9

IndlanOil
Yea f'
INNOVATION
& TECHNOLOGY
of

Inter office Memo

CO/HSE/08 24.03.2017

From: GM I/C (HSE),CO, New Delhi

For: ED (HSE),Mktg. HO, Mumbai,

ED, BD (Petrochemical)
ED, BD (Gas)
GM (HSE), RHO, New Delhi
GM (MWO), R&D Centre, Faridabad
GM (HSE), PLHO, NOIDA

Sub: Electrical Safety Booklet.

As you are aware that electricity is the lifeline of any industry but can also be a major hazard for
potential injuries and even death for individuals working on it. With a view to re-emphasize on
the same, an Electrical safety booklet has been developed to act as a guide covering the key
aspects pertaining to electrical safety and requirements thereof.

Though employees may be aware of safety procedures and practices from the perspective of
electrical work, the purpose of this Electrical Safety handbook is to refresh the same and
enhance electrical safety awareness and mitigate electrical hazards to employees, the public,
and the environment.

This will also help in attaining our goal of Zero Tolerance towards electrical accidents and
enhance safety culture within the organization.

The same has also been uploaded on the Corporate HSE intra net website. It is requested to
circulate the same to all concerned locations to adopt the same to benefit in terms of increased
electrical safety. A line of confirmation on its circulation to all concerned may please be
intimated to us.

Cc: Sh. P. Jayadevan, GM (CH Sectt.): For Kind information.

 1
ELECTRICAL SAFETY HANDBOOK
 Chapter Title Page no.
1.0 Safety Policy 4-5
2.0 Purpose 6

priority
3.0 Introduction to Electrical 7-13
Safety has Safety
4.0 Identifying the Hazards 14-20
over Operations continuity, 5.0 Statutory Requirements 21-22
equipment damage or 6.0 Hazardous (Classified) 23-27
economics locations
7.0 Earthing 28-31
8.0 Work Permit System 32-33
9.0 Lock out/Tag out 34-35
10.0 Personnel Protective 36-37
Equipments and Devices
2
ELECTRICAL SAFETY HANDBOOK
 Chapter Title Pge No.
11.0 Safety Instructions
a Cables 38-40
b Sub Stations 41
c Transformer 42-43
You have the d Circuit breakers 43

Power e Metal clad Switch gear and

Control panel
44

f Capacitors 45
to follow Electrical g Storage batteries 46
Safety. 12.0 Electrical Maintenance and 47-48
its relation with safety
13.0 Static Electricity 49-51
14.0 First Aid 52-23
15.0 Housekeeping 54-55
16.0 Dos And Donts 56-59

3
ELECTRICAL SAFETY HANDBOOK
 1.0 Safety Policy
Indian Oil Corporation is committed to conduct
business with strong environment conscience ensuring
sustainable development, safe workplaces and
enrichment of quality of life of Employees, Customers
and the Community. We, at Indian Oil, believe that
good H, S&E performance is an integral part of
efficient and profitable business management. We
shall:

Establish and maintain good standards for safety of

the people, the processes and the assets.

Comply with all Rules and Regulations on Safety,

Occupational Health and Environmental Protection.
Plan, design, operate and maintain all facilities,
processes and procedures to secure sustained Safety,
Health and Environmental Protection.

Remain trained, equipped and ready for effective

and prompt response to accidents and emergencies.
4
ELECTRICAL SAFETY HANDBOOK
 Welcome audit of our H, S&E conduct by external
body, so that stakeholder confidence is safeguarded.

Adopt and promote industry best practices to avert

accidents and improve our H, S&E performance.

Remain committed to be a leader in Safety,

Occupational Health and Environmental Protection
through continuing improvement.

Make efforts to preserve ecological balance and

heritage.

5
ELECTRICAL SAFETY HANDBOOK
 2.0 Purpose
This Electrical Safety handbook aims to:

Provide increased awareness of safety issues

faced by individuals who work on or near
Electricity can be a electrical equipment, as well as system operators
Provide safety guidelines to be used for
silent co-worker or a protecting individuals from potential injuries and
even death caused by electrical hazards
deadly hazard. Though employees may be fully aware of safety
Choice is yours. procedures and practices from the perspective of
electrical work, the purpose of this Electrical Safety
handbook is to refresh the same and enhance electrical
safety awareness and mitigate electrical hazards to
employees, the public, and the environment.

6
ELECTRICAL SAFETY HANDBOOK

Remember, electricity is a fire source too
7
ELECTRICAL SAFETY HANDBOOK
3.0 Introduction to Electrical Safety
Every year, workers are injured or killed by
circuits they thought were safely turned off.
These injuries are not isolated to any one
industry or field of work. They could happen to
anyone when they least expect it. Anyone can be
exposed to the dangers of electricity while at
work and everyone should be made aware of the
dangers.
Those most at risk include maintenance staff,
those working with electrical plant, equipment
and machinery, and people working in harsh
environments such as construction sites.
Workers often find themselves in
environments where they are exposed to unseen
electrical hazards.
 Most electrical accidents occur because
individuals:

are working on or near equipment which

is thought to be dead but which is, in fact,
live

are working on or near live equipment

without adequate training or appropriate
protective equipment, or they have not
taken adequate precautions

misuse equipment or use faulty electrical

equipment.

