Electrical Maintenance: How Does This Affect Your Company?
Electrical Maintenance: How Does This Affect Your Company?
Electrical Maintenance: How Does This Affect Your Company?
Risk Assess Consider loss prevention issues when designing the programmes.
This could include special focus on critical machinery, (process bottlenecks), or hazardous
process machinery that could cause a safety issue or a fire if they fail catastrophically.
Certified Only install certified electrical equipment. Also ensure all circuits are certified
to the current European standards when they are newor when they are modified.
Evaluate Evaluate the usage and importance for all electrical equipment when
considering the periodic maintenance schedules.
Evaluate
What shouldyour company do/ have?
PortableAppliances ReportingFaults
Manufacturers
Recommendations
MaintenanceProgrammes
Poor Housekeeping Certified RiskAssess
www.tokiomarine.eu
Andwhat couldhappento
your company if youdont take
thesesteps?
This document highlights thebasic
requirements neededtoproduce
aneffectiveelectrical maintenance
programme, andemphasises
theneedfor companies tocarry
out a well balancedprogramme
basedonmanufacturers
recommendations, legislative
requirements andyour own
standards. Theconsequences
of a fire, especially incritical
equipment, couldprove
disastrous for any business.
For further informationon
Electrical Maintenance please
contact your local TokioMarine
Europeofficeor contact the
Risk EngineeringAdministrator
TokioMarineEuropeLimited
60GracechurchStreet
LondonEC3V0HR
Telephone+44(0)2073983133
Electrical
Maintenance
Member of the Association of British Insurers
Authorised by the Prudential Regulation Authority and regulated by the
Financial Conduct Authority and the Prudential Regulation Authority Firm Reference Number 202574
Registered Office: 60 Gracechurch Street, London EC3V 0HR Registered Number: 989421 England
In all businesses changes occur when
modifications are made to the facility,
process, equipment or personnel.
The most radical changes occur during
major construction projects, whereas
changes in process, equipment or personnel
can be much more subtle. All such changes
must be managed carefully to ensure they
do not introduce newhazards that could
increase the risk of property damage or
business interruption in the facility.
Poorly managed changes could result
in a catastrophic fire or another type
of loss.
Howdoes this affect your company?
Management of Change
Why does this affect your company?
Changes large enough to be considered
capital projects are obvious candidates
for Management of Change (MOC)
procedures. The construction of a newplant
or extension to an existing facility should
always be subject to MOCprocedures.
An example would be the inadequate space
separation leading to potential fire exposure
and increased business interruption loss.
Changes involving smaller and less obvious
projects can also cause unexpected losses.
An example of this could be changing the
type of adhesive used on a production line
froma non flammable, (often expensive), to
a much cheaper type that is solvent based
and flammable. This change will require
fume extraction, earth bonded safety
dispensers, storage in a specially designed
cupboard, and explosion rated electrical
equipment within the vicinity of application.
Suddenly a small change of the adhesive
introduces a number of additional hazards.
If these are not managed correctly and risk
engineered, they will increase the fire risk
in the facility significantly.
Detailed beloware the main key features required for
an effective Mangement of Change system:
Establish appropriate and consistent terminology
Keep the procedure simple and easy to understand
Define roles and responsibilities
Define the scope of the MOCsystem
Integrate MOCwith company policies
Establish requirements for reviewand authorisation
Issue guidelines for key MOCissues
Develop a written description of the MOCsystem:
Howto identify likely change situations
Establish request for change reviewand approval procedures
Design MOCsystemdocumentation
Define training requirements
Develop communication between the MOCteamand senior management
Provide adequate training for the specific roles and responsibilities in the
MOCsystem
The most important factor is that the systemshould become part of the companys
operating procedures.
Andwhat couldhappento
your company if youdont take
thesesteps?
Inorder for this typeof programme
tosucceedit is essential that
management demonstrate
leadershipandcommitment.
TheMOCprocess must beprovided
withadequateresources. As with
most aspects of loss prevention
andcontrol, it is essential senior
management understandwhat
is at stakeif things gowrong.
For further informationon
Management of Changeplease
contact your local TokioMarine
Europeofficeor contact the
Risk EngineeringAdministrator
TokioMarineEuropeLimited
60GracechurchStreet
LondonEC3V0HR
Telephone+44(0)2073983133
What shouldyour company do/ have?
Management of
ChangeProcess
Safer Alternative Whenever considering changes always look for the solutions that
are inherently safer. It is better to eliminate a hazard than try to reduce the risks through
physical changes or procedures.
