This document provides an overview of safety basics for technician training, including general safety, electrical safety, mechanical safety, and preventing spills and overfills. It outlines key safety requirements such as following detailed lockout/tagout procedures, checking that equipment is de-energized before working on it, making sure piping and tanks are properly isolated and drained before work, wearing appropriate protective equipment, attending safety meetings, and being aware of electrical area classifications and their implications. Compliance with comprehensive jobsite safety programs is critical.

1. Technician Training: Safety Basics

2. Safety Basics
o General
o Electrical
o Mechanical
o Preventing Spills & Overfills
o Hazardous Electrical Power and Control

3. o Most of the projects where we participate have excellent jobsite
safety programs
o It is critical that you comply with all aspects of the safety program
 Jobsite specific safety training
 Possible drug test
 Hard hat, safety glasses, gloves, boots, vest, ear protection, &
fall protection over 6 feet
 Lockout & tag out procedures
 Weekly safety meetings
General

4. o Many sites have extensive lockout-tagout procedures with specific rules for
energizing equipment
 These procedures must be strictly followed!
o Control panels can have multiple sources of electrical energy, so that a safety
disconnect may not ensure that all power sources are de-energized within the
panel
 For example, a motor start disconnect may be off, but there may be a signal
sent from a master control panel
o All control panels should be de-energized with the source locked out while
performing any work inside the panel
 Observation of the panel internals while energized may be required and
performed if allowed at the site
 Panel interior should always be check with a voltage detector prior to
any work inside the panel!
Electrical

5. o When performing work on a pump system, a piping system,
or a filter system, confirm that:
 The pipe section or component is isolated by closed
valves
 Any pressure has been drained from the
pipe/equipment
• Fluid has been drained from the pipe/equipment
 Pumps have been locked out
 Proper tools are available
 Fluid cleanup supplies are available
Mechanical

6. o Before fuel enters the tank/pipe/pump system be sure:
 Pipe systems have been pressure tested
 There is a spill kit available
 A fire extinguisher is available
 All applicable inspections and approvals have been performed
o When initially filling pipelines have personnel available to inspect the length of the
pipeline for potential leaks
o When initially filling any tank, continually observe the fluid level in the tank directly
or with a gauge stick
 Do not rely on any electronic equipment
o During startup of pump and filtration, continually observe tank level to assure that
fuel is not transferred inadvertently between tanks with the potential for overfill
Preventing Spills & Overflows

7. o Electrical systems for fuel transfer can be classified as hazardous electrical areas
 Gasoline used in service stations is always a hazardous electrical area
 Diesel fuel at ambient temperature is usually classified as ordinary area
 However diesel fuel when heated or confined within building spaces, may be
classified as hazardous by design or local code
o Electrical classifications for diesel fuel systems can be:
 Ordinary Area: No Risk of Explosion during Normal Operation
 Class 1 Division 2: Risk of Explosion during Upset Condition
 Class 1 Division 1: Risk of Explosion always Present
o Ordinary are systems allow the use of the most standard electrical components
Hazardous Electrical Power & Control

8. o Class 1 Division 2 systems usually exclude spark producing devices (standard
relays/contactors)
 Many PLCs and control components are rated for C1D2 environments, so with some
design medications control panels can meet these standards (motors will be
explosion proof)
o Class 1 Division 1 Systems will require explosion proof control enclosures, motors, and
most conduit accessories along with rigid conduit and conduit seals
o Intrinsically safe:
 Sensors and instruments may be used in C1D1 areas built to an intrinsically safe
standard rather than explosion-proof
 This means that the energy required for the sensor is limited at the controller
to a level insufficient to cause a spark
Wiring must be isolated in separate conduits form other wiring
Hazardous Electrical Power & Control (cont.)