8
ELECTRICAL SAFETY HANDBOOK
 In other words, Electrical accidents, when initially
studied, often appear to be caused by circumstances
that are varied and peculiar to the particular
incidents involved. However, further consideration
What is the best way to prevent the usually reveals the underlying cause to be a
combination of three possible factors:
hazards of electricity?
Work involving unsafe equipment and
Stop - Before Action installations;
Think - Risks/Hazards Workplaces made unsafe by the environment;
Options - LOTO and
Protection - Proper PPE Unsafe work practice.
Avoiding energized circuits is the safest way!
The first two factors are sometimes considered
together and simply referred to as unsafe
conditions. Thus, electrical accidents can be
generally considered as being caused by unsafe
conditions, unsafe work performance or, in what is
usually the case, combinations of the two.
9
ELECTRICAL SAFETY HANDBOOK
 It should also be noted that inadequate maintenance
can cause equipment or installations that were
originally considered safe to deteriorate, resulting in
an unsafe condition.

Some unsafe electric equipment and installations

can be identified, for example, by the presence of
faulty insulation, improper grounding, loose
connections, defective/ broken parts, ground faults in
equipment, unguarded live parts, and underrated
equipment. The environment can also be a
contributory factor to electrical accidents in a number
of ways.
Environment containing flammable vapors/ gases,
liquids ; areas containing corrosive atmospheres; wet
and damp locations are some unsafe environments
affecting electrical safety.

Unsafe acts include the failure to de-energize

electric equipment when it is being repaired or
inspected or the use of tools or equipment too close
10 to energized parts.
ELECTRICAL SAFETY HANDBOOK
 Following Safety Management principles should
improve the safety of the workplace:
1. Define Work Scope

5 Step Safety method a. Ensure that work is adequately planned through an

approved work control process;
b. Plan and analyze for safety in each step of a project;

Scope
c. Conduct a pre-job briefing; and
1. Define Work d. In case of change, scope and conditions due to
change be defined.
2. Identify the hazards 2. Identify the hazards

controls
a. Refer to system drawings and perform system walk
downs with workers;
3. Establish b. Identify potential hazards;
c. Maintain electrical equipment in accordance with

safely
the manufacturers instructions; and
d. Post electrical hazard warning labels.
4. Perform the work
3. Establish controls
5. Feedback a. Use properly rated test equipment and verify its
condition and operation before and after use;
b. Know and practice applicable emergency
11 procedures;
ELECTRICAL SAFETY HANDBOOK
 c. Become qualified in CPR and first aid and maintain
current certifications;
d. Inspect and wear appropriate PPE and apparel;
e. Control access to work area.
4. Perform the work safely
a. Maintain good housekeeping and cleanliness;
b. Anticipate problems;
c. Resist pressure to "hurry up"; and
d. Maintain a questioning attitude.

Stop - Before Action

5. Feedback
a. Document work; and
b. Conduct a post job briefing.
Think - Risks/Hazards Here are some essential ways to ensure safety every
Options - LOTO day:

Protection - Proper PPE Deenergize Be Proactive About Your Safety

One way to prevent electrical injuries and fatalities is
to deenergize the equipment being worked on. It may
take a little more time and planning, but your life and
your health are worth it. Be proactive about
deenergizing equipment and taking steps to ensure
12 that your work environment remains safe.
ELECTRICAL SAFETY HANDBOOK
 Lockout/Tagout Helps Prevent the Unexpected
Lockout/tagout procedures safeguard workers from
the unexpected energization or startup of machinery
and equipment. This will ensure non-operation of
electrical equipment.

Arc Flash Prevention & Personal Protective

Equipment (PPE)

In the blink of an eye, an arc flash can forever change

your life. Protect yourself by choosing the appropriate
protective equipment for the job.

Job Planning & Work Permits

Assess the hazards and define each job will entail.
Never work energized unless it is absolutely necessary.

Details are taken up in subsequent chapters.

13
ELECTRICAL SAFETY HANDBOOK
 4.0 Identifying the Hazards

Electricity has become such an integral part of our

society that it is often taken for granted. Yet, electricity
remains a very dangerous hazard for people working
on or near it.
Hazards can include poor work conditions,
equipment or practices.
It may also include careless, inadvertent actions
made on the part of individuals.
Eliminating hazards requires the precautions be
taken to provide a safe work environment. This starts
at the design of the project and electric system.
It includes the design and specification of the
electrical components and equipment, through the
installation start-up, operations and during equipment
maintenance.

First, we must recognize the three common electrical

hazards that cause injury and even death, while
working on or near electrical equipment and systems:

14
ELECTRICAL SAFETY HANDBOOK
 electrical shock
arc-flash burns from contact (current) and flash
(radiant)
Electric Shock arc-blast impact from expanding air and vaporized
materials
Many electrical circuits do not directly pose serious shock
or burn hazards by themselves. However, many of these
circuits are found adjacent to circuits with potentially
lethal levels of energy. Even a minor shock can cause a
worker to rebound into a lethal circuit or cause the
Arc Blast worker to drop a tool into the circuit. Involuntary
reaction to a shock may also result in bruises, bone
fractures, and even death from collisions or falls.

Electrical Shock
It is well known that the human body conducts electricity.
If direct body contact is made with an electrically
energized part while a similar contact is made
simultaneously with another conductive surface that is
maintained at a different electrical potential, a current will
flow, entering the body at one contact point, traversing
the body, and then exiting at the other contact point,
15 usually the ground.
ELECTRICAL SAFETY HANDBOOK
 50 V???
Hence the danger of electrical shock, even
electrocution arises.