Contact Advise your local Tokio Marine Europe office of the proposed changes. The
assigned risk engineer will then provide valuable and cost effective loss prevention advice.
Project Review Once a project has commenced, Tokio Marine Europe will formally
reviewthe drawings and relevant information.
Monitor Establish a procedure for the audit of the MOCprocedure to measure the
performance and effectiveness. It should be recognised that all changes will not require
the same level of review. Plant personnel should examine randomexamples and verify
that the MOCprogramme was correctly implemented. If the systemhas not been
applied correctly or it has not been effective then suitable actions should be taken to
rectify the issue.
Integration Integrate the MOCprocedures into existing plant and operating processes.
The safety procedures should not be compromised and need to be analysed before
implementation.
Guidelines Written guidelines should be produced and implemented for the MOC
system. These should address roles, responsibilities, scope and activities. The procedures
should incorporate technology, equipment, facilities, chemicals, health and safety, loss
prevention, fire protection, temporary changes, acceptance testing, and verification testing.
Request for Change Establish a procedure for requesting and managing changes.
Simple flowcharts with accompanying written procedures will simplify the process and
help to ensure implementation. The change process should allowfor relevant reviews,
actions and approvals before a change is implemented.
References
FireRisk Assessment
HMGovernment 2006
www.tokiomarine.eu
Request for Change Safer Alternative Contact
Project Review
Management Monitor IntegratetheMOCSystem
DevelopGuidelines
Member of the Association of British Insurers
Authorised by the Prudential Regulation Authority and regulated by the
Financial Conduct Authority and the Prudential Regulation Authority Firm Reference Number 202574
Registered Office: 60 Gracechurch Street, London EC3V 0HR Registered Number: 989421 England
Disabledfirealarmpanel
Sprinkler control valvesets
Impairments toFireSystems
An impairment is a partial or complete
isolation of any type of fire protection or
detection systemwhich is installed within
your premises. It can also be applicable for
security systems.
The essence of this process is to ensure
that the impairments are only carried out if
absolutely necessary, and are monitored to
ensure that the systemis reactivated at the
earliest opportunity. It is essential that all
impairments of critical fire systems are kept
to the absolute minimumin terms of scope
and duration.
The Tokio Marine Europe Impairment
Systemcovers all the key elements to
consider in order to carry out an impairment
safely and quickly. It is strongly
recommended that you contact Tokio
Marine Europe if you have any questions
about an impairment that you need to
implement. Our risk engineers will be able
to provide further advice and guidance
based on their experience to help limit the
duration and scope of an impairment.
Howdoes this affect your company?
Why does this affect your company?
While planned impairments may be
necessary during day to day maintenance
and projects, it must be understood that
if part or all of the fire protection system
is impaired then the facility is at risk.
The fire protection systems are there
because occupancy or process hazards have
been identified and the fire risks associated
with these need to be minimised. When an
impairment occurs, whether it be accidental
or planned, it is necessary to minimise the
risks. These may include arranging
temporary protection, reducing the hazards
and managing the impairment to ensure that
the impairment is restored in the shortest
possible time.
There are three types of impairments that
occur: the first being a planned impairment;
the second being an emergency
impairment; and the third and most
dangerous is the hidden impairment.
Obviously, it is preferable to have a planned
impairment with time to prepare. However,
when unforeseen circumstances occur it is
essential that when a systemis isolated
due to a problemor fault, that it is not left
and forgotten about.
Planned impairments are implemented
during maintenance or projects, or if a fire
systemneeds to be extended / isolated.
Whatever the reason for the impairment,
good planning means that the risks can
be minimised. In order to minimise the
duration of planned impairments all
required materials and parts should be
on site before isolating the system.
Emergency impairments tend to be
at a time of routine testing where an
impairment has been discovered, or a
fire systemneeds to be shut down in
an emergency.
Hidden impairments are ones that
no one is aware of or that have been
forgotten. Correct application of the
Tokio Marine Europe Impairment System
could help reduce the risk of hidden
impairments. Such hidden impairments
do occur, and if a systemis isolated it will
not extinguish a fire or raise the alarm.
www.tokiomarine.eu
Andwhat couldhappento
your company if youdont take
thesesteps?
Therehavebeenmany highprofile
incidents wherefireprotection
systems hadbeenisolatedand
thebuildingor facilities werelost.
