Health and Safety Bae Generation Our energy working for you. General Information (Diesel Sets) English Publication 0908-0110-00 Issue 02-Dec 04Health and Safety Publication 0908-0110-00 General information (Diesel Generator Sets) Issue 02 - Dec ‘04 FOREWORD ‘The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation Limited ‘cannot accept any liability whatsoever for problems arising as a result of following recommendations in this ‘manual The information contained within the menual is based on information available at the time of going to print. In line with Cummins Power Generation Limited policy of continuous development and improvement, information may change at any time without notice. The users shauld therefore ensure that before commencing any work, they have the latest information available. Users are respecttully advised that itis their responsiblity to employ competent persons to carry out any installation work in the interests of good practice and safely. Consult your Authorised Distributor for further installation information. It is essential that the utmost care is taken with the application, installation and ‘operation of any diesel engine due to their potentially hazardous nature. Careful reference should also be made to other Cummins Power Generation Limited literature, in particular the Controller, and the Engine (Operation and Maintenance Manuals, ‘Should you require further assistance contect'- ‘Cummins Power Generation Limited, Columbus Avenue Manston Park Manston Ramsgate Kent CT12 58F Tol. No.: +44 (0) 1843 255000 Fax. No.: +44 (0) 1843 255902 e-mail seamen Web Sites: www.cumminspower.comPublication 0908-01 10-00 Health and Safety Issue 02 - Dec '04 Generat information (Diesel Generator Ses)Health and Safety Publication 0908-0110-00 General Information (Diesel Generator Sets) seve 02 - Dec 04 CONTENTS Section Tile Page 1 14 General information 12 Safety Precautions 124 Engine Waring 13 Generator Plant Safety Code 134 Generator Set Warning Labels. 2 Waming Notes = = 4 24 Waring, Cauton and Note Sve Used This Man 22 Warnings... 224 Electricity 222 High Pressures 223 Maintenance... 224 ‘Supply isolation - 225 Reinstatement of Supply 3. Standards = 34 Radio Frequency... 32 Standards, Codes & Regulations... 33 Build Standards... 4 Safety Precautions 4a General... 42 Electrical Hazards 43 Engine Waste. : 44 Exhaust Gas Hazard: 43 45 Fire Hazards “4 48 Fis 45 47 High Temperature Hazar 45 43 Moving Part Hazards, 49 NOISE nn 5 Substances Hazardous to Health...... S41 5A ‘Aniteeze (Fleetquard — ES compeaiéG emi). “82 S14 Hazardous Reactions 52 512 Protective Measures 52 513 Storage / Transport 52 514 Emergency Action 53 52 Antiteeze (Valvoline coolant premix) 54 524 Hazardous Reactions. 54 522 Protective Measures. 54 523 Storage / Transpor. 54 524 Emergency Action.. 55 53 Antteeze (Valine NPG Godan S056) 56 534 ‘azardous Reactions. 56 532 Protective Measures: 56 533 Storage / Transport. 56 534 Emergency Action. “87 Contents 5 PagetPublication 0908-0110-00 Health and Safety Issue 02 - Dec 04 information (Diesel Generator Sets) Section 54 544 542 543 544 55 55.1 552 553 554 56 5.64 562 563 564 57 S74 572 573 574 584 582 583 584 59 594 592 593 594 5.10 5.10.1 5.10.2 5.10.3 5.104 811 “sad 512 5113 SA14 5.12 5.124 5.122 5.123 5.124 5.13 5.13.4 5.13.2 5.133 5.134 Tit. ‘Antiroeze (Valin = MPG Coolant 67/9). 58 Hazardous Reactions. Protective Measures. Storage / Transport. Emergency Action... Coolant Treatment - Water Fitter Hazardous Reactions. Protective Measures... Storage / Transport Emergency Action... Coolant Treatment - Liquid Hazardous Reactions. Protective Measures Storage / Transport Emergency Action. Gas Oil... Protective Measures ‘Storage / Transport Emergency Action ‘Grease ~ Chevron SRI No. 2. Hazardous Reactions. Protective Measures. Storage/Transport Emergency Action. Grease - Exxon Polyrex® EM Hazardous Reactions... Protective Measures. : Storage/Transpott neem Emergency Action. Grease ~ Kidber Asonic Hazardous Reactions. Protective Measures. Storage/Transport.. Emergency Action, Grease ~ Mobilgrease XTC... Hazardous Reactions. Protective Measures... Storage/Transpor. Emergency Action. Grease -Val-Lith EP Hazardous Reactions. Protective Measures. Storage/Transport Emergency Action. Lubrication Oil - Premium Hazardous Reactions. Protective Measures. ‘Storage / Transport Emergency Action PageHealth and Safety Publication 0908-0110-00 