Why A little current is required to cause injury, even

death.

Resistance and the Body

Current through the body, even at levels as low as 3
The body has a natural defense system to shock (skin)
milliamperes, can also cause injuries of an indirect or
As you can see from the calculation below, a 50 volt exposure would secondary injuries in which involuntary muscular
not cause muscles to lock and is insufficient to cause physical harm. reaction from the electric shock can cause bruises,
The key to survival is to decrease our exposure to energized circuits. bone fractures and even death resulting from
Ohms Law for electric current (amps), voltage and body resistance collisions or falls.
The typical body has a contact resistance of approximately 500
ohms at the point of contact with the electrical source. Current (mA) Effect on Person
The body has an internal resistance of approximately 100 ohms. 0.5 - 3 - Tingling sensations
There is another ac resistance or impedance to ground of 3 - 10 - Muscle contractions and pain
approximately 5000 ohms. 10 - 40 - Let-go threshold
30 - 75 - Respiratory paralysis
- 120v / (500 + 100 + 5000) = 21mA
- 50v / (500 + 100 + 5000) = 8.9 mA 100 - 200 - Ventricular fibrillation
It is around 10 mA that the cannot let go level is reached. 200 - 500 - Heart clamps tight
1500 + - Tissue and Organs start to burn

16
ELECTRICAL SAFETY HANDBOOK
 The effects of electric current on the human body
depend on:

circuit characteristics (current, resistance, frequency

How to prevent shock? and voltage)

Ground Fault Circuit Interrupters contact and internal resistance of the body
(GFCIs)
the currents pathway through the body, determined
GFCIs are designed to protect a person
by contact location and internal body chemistry
from electric shock when he or she
simultaneously contacts a live (usually 120 duration of contact
V) wire or part and a grounded object.
The GFCI works by sensing a difference environmental conditions affecting the bodys
between the supply and return currents. When contact resistance
the difference exceeds 4 - 6 mA, indicating
that current is flowing to ground (through the
person), the device is designed to open the
circuit.
GFCIs do not protect against a line-to-
neutral or a line-to-line shock.
17
ELECTRICAL SAFETY HANDBOOK
 Arc Flash
An electrical arc flash is the passage of electric
current between two conducting metals through an

35000 F F
ionized gas or vapor, usually air.

o A misconception is that the magnitude of an arc is

solely due to magnitude of the voltage. The amount of
arc energy generated is actually dependent more upon
the short circuit current available and the time taken
by the circuit breaker of fuse to clear the fault.
Electric arcs produce the highest temperatures on earth
up to 35,000 degrees Fahrenheit (4 x temp of the sun)!
Recent studies of reported electrical injuries have
indicated that as many as 80% of documented injury
The intense heat from arc causes the sudden expansion
cases were burns resulting from exposure to radiant
of air that results in a blast with very strong air pressure
energy from electrical arcs. In addition, each year
(Lightning is a natural arc).
more than 2,000 people are admitted to burn centers
with severe electrical burns. Standards organizations
All known materials are vaporized at this temperature.
are now taking a more active role in addressing the
(Copper expands 67,000 times, Water 1,670 times).
problem.

18
ELECTRICAL SAFETY HANDBOOK
 C. Arc Blast
High energy arcing faults generate a tremendous
amount of heat. This heat causes melting,
vaporization and expansion of conducting material as
well as expansion of air creating a pressure wave. This
pressure wave (blast) is a serious electrical hazard.
An arc blast also rapidly hurls victims away from the
arc heat source, causing serious falls and other
injuries.
Physical injuries include:
impact with objects
hearing damage
Concussion
Flying shrapnel from damaged electrical and
mechanical components, as well as molten conductive
metals, may cause injuries. Individuals in close
proximity to these severe pressures are also likely to
suffer short-time loss of memory or may not
remember the intense explosion of the arc itself.

19
ELECTRICAL SAFETY HANDBOOK
 Another consequence of arcs is damage to equipment
and nearby structures.

Electrical equipment must sometimes be maintained

while energized. This means that workers could be
exposed to energized circuits during a fault. The risk
of a fault occurring while people are in close
proximity to equipment must be taken into account.
As in shock and arc flash, the ideal method to avoid
this hazard is to stay away from exposed energized
electrical systems.

20
ELECTRICAL SAFETY HANDBOOK
 5.0 Statutory requirements
The modern trend in electrical safety is toward more
and more individual responsibility as employees are
being held increasingly responsible for their actions.
For individuals to successfully fulfill their
responsibilities, they must be aware of the rules that
apply to their performance.

This means that company safety rules; national and

international standards; and local, state, and federal
laws must be part of an employees knowledge base.
Several organizations have developed and continue to
revise standards to address the numerous concerns
involving electrical power.
Standards and safety organizations include:
OSHA -Occupational Safety & Health Administration
NFPA -National Fire Protection Association
IEEE -Institute of Electrical and Electronic Engineers
UL- Underwriters Laboratories NEMA -National
Electrical Manufacturers Association
ANSI -American National Standards Institute
ASTM -American Society for Testing and Materials
21 NECA- National Electrical Contractors Association
ELECTRICAL SAFETY HANDBOOK
 In addition to the above it shall be ensured that the
installation conforms to the requirements of the following
as applicable:

a. CEA Regulations
b. OISD (Oil Industry Safety Directorate)
c. Regulations laid down by PESO (Formerly CCOE)
/DGMS (as applicable).
NFPA 70 E
d. The petroleum rules (Ministry of Industry,
Standard for Electrical Safety in the
Government of India)(As applicable)
Workplace
e. Any other regulations laid down by central/state/local
Formally Standard for Electrical Safety
authorities and insurance agencies.
Requirements for Employee Workplaces
In most cases, a standard tends to define some protective
Began in 1976 by NFPA to assist OSHA
measures. However, defined protective measures are
intended to protect the equipment from destruction in
case of a failure. Generally, consideration for the people
factor is missing from the standards puzzles, even though
actions of people account for more than 75 percent of all
accident incidents that result in injury.