In1988thePiper Alfa oil andgas
platformintheNorthSea hada gas
explosionona compressor andthe
firespreadquickly. Theplatform
was fully protectedwitha deluge
system, but thefirepumps had
beenimpairedwhilesomedivers
hadbeencarryingout maintenance
earlier intheday. Twoengineers lost
their livestryingtoreachthesprinkler
pumpcontrol panel toturnthem
backon. Intheend, over 160people
lost their lives inthis oneincident.
Toobtaincopies of theTokio
MarineImpairment Systemplease
contact your local TokioMarine
Europeofficeor contact the
Risk EngineeringAdministrator
TokioMarineEuropeLimited
60GracechurchStreet
LondonEC3V0HR
Telephone+44(0)2073983133
ResponsiblePerson
What shouldyour company do/ have?
Safer Alternative
TokioMarineEurope
Impairment System
OneImpairment
FireBrigade/ Emergency
ResponseTeam
Manual FireFighting
Equipment
Training Notification
Impairment
Safer Alternative Consider whether the fire systemneeds to be shut down to complete
the job or could another method be implemented to ensure that the systems remain
operational.
Tokio Marine Europe Impairment System Apply the Tokio Marine Europe Impairment
Systemor an equivalent systemand limit the permit validity to one shift only. This should
apply to employees as well as contractors, and should formpart of the risk assessment
undertaken for the impairment. Hot work, smoking and hazardous operations should not
be permitted in the affected area during the impairment.
Training All people involved with impairment activities should be fully trained and
educated on implementing impairment handling procedures, together with the possible
hazards associated with them.
Manual Fire Fighting Equipment Fire hoses should be laid out and connected,
(if not impaired), and / or additional fire extinguishers should be positioned in the area
of the impairment. The person undertaking the impairment should be trained in the
use of this equipment.
Responsible Person There should be dedicated site employees with the authority and
knowledge to issue an impairment system. Contractors should not be allowed to issue
any impairment system, and they should be fully supervised on site. Where possible
plans should be developed to allowrapid reinstatement of the fire systemin the event
of an incident.
References
TokioMarineEuropeImpairment System availableinEnglish, French,
GermanandSpanish
NFPA25 InspectionandTestingof Water BasedProtectionSystems
Member of the Association of British Insurers
Authorised by the Prudential Regulation Authority and regulated by the
Financial Conduct Authority and the Prudential Regulation Authority Firm Reference Number 202574
Registered Office: 60 Gracechurch Street, London EC3V 0HR Registered Number: 989421 England
Hot work is any temporary operation that
produces open flames, sparks or heat.
Hot work activities include
Brazing and soldering
Grinding and cutting using disc grinds
Use of blowlamps / blowtorches
Welding or cutting using gas or
electric equipment
Use of bitumen / tar boilers
Many serious fires have occurred during
construction or maintenance activities
where hot work was carried out on either
the fabric of the building or machinery
within the facilities. These fires could
have been prevented if the sites had
operated an effective hot work permit
systemand personnel were trained
on howto deal with the hazards of
hot work.
The Tokio Marine Europe Hot Work Permit
covers all of the key elements of a good
system. Every facility is different, so it is
strongly recommended that each site
develops their own procedure covering any
specific on site hazards in addition to the
core attributes of the Tokio Marine Europe
system. If you have a question about any
hot work procedure you need to carry out
please contact Tokio Marine Europe.
Howdoes this affect your company?
Hot Work
Number of Serious Hot Work Fires intheUK Total Losses DuetoSerious Hot Work Fires (m) intheUK
14
12
10
8
6
4
2
0
2001 2002 2003 2004 2005
14
12
10
8
6
4
2
0
2001 2002 2003 2004 2005
Source Fire Prevention & Fire Engineers Journal June 2007 Source Fire Prevention & Fire Engineers Journal June 2007
Why does this affect your company?
One of the major causes of industrial fires
is hot work. It is also commonly recognised
that a large percentage of hot work fires
are started by external contractors who
are appointed to undertake maintenance
activities. This percentage is likely to
increase as more and more facilities
sub-contract everyday maintenance
activities to third party companies. The
employees of these companies are
sometimes not aware of specific on site
hazards such as combustible construction,
which could be exacerbated by hot work.
In the period 2001-2005, the FPArecorded
forty-two serious hot work fires resulting in
an estimated loss of 19 million. Seventeen
of these fires occurred in roof spaces whilst
five occurred in workshop areas.
Many sites believe it wont happen to them,
but unfortunately the lawof averages
dictates otherwise. Once people have been
suitably trained, the application of safe hot
work practices should become second
nature and integrated.
Andwhat couldhappento
your company if youdont take
thesesteps?