General Information (Diesel Generator Sets) Issue 02 - Dec 04 Section 5.14 5144 5142 5.143 5.144 5.145 5.148 5147 5.15 SAA 5.152 5.153 5.154 5.16 5.16.1 5.162 5.163 5.164 5.165 5.166 CONTENTS (Continued) Tite, ee Sulphur Ack Battary Qualty 1140 ~ 1400 $6 (15-50%) . Hazardous Reactions Protective Measures. ‘Storage / Transport Emergency Action ‘Special Note: Identification of Usage. Special Note: Concentrated Sulphur Aid Special Note: Lead = Potassium Hydroxide ~ Solid Hazardous Reactions Protective Measures. Storage / Transport... Emergency Action, Potassium Hydroxide — Solution Hazardous Reactions... Protective Measures. Storage / Transport. Emergency Action ‘Special Note: Identification of Usage. ‘Special Note: Disposal Cortents PagetPubiication 0908-0110-00 Heettn and Safety Iesve 02 - Dee'4 Gonerat information (Diesel Generator Sets) FHS IS A BLANK PAGE € Page ‘ContentsHealth and Safety Publication 0908-0110-00 Genera ormation (Diesel Generator Sets) Tssue 02 -Dec'04 SECTION 1-INTRODUCTION | 1 Introduction 1.1 General Information 1.2 Personnel engaged in the installation, commissioning, operation and maintenance of generator sets must be competent and experienced In these fields. They must also comply with all relevant and current statutory requirements and regulations, including the provisions of the Health and Safety at Work Act (1974), and any modification and amendment that may subsequently become a legal requirement, together with any local requirements/regulations. Before operating the generator set, read this manual and become familiar with the equipment and its operation (including all controls, manually operated valves and shutdown devices). Cofrect operation and maintenance is essential for safe and efficient operation of this set. Read and become familiar with the Safety Precautions listed in this manual and within any other ‘manuals related to the equipment. Many accidents result from a failure to observe fundamental safety rules and precautions. There are many potential hazards that can occur during the operation of a generator set, which cannot always be anticipated. Therefore a warning cannot be included in the manual Tor every possible circumstance that might Involve a potential hazard. Should a procedure be used that has not been specifically recommended, then the personnel involved must be satisfied that itis safe and will not damage the generator set. Safety Precautions Copy and post these suggestions in potentially hazardous areas. 1.2.4. Engine Warning WARNING: DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE, OR CAN BE, ‘COMBUSTIBLE VAPOURS. ‘THESE VAPOURS CAN BE SUCKED THROUGH THE AIR INTAKE SYSTEM AND CAUSE ENGINE ACCELERATION AND OVER-SPEEDING, WHICH CAN RESULT IN A FIRE, OR AN EXPLOSION. WHERE AN ENGINE, DUE TO ITS APPLICATION, MIGHT OPERATE IN A COMBUSTIBLE ENVIRONMENT, SUITABLE OVERSPEED SHUTDOWN DEVICES MUST BE FITTED. THE EQUIPMENT OWNER AND OPERATOR ARE RESPONSIBLE FOR ‘SAFE OPERATION IN A HOSTILE ENVIRONMENT, CONSULT YOUR AUTHORISED DEALER FOR FURTHER INFORMATION. Beallon 1—nvoduction Page TAPublication 0908-0110-00 ~Dec "Od Issue 02 Health and Safety General Information (Diesel Generator Sets) 1.3. Generator Plant Safety Code 1.3.1 Before operating the ger rator set, read the Operation and Maintenance manuals and become familiar with them and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained, Many accidents are caused by failure to follow fundamental rules and precautions. Generator Set Warning Labels Warning signs are provided on the generator set at the point of risk. To avoid injury, aways take the necessary precautions - as indicated on the sample signs shown below. Caution / Warning. Indicates a risk of personal injury. ‘Caution / Warning of Pressure Hazard. Indicates a risk of personal injury from pressurised fluids. Caution / Waring of Temperature Hazard. Indicates a risk of personal injury from high temperature. ‘Caution / Warning of Radio Frequency Hazard. Indicates a risk of operating radio frequency communications equipment in the vicinity of the generator set, Caution / Warning of High Voltage Hazard. Indicates a risk of personal injury from electric shock. ‘Caution / Warning of High Voltage Hazard. Indicates that earth leads only must be connected at this point. IeSeer Caution. Indicates a risk of personal injury from equipment that may be subject to Automatic Starting. Page 12 ‘Section 1 Induction