22
ELECTRICAL SAFETY HANDBOOK

Testing Authorities
In India there are four statutory authorities whose approval
is necessary for the installation and operation of any electrical
equipment in hazardous areas falling under their jurisdiction.
They are :
The Director General of Mines Safety, Dhanbad (DGMS)
Coal Mines Research Institute (CMRI), Dhanbad
The Chief Controller of Explosive, Nagpur (CCE)
The Director General of Factory Advice Service and Labor
Institute, Mumbai- (DGFAS)
Other Govt. testing agency like ERTL is also entitled to test and
issue certificate for Flameproof equipment.
23
ELECTRICAL SAFETY HANDBOOK
6.0 Hazardous (Classified) Locations
Flammable & Explosive Gases in Vapour or Liquid
form are being handled & Processed in petroleum
industry. Electrical equipment installed in such
industry causes sparks or High Temperature under
normal operation or in fault condition which can lead
to fire & explosion.
Hazardous area is one where risk of explosion is
present due to presence of explosive gases or vapour
or mist. An area classification of hazardous area
determines the extent of zones within which the
likelihood of the existence of an explosive gas /
mixture is judged to be high, medium, low or very
low.
An area classification provides a basis for the
selection of electrical apparatus that is protected to a
degree appropriate to the risk involved.
The area classification process reduces the overall
installation risk level through design improvements.
 For the purpose of installation of electrical
equipments, all hazardous areas can be classified into
3 zones according to the probability of there being an
explosive gas air mixture present :
1. Zone - 0
Following table lists the equipment type of protection and its
An area in which a flammable atmosphere is present
suitability for the appropriate hazardous location. continuously or is likely to be present for long
Type of Protection Relevant Standard Suitable for Zone periods. Examples are vapour space above closed
Intrinsically Safe Ex ia IS/IEC 60079-11- 2006 Zone 0, 1 and 2 process vessels, storage tanks or closed containers,
Intrinsically Safe Ex ib IS/IEC 60079-11- 2006 Zone 1 and 2
areas containing open tanks of volatile, flammable
liquids etc.
Flameproof Enclosures Ex d IS/IEC 60079-1-2007 Zone 1 and 2 2. Zone-1
Pressurized or Purged Ex p IS/IEC 60079-2 - 2007 Zone 1 and 2 Area in which an explosive gas/mixture is likely to
occur in normal operation.
Encapsulation Ex m IS/IEC 60079-18-2004 Zone 1 and 2
Powder Filled Ex q IS/IEC 60079-5 - 2007 Zone 1 and 2
The zone-1 classification typically includes:
Oil Immersed Ex o IS 7693 , IEC 60079-6- Zone 1 and 2 i)Imperfectly fitted peripheral seals of floating-roof
1995 tanks.
Increased Safety Ex e IS/IEC 60079-7-2006 Zone 2 ii)Inadequately ventilated pump rooms for volatile,
Non-sparking Ex n IS/IEC 60079-15-2005 Zone 2 flammable liquids.
iii)Interiors of Sample Retention Room/ Cabinet as
part of quality control laboratories, refrigerators and
freezers in which volatile flammable materials are
24 stored in lightly stoppered or easily breakable
ELECTRICAL SAFETY HANDBOOK containers.
 iv) API Separators
v) Oily waste water sewer/basins
vi) LPG cylinder filling and cylinder evacuation area.
vii) Areas in the immediate vicinity of vents and filling
hatches.
Sample Certificate by testing authority
3. Zone-2

Areas in which an explosive gas/air mixture is not likely to

occur in normal operation and if it occurs it will exist only
for a short time.

Zone-2 locations may be :

i) The system handling flammable liquid or vapour in
an adequately ventilated area so that the explosive or
ignitable liquids, vapours or gases will normally be
confined within closed containers or closed systems
from which they can escape only during abnormal
conditions such as accidental failure of a gasket or
packing.

ii) The flammable vapours can be conducted to the

25 location as through trenches, pipes or ducts.
ELECTRICAL SAFETY HANDBOOK
 iii) Locations adjacent to Zone-1 areas.

iv) In case positive mechanical ventilation is used, the

failure or abnormal operation of ventilating
Gas Grouping : equipment can permit atmospheric vapour mixtures
to build up to flammable concentrations.
Gas Gases
Group Gas Grouping :
All gases and vapours are classified into 4 major gas
I Methane
groups, I, IIA, IIB and IIC as per IS, IEC, BS.
IIA Propane, Butane, Acetone,
Ammonia, Carbon Monoxide, The Classification criteria is based upon Laboratory
IIB Ethylene, Butadiene, Tests to determine the max experimental safe gap
IC Hydrogen, Acetylene, Carbon (MESG) and the min ignition current (MIC). Some of
disulphide the common gases coming under different gas group
are given in the adjacent table.