TokioMarineEuropesuffereda
major loss in2002whena fully
sprinkler protectedwarehousewas
destroyedby fireduetohot work
beingperformedwhilst thesprinkler
systemwas isolated.
Toobtaincopies of theTokioMarine
EuropeHot Work Permit please
contact your local TokioMarine
Europeofficeor contact the
Risk EngineeringAdministrator
TokioMarineEuropeLimited
60GracechurchStreet
LondonEC3V0HR
Telephone+44(0)2073983133
References
TokioMarineEuropeHot Work
Permit availableinEnglish, French,
German, SpanishandItalian
FireProtectionAssociation,
Hot Work Permit Scheme
ISBN190279019-7
FireProtectionAssociation, Hot Work
Risks DVD www.thefpa.co.uk
NFPA51B Standardfor Fire
PreventionDuringWelding, Cutting,
andOther Hot Work www.nfpa.org
ResponsiblePerson
What shouldyour company do/ have?
Safer Alternative FireWatch
Training Removal of Combustibles
Manual FireFighting
Equipment
FireProtection/ Detection Permit
Safer Alternative Only use hot work as a last resort. For example, can cold cutting
techniques be employed such as a reciprocal sawto eliminate torch cutting, can
mechanical fixings be used instead of welding, can pipe be joined using threaded
connections as opposed to welding, can the hot work be undertaken outside of the
facility in the yard area?
Fire Watch This should be continuous during the work and for at least one hour after
completion of the work. In addition regular monitoring of the area should take place for
at least a further three hours. The majority of hot work fires smoulder for a number of
hours before escalating into a more serious incident.
Permit Apply the Tokio Marine Europe Hot Work Permit or an equivalent permit and
limit duration of permit validity to one shift. This should apply to employees as well as
contractors and should formpart of the risk assessment undertaken for the work.
Fire Protection / Detection All fire protection / detection systems should remain
operational during periods of hot work unless there is a danger that the systemcould be
accidentally actuated. If a systemhas to be isolated, then the unprotected area should be
as small as possible and the systemshould be reinstated as soon as possible after the hot
work is completed. The Tokio Marine Europe Fire Protection Impairment Formshould be
used when isolating fire protection systems.
Manual Fire Fighting Equipment Fire hoses should be laid out and connected and / or
fire extinguishers should be positioned in the area of hot work. The person undertaking the
fire watch should also be trained in the use of this equipment.
Training All people involved with hot work activities should be fully trained on the
possible hazards.
Responsible Person There should be dedicated site employees with the authority and
knowledge to issue hot work permits. Contractors should not be allowed to issue hot work
permits and they should be fully supervised on site.
www.tokiomarine.eu
Hot Work
Member of the Association of British Insurers
Authorised by the Prudential Regulation Authority and regulated by the
Financial Conduct Authority and the Prudential Regulation Authority Firm Reference Number 202574
Registered Office: 60 Gracechurch Street, London EC3V 0HR Registered Number: 989421 England
Flammable liquids are used in many
different operations within the workplace
and create a special fire and explosion
hazard. The liquid itself and the vapours
generated can potentially cause significant
property damage, injury and death if
adequate safety measures are not
implemented.
Aflammable liquid is any liquid that has
a closed cup flash point below55Cand
can be further sub-categorised as
extremely flammable, highly flammable
or flammable depending on the flash point.
Flammable liquids such as petrol, solvents
and heating fuels not only provide a ready
ignition source for a fire to start, but also
contribute to the growth and spread of a
fire once it has started. Consequently,
flammable liquids require specific control
measures in relation to their safe use,
handling, storage and transportation.
Tokio Marine Europe has specialist
knowledge in the field of loss prevention
engineering and we would strongly
recommend that you contact us if you
have any questions about the safe use
and handling of flammable liquids in
your workplace.
Howdoes this affect your company?
FlammableLiquids Handling
Legislation&Guidance
Health&Safety at Work Act 1974
Management of Health&Safety at Work Regulations 1992
Highly FlammableLiquids &LiquefiedPetroleumGases Regulations 1972
Control of Substances Hazardous toHealth(COSHH) revised2002
Chemical (HazardInformation&Packagingfor Supply) Regulations 1994
Dangerous Substances &ExplosiveAtmospheres Regulations 2002(DSEAR)
Extremely flammable Any liquid which
has a flash point below0C.
Highly flammable Any liquid which
has a flash point between 0Cand 21C.
Flammable Any liquid which has a flash
point between 21Cand 55C.
