes 42 0 23 19

Stockport 07/07/2013 Yes 51 0 35 16

Stoke 09/10/2013 Yes 148 0 68 80

West Brom 01/04/2013 Yes 27 0 15 12

Stevenage 10/05/2013 Yes 84 0 67 17

Cardiff 10/10/2013 Yes 73 0 60 13

London 22/11/2013 Yes 84 0 44 40

Orpington 01/12/2013 Yes 21 0 11 10

Electrical Panel AuditsIP2x + Perspex Guard  Non IP2x Non IP2xIP2x

Panel Energised

Panel Rating

PersonalProtection

Permit ForAccess

Panel Locked

Panel Colour Coding

How does it all fit together?

The Right to work on our systems is?

The Right Skills

ECOPs

Certification

Understand and achieve the Standards

Gives you the Keys

To our Systems!!

Our Investment Journey

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 2013. 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” 

Our Challenge!

On our Investment journey,

how do we incorporate the right Electrical Design and Electrical safety

into our major investment programme?

Engineering Director’s Electrical Design Challenges

“Electricians Grrrr!!!!”

“You just need to get the right density of smoke down

the right pipe and make sure you connect the

overflow!”

“No armoured Cablesno Basket Containment no

Cable Trayand……..

no Unistrut”

“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”

“Best of Luck”

27

Allied Bakeries Strategic investment 

• Glasgow• Stockport• West Bromwich• West Bromwich Rolls• Stevenage• Walthamstow

28

Electrical Design Install and Commission Maintain

Our Challenge?

29

Electrical Design

Electrical Design

Control Panel & Systems Access

E-Stop Zoning

IP Rating

Safety System Rating

Containment Runs

Cable Protection

AtexFactors

Lighting of Plant

System Redundancy

Harmonics Surveys

Power Factor Correction

Metering

Plant and System Isolation

30

Installation and Commissioning

Install and Commission

Contractor Competency

Panel Colour Coding

Panel Energise Procedure

Panel Testing

Area Control and Request for Access

Field Wiring Tested

I/O Testing

System Functionality Checklists

Stage 1 Sign offSystem Crash Tests

and Recovery

System Isolator Tests Contractor Audits

Job Audits

Permits Plant and System Isolation

31

On going Maintenance

Maintenance

Fixed Installation Electrical Testing

Thermography

Planned Preventative Maintenance

Distribution System Maintenance

Other Challenges…!!!

Project Challenges Stockport Bakery

Allied Bakeries Stockport

ENW Cromwell Rd Substation

ENW HorsfieldWay Sub Station

Stockport 11000v Network Upgrade – 3km of cable laid and road excavated

Project Challenges London Bakery

New Switch installed behind the existing

1. Application for increased capacity and substation relocation October 2011

2. Final relocation of HV Substation March 2013

17 Months later!!

Easement – City of London electrical supply

4 x 66,000 volt cables 

900mm below ground

Project Challenges West Brom Bakery

• 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

Electrical Services Moves West Brom

Area effected

Sub Station

Electrical Services Relocation

Existing Cable Routes

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

And Remember

It is not as easy as it looks

It will take longer than you think

If anything can go wrong it will

It will cost more than you estimated

Health & Safety 2013/14                         

Thanks for Listening!