Temperature classification:
The surface temperature or any parts of the electrical
equipment that may be exposed to the hazardous
atmosphere should be tested that it does not exceed
26 80% of the auto-ignition temperature of the specific
ELECTRICAL SAFETY HANDBOOK
 gas or vapor in the area where the equipment is intended
to be used.

The use of Explosion proof electrical equipments

requires special attention from the point of view of their
Temperature classification construction and maintenance.
Proper maintenance of electrical equipment in
Temperature Ignition Limiting hazardous area is an extremely important factor. No
Class Temperature of gas Temperat matter how much thought and efforts may have gone into
or Vapour in 0C ure in 0C the classification of hazardous area, proper selection and
Above Upto installation of equipment but poor or no maintenance
can invalidate all this in a second.
T6 85 100 85
T5 100 135 100 Failure of any Explosion proof electrical equipment can
T4 135 200 135 lead to the following hazards.
T3 200 300 200 Explosion in the hazardous area due to electrical
T2 300 450 300
sparks and hot surfaces.
Sudden interruption in operation of the plant
T1 450 -- 450
resulting in loss of production.
Fatal accidents or injuries due to electric shocks
and burn injuries due to sparks or hot surfaces.
27
ELECTRICAL SAFETY HANDBOOK
 7.0 EARTHING

Objectives of Earthing

The basics of safe earthing are:

To provide an alternative path for the fault current
to flow so that it will not endanger the user.
To save human life from danger of electrical shock
or death.
To provide safe path to dissipate lightning and short
circuit currents.
To ensure that all exposed conductive parts do not
reach a dangerous potential.
To design and construct system that is capable to
carry current under normal and fault conditions to
ground.
The earth path should be capable of handling
magnitude and duration of current as per the
overcurrent protection of the system without any fire
or flash or explosion.

28
ELECTRICAL SAFETY HANDBOOK
 General guidelines for Earthing

An effective earthing system must satisfy the following

conditions: -
Provide a low impedance path to ground for
personnel and equipment.
Withstand and dissipate repeated faults and surge
currents
Provide ample corrosion allowance to various
chemicals to ensure continuous service during life of
the equipment being protected.
Provide rugged mechanical properties for easy
driving of earth electrodes with minimum difficulty.

Statutory Stipulations
All medium voltage equipment shall be earthed by
two separate and distinct connections.
As far as possible, all earth connections shall be
visible for inspection.
Each earth system shall be so designed that testing
of individual earth electrode should be possible.
Resistance of earth system shall conform to degree
29 of shock protection desired.
ELECTRICAL SAFETY HANDBOOK
 Safety precautions for Earthing

1) Examine earthing devices periodically and always

prior to their use.

2) Use only earthing switches or any other special

apparatus where provided for earthing.

3) Verify that the circuit is dead.

4) Earthing should be done in such a manner that

the persons are protected by earth connections on
both sides of their working zone.

5) All the three phases should be effectively earthed

and short circuited though work may be
proceeding on one phase only.

30
ELECTRICAL SAFETY HANDBOOK
 Treatment for Minimizing Earth Resistance

Remove Oxidation on joints and joints should be

tightened.
Maximum Allowable Earth Resistance Earthing of Resistance Value

Earthing of Resistance Earthing of Resistance Pour sufficient water in earth electrode.

Value Value (Ohm)
(Ohm) Use Earth Electrodes as per norms.
Major power 0.5 Medium Voltage 2.0
station Network
Electrodes should be connected in parallel.
Major Sub- 1.0 Lightening Arrestor 4.0
stations
Earth pit of size (depth & width- breadth) should be
made strictly as per norms.
Minor Sub- 2.0 L. T. Pole 5.0
station
Neutral Bushing 2.0 H. T. Pole 10.0
L. T.
Service 4.0 Tower 20.0-30.0
connection

31
ELECTRICAL SAFETY HANDBOOK
 8.0 Work Permit System

Work permit system provides in-built safety to

workmen engaged in electrical work.

The Work Permit & Safety Tagging System is the

process to provide standard working practice which
promotes a culture of safe working among personnel
while carrying out any work in electrical
equipment/system.

Work Permits are This in turn will ensure safety of personnel, safety

Safety Tools
of equipment and safety of society at large.

The process requires obtaining a permit to work on

a certain electrical equipment and also putting in place
the usage of the relevant Tags to designate the
electrical equipment under maintenance or during any
activity that puts off the circuit or abnormal
conditions.

32
ELECTRICAL SAFETY HANDBOOK
 IE RULES: AUTHORIZATION

The statutory document governing the criteria of

authorization is IE Rules 1956. Following are the
references to the IE Rules pertaining to authorization

a) IE Rule 3: Provides the details pertaining to the

level of the individual who is to be authorized and the
type of installation where he / she is purported to
work
b) IE Rule 36: Provides the details pertaining to the
safety procedures and the related authorizations that
need to be adopted while carrying out work on
Electric Supply Lines & Apparatus.

The work permit systems may be followed as per

OISD-STD-105.

33
ELECTRICAL SAFETY HANDBOOK
 9.0 Lockout/Tagout

The Lockout/Tagout system has been created to

help reduce the death and injury rate caused by the
unexpected energization or start-up of machines, or
the release of stored energy.

This applies to energy sources such as electrical,

mechanical, hydraulic, chemical, and thermal.

Lockout is the placement of a key or combination

lock on an energy isolation device (disconnect switch,
circuit breaker, etc.) to ensure that the energy isolating
device and equipment being controlled cannot be
operated until the lockout device is removed.