Flash point The lowest temperature of
a liquid at which point ignitable vapours
are given off in sufficient concentration to
forma combustible mixture with air near
the surface of the liquid.
This is a direct measure of a liquids volatility.
The lower the flash point, the greater the
volatility and the greater the risk of fire.
N.B. Flammable liquids with a flash point
above 55Cthat are handled at temperatures
above their flashpoints may also present a
fire and explosion hazard.
Why does this affect your company?
Many serious fires have occurred in
industrial premises where flammable liquids
have either been used in the production
processes or stored on site. These fires
could have been prevented if the company
had effective procedures in place for
preventing, protecting and responding to
incidents involving flammable liquids.
Flammable liquids are categorised as
extremely flammable, highly flammable
or flammable depending on the flash
point of the particular liquid, (consult the
Material Hazard Safety Data Sheet issued
by the manufacturer / supplier).
References
Health&Safety Executive(HSE)
GuidanceSeries publications available
fromHSEBooks on01787881165,
websitewww.hsebooks.co.uk:
Thesafeuseandhandlingof
flammableliquids HSG140
Thestorageof flammableliquids
incontainers HSG51
Thestorageof flammableliquids
intanks HSG176
Thesprayingof flammableliquids
HSG178
Dangerous Substances &Explosive
Atmospheres Regulations 2002.
ApprovedCodeof Practiceand
Guidance L138
Themainconsiderations when
dealingwithflammableliquids in
theworkplaceare:
Environment inwhichthe
flammableliquidis beingused
For example, is it beingheated,
is it pressurisedfor paint, is it
beingusedinareas proneto
electrostatic discharges, is it being
usedina closedenvironment or
somewherewithadequate
ventilation, or does theliquid
react withother liquids badly?
Potential ignitionsources
For example, nakedflames, hot
work, smoking, electrical lighting,
power circuits, heatingequipment,
processes that involvefrictionor
generatesparks, hot surfaces,
static electricity.
Firedevelopment
Howthefirecouldstart, continue
togrow, spread, becontrolled
andextinguished.
For further informationon
FlammableLiquids Handlingplease
contact your local TokioMarine
Europeofficeor contact the
Risk EngineeringAdministrator
TokioMarineEuropeLimited
60GracechurchStreet
LondonEC3V0HR
Telephone+44(0)2073983133
ResponsiblePerson
What shouldyour company do/ have?
Safer Alternative Pre-incident FirePlan
Training
Separationand
Containment
Manual FireFighting
Equipment
FireProtection/ Detection EmergencyResponse
Pre-incident Fire Plan This should be developed and issued to the fire brigade to provide
themwith details of the building location, layout, construction, flammable liquids on site,
water supplies, fire protection and detection systems, venting arrangements and
emergency organisation.
Separation and Containment Areas where flammable liquids are handled or stored
should be fire separated fromother areas of the building in a well ventilated area
constructed to contain any accidental release of the flammable liquids. Where possible,
this roomshould be located on an external wall with additional direct access fromoutside
the building. Small quantities in the workplace should be kept in specially designed safety
cans and stored in a Flammable Liquids Cabinet.
Emergency Response This is a written document that includes contact with the fire
brigade, trained fire squad to tackle incipient fires (if safe to do so), isolation of plant and
utilities safely, and evacuation of the building.
Fire Protection / Detection It is essential that all fire protection / detection systems are
kept operational at all times and any impairments carefully managed to ensure minimum
down time. Fire protection systems should also be designed to adequately protect
flammable liquids.
Manual Fire Fighting Equipment Fire hoses and hand held fire extinguishers should
be readily available. This equipment should be sited in a prominent location and provided
with signage to explain the type of fire that can be extinguished with the equipment.
Staff should be familiar with the operation of this equipment in their area of work
Near Miss and Loss Reports All reports should be recorded and reviewed to highlight
deficiencies. Actions to prevent similar situations occurring should be shared within the
company and additional training provided where necessary.
Training and Education All people involved with impairment activities should be fully
trained and educated on implementing impairment handling procedures and the possible
hazards associated with them.
Record and Maintain Results Routine monitoring and evaluation of the inspection
results by management can help to highlight recurring problems. This will ensure that
prompt corrective actions are taken to address unsatisfactory conditions that could lead
to property damage or business interruption.
FireSafety
Inspections
Member of the Association of British Insurers
Authorised by the Prudential Regulation Authority and regulated by the
Financial Conduct Authority and the Prudential Regulation Authority Firm Reference Number 202574
Registered Office: 60 Gracechurch Street, London EC3V 0HR Registered Number: 989421 England