Lockout devices hold an energy isolating device in a

safe position and prevent the energization of a
machine or equipment. The lockout device must be
substantial enough to prevent removal without use of
excessive force or unusual techniques.
34
ELECTRICAL SAFETY HANDBOOK
 Tagout is the placement of a tag or other prominent
warning device and a means of attachment on an energy
isolation device to indicate that the energy isolating
device and the equipment being controlled may not be
operated until the tagout device is removed.

Tagout devices shall be non-reusable, attached by

hand, self-locking, and non-releasing .

35
ELECTRICAL SAFETY HANDBOOK
 10.0 PERSONNEL PROTECTIVE EQUIPMENTS
(PPEs) AND DEVICES

In the event of a momentary electric arc, flash fire, or

Personal Protective Equipment is Your
Defense
exposure to energized equipment, a worker can find
himself completely unprotected against forces that cause
Last Line of severe or fatal injuries.
Everyday work clothes can ignite and will continue to
burn even after the source of ignition has been removed.

Personal protective equipment (PPE) is your last line of

defense and will be the major factor in differentiating
between an electrical event you walk away from and one
that requires months of painful healing.

PPE comes in many different forms, including hard hats,

gloves, goggles, safety shoes, flame-resistant shirts and
pants, safety glasses, face shields, fall protection equipment,
and more.

36
ELECTRICAL SAFETY HANDBOOK
 PPE Guidelines:-

1. Use suitable protective equipment, like safety gloves,

mats, safety glasses, etc., wherever required as
PPE should be: per instructions or wherever it provides greater safety.

2. All safety devices should be checked before starting

Appropriate for the work.
hazard
Worn as the 3. Safety equipment should be tested at frequent intervals
outermost layer to ensure that equipment would provide the safety desired.
Worn CORRECTLY
4. Protective gears such as helmets, safety shoes , gloves
(i.e., zipped, buttoned, are issued to linesmen, jointers, supervisors as applicable
etc.) for personal protection and their usage is monitored.
Repaired properly and
removed from service 5. It is responsibility of supervisor to ensure the usage of
when needed P.P.E.s.

6. The P.P.E.s shall not be carried / stored with tools etc.

to avoid damage to them.
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ELECTRICAL SAFETY HANDBOOK
 11.0 Safety Instructions

This section gives safety measures for providing safe

working conditions at site.

A. CABLES

A.1. Identification of cables to be worked upon

A cable shall be identified as that having been proved

dead prior to cutting or carrying out any maintenance. It
is to be ensured that cable is dead.

A.2. Working on high voltage cable

Work on high voltage cables shall be only permitted on

receipt of the work permit. In addition to the
precautions taken under the person carrying out such
work shall be personally instructed on the spot by an
authorized person who shall first satisfy himself that the
cable has been isolated and earthed and suitable danger
boards installed in position.
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ELECTRICAL SAFETY HANDBOOK
 A.3. Working on under ground cables

1) It is to be ensured that cables are isolated.

2) Cable route indicators should be provided and cable

route records maintained. It would indicate the
particulars of all underground cables correctly in the
vicinity of the faulty cable.

3) Use of sharp edged crowbars or pick axes should be

avoided during excavation while locating the faulty
cable or laying new cable.

4) All the cables in the vicinity in the fault area shall be

exposed to establish the identification of the faulty
cable.

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ELECTRICAL SAFETY HANDBOOK
 5) Before any high voltage joint of chamber is to be
opened in circumstances where it is not desirable to
spike the cables or earthing the joint or chambers, the
authorized person shall satisfy from cable route record
and, if necessary, by approved tests that the joint or
chamber is associated with the particular cable which
has been made dead and it is safe to work on it.

6) Insulation resistance test on HT cables shall be

conducted as per IS 10810 Part- 43.

7) All checks and tests shall be made as per standard

test format available with the site engineer.

8) Employees shall not step on live cables even though

those are insulated and enclosed in a lead sheath.

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ELECTRICAL SAFETY HANDBOOK

OISD-STD-173 for
Fire prevention and protection system
For electrical installations
In line with provisions under Rule-64-2(e-iv) of Indian
Electricity Rules, Dry Type transformers should be
preferred over Oil filled transformers for indoor duty.
If unavoidable, location and provisions for indoor
transformers shall be governed by relevant clauses of
Rule-64 of Indian Electricity Rules
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ELECTRICAL SAFETY HANDBOOK
B. Working in Sub Stations
1) Safety Tags should be placed on all enclosures of high
voltage equipment and wherever necessary warn persons
of the presence of high voltage equipment.
2) Gates in switchyard fences and doors to switch gear
and other enclosures containing live equipment, or other
hazards, should be kept locked at all times except when
Authorized Person entered for working inside.
3) When carrying ladders, pipes, conduits, reinforced
rods and other long material in to stations, switchyards,
switch gear rooms and other places where there is a
danger of touching the live parts, the material should be
held by two men, one at each end, and carried in the
hands and not on the shoulders.
4) When working in the vicinity of circuit breakers or
buses use every precaution to avoid injury from arcing.
5) Area is to be guarded off wherever possible, where
men are working on H.T. equipment.
 C. Working on Transformer

1) When work is to be carried out on a transformer,

both low and high tension breakers and isolators shall be
opened. Similarly, during isolation of transformers to
which potential transformers are connected, such
potential transformers shall be isolated.
2) Before starting any work on a transformer installation,
it is important to check carefully for back feed, abnormal
voltage or other dangerous conditions. Unusual circuit
conditions may exist which may require special
consideration.
3) Whenever transformers are replaced, the new
transformer should be checked carefully for voltage,
polarity and phase sequence before taking into service.
4) Area should always be cordoned off & Safety tagging
should be done prior to starting the job on transformer.

C.1.Working on Instrument Transformers

1) The instrument transformers should be grounded.

2) Current transformers secondaries should never be
42 open circuited when current is flowing in the primary.
ELECTRICAL SAFETY HANDBOOK
 3) The secondary circuit of current transformers should
be connected to ground at all times when the transformer
is in service.
4) Potential transformers secondaries should never be
short circuited.
5) The low voltage winding of potential transformers
should always have one side permanently and effectively
grounded.

D. Working on Circuit Breakers

For isolation purposes it shall be ensured that

1. Disconnecting switches on sides, control switches,

relay trip blocking switches and compartments
doors are open.

2. Mechanical blocking, wherever necessary, to prevent

unauthorized movement of the mechanism is installed.

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ELECTRICAL SAFETY HANDBOOK
 E. Working on Metal Clad Switch Gear and Control
Panel
1) While working on manually operated panel mounted
circuit breakers when the operating handle is on the front
and the circuit breaker is on the rear of switchgear or on
another panel, a danger notice shall be placed on the
handle.
2) When the work is to be carried out on the bus bars
spouts the following operations shall be carried out.
2.1 The section of bus bars on which the work is to be
carried out shall be made dead and shall be isolated from
all points of supply.
2.2 The isolating arrangements and the shutters of live
spouts shall be locked so that they cannot be operated.
2.3 Where duplicate switches in one tank or on load bus
bar isolators are installed and is impossible to isolate
them from all points of supply, then all switches and
selectors that could be closed on the bus bars on which
work is to be carried out shall have their mechanism
locked in the open position and the closing mechanism
shall be made inoperative.
2.4 The bus bar shall be earthed with approved earthing
44 equipment at a panel other than at which work is to be done and
ELECTRICAL SAFETY HANDBOOK the isolated section of the bus bars.
 F. CAPACITORS
1) Every capacitor shall be treated as hot until proved
otherwise. Capacitors stores energy and are not
necessarily dead when disconnected from the line.
Once charged, a capacitor may retain its charge for
several hours after it has been disconnected.

2) When a capacitor is to be worked on, first open all cut

outs or disconnecting devices to the capacitor, then wait
for at-least five minutes for the internal resistors to
reduce the voltage. Next, using the hot stick (discharge
rod), short circuit and ground all terminals of the
capacitors. These terminals should remain short
circuited and grounded while work is being done on the
capacitor.

3) To bring the capacitor banks back into service, first

remove the jumpers with hot sticks, and then close the
cutouts.

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ELECTRICAL SAFETY HANDBOOK
 G. Working on Storage Batteries

1) Name plate details and number of cells are as per

approved drawings.

2) Ensuring the usage of PPEs by contract labour is the

responsibility of the concerned Officer.

3) Smoking and use of matches or other open flames

are not permitted in battery rooms or while inspecting
filling, testing or handling batteries.

4) Proper ventilation to be provided in battery room.

5) Ensure that an eyewash shower and wash basin are

available nearby.

6)Suitable drainage has been provided for likely

electrolyte spillage.

7) Acid treatment chart is prominently displayed inside

the room
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ELECTRICAL SAFETY HANDBOOK
 12.0 Electrical Maintenance and its relation with safety

The relationship between safety and preventive

maintenance is not a difficult one to establish. Properly
designed equipment that is properly installed is well
capable of doing its job when it is new. As equipment
ages however, several factors begin to take their toll on
electrical equipment
Dust, dirt, and other contaminants depositing over a
period of time on equipment causing the equipment to
overheat and bearings and other moving parts to bind.
Vibration causes hardware to loosen. Subsequent
operations of equipment can cause joints and equipment
to fail explosively.
Heat and age can cause insulation to fail, resulting in
shock hazards to personnel.
Increased loads, motor starting surges, and power
quality issues such as harmonics combine to increase the
aging process and set the stage for equipment failure.

47
ELECTRICAL SAFETY HANDBOOK

Both the National Electrical Code (NFPA 70)4 and the
Standard for Electrical Safety in the Workplace (NFPA
70E) 3 require that
Switchboards, panelboards, industrial control
panels, and motor control centers that are in other
than dwelling occupancies and are likely to require
examination, adjustment, servicing, or maintenance
while energized shall be field marked to warn
qualified persons of potential electric arc flash
hazards. The marking shall be located so as to be
clearly visible to qualified persons before
examination, adjustment, servicing, or maintenance
of the equipment..
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ELECTRICAL SAFETY HANDBOOK
Unfortunately, the ultimate failure of unmaintained
equipment usually occurs when the equipment is
needed the mostduring electrical faults. Such failures
result in arc and blast events that can and do harm to
workers in the area. They also result in significant
downtime, loss of equipment, and construction cost
incurred in rebuilding the equipment.
The only way to ensure that electrical equipment
continues to operate in an optimal manner is to
maintain it so that it stays in factory-new-operating
condition.
Regulatory requirement
The catastrophic failure of electrical equipment
creates severe hazards for personnel working in the area.
Recognizing this the Standard for Electrical Safety in the
Workplace (NFPA 70E)3 requires that electrical
equipment be properly maintained to minimize the
possibility of failure.
 13. STATIC ELECTRICITY

Static electricity is generated by the separation of like or

unlike bodies. Electro-static charges, positive & negative,
always occur in pair and are developed when any two
bodies that have been in contact are separated.
The negative charges migrate to one body, leaving the
other body with a positive charge. For sufficient charges
to be developed, the bodies must become and remain
insulated with respect to each other so that the electrons,
which have passed over the boundary surface or
interface, are trapped when separation occurs.
Insulation may occur through complete physical
separation of the bodies or because at least one of the
bodies is an insulator. Petroleum products which have a
low conductivity can serve as an insulator.
COMMON SOURCES OF STATIC ELECTRICITY
Some common sources of static electricity which are
experienced in oil industry are as follows:
a) Pulverised materials passing through chutes or
pneumatic conveyors, e.g. catalyst handling.

49
ELECTRICAL SAFETY HANDBOOK
 b) Steam or air/gas flowing from any opening in a pipe
or hose
c) Non-conductive power transmission belts or conveyor
belts in motion.
d) Moving vehicles.
e) Motion of all sorts that involve changes in relative
position of contacting surfaces, usually of dissimilar
liquids or solids, e.g. Loose wooden /metallic pieces/
projections in tanks / pipes / vessels, etc.
f) Hydrocarbon flow through micro-filters made of
paper/felt elements.
g) Hydrocarbon liquids flowing at high velocities in
pipes/nozzles/fittings, etc.
h) Spraying/splashing and misting
i) Agitation/mixing & blending including mechanical
mixing/agitation with air /steam/gas/ jet nozzles.
j) Water entrainment, e.g. free presence of water in
hydrocarbon products or in tanks.
k) Switch loading (term used to describe a product being
loaded into a tank or compartment which previously
held a product of different vapour pressure. )
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ELECTRICAL SAFETY HANDBOOK
 General guidelines for control of Static Electricity

Avoid spraying, splashing and misting

Avoid agitation and mixing

Presence of water to be minimised

Avoid filters to the extent possible

Conductive probes or insulated

Conductive objects to be avoided.

Conducting projections and probes to be avoided.

Bonding

Grounding

Use of additives.

51 .
ELECTRICAL SAFETY HANDBOOK
 14.0 First Aid

General

First Aid means what one should do to reduce the

suffering of the patient after an accident until the doctor
arrives, it may give life to dying person.
First Aid Instructions
1. Remove the patient from the source of accident /
remove the cause of injury.
2. Keeps the injured person lying down in a comfortable
position.
3. If the breathing has ceased, immediate measures must
be taken to restore it.
4. If the patient has received burn injuries, immediately
attend to them.
5. When the patient has fractured a bone, no attempt
must be made to move him.
6. Treat the patient for shock.
7. Send for medical help.
8. Never give water to patient.
9. Keep people away from the patient.
52 10. Keep the patient warm.
ELECTRICAL SAFETY HANDBOOK

Dont touch an electrical shock victim,
because it might make you another victim!
53
ELECTRICAL SAFETY HANDBOOK
Treatment for Electric Shock
Release from contact
Switch off the electric supply immediately or send
someone to do so.
Do not attempt to remove a person from contact with
high voltages unless suitable articles insulated for the
system voltages are used for the purposes.
When attempting to free a person from contact with low
or medium voltage use rubber gloves, shoes, mat or
insulated stick, but if these are not available use a loop of
rope, cap or coat to drag the person free.
Whatever is used should be dry and non-conducting.
After release
As soon as the victim is clear off the conductor and is
found breathless, rapidly feel with your finger in his mouth
and throat and remove any foreign matter (tobacco, false
teeth etc.). Then begin artificial respiration.
Do not stop to loosen the victims clothing now; every
moment of delay is serious. Keep the patient warm
 15.0 Housekeeping

Workmen are frequently injured, by stumbling, stepping

on, or bumping into tools, material and other objects left
lying around, or by objects falling from above.
A. To ensure good housekeeping following precautions
should be observed:
1. Walks, stairways, fire escapes and all other passageways
shall be kept clear of all obstructions.

2. Tools and materials should not be placed where they

may cause tripping or stumbling hazards or where they may
fall and strike anyone below.

3. Puddles of oil and water create slipping hazards and

should be cleaned up promptly.

4. Nails in boards, such as those removed from scaffolds,

forms and packing boxes, constitute hazards and should be
removed. The boards should be carefully stacked or
stored.

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ELECTRICAL SAFETY HANDBOOK
 5. Dirty and oily waste rags should be deposited in
approved containers and disposed off as soon as
practicable to avoid fire hazard.

6.Broken light bulbs, glass metal and scrap and other

sharp objects should be dumped in places or containers
provided specially for them.

7.Discarded fluorescent and other gas filled tubes shall

be disposed off safely.

8.Places where persons work or pass in emergencies,

shall be provided during time of use with adequate
lighting (natural / artificial / or both) for operations or
special type of work performed.

9.General lighting shall be of a uniform level widely

distributed.

10.In big installations / offices emergency lighting shall be

provided.

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ELECTRICAL SAFETY HANDBOOK

Points That counts
Avoid electrical job under multiple
instructions. Follow only the instruction
of your commander who is in command
Understand the Job and Plan accordingly
Go through Tool Box Talk
56
ELECTRICAL SAFETY HANDBOOK
16.0 Dos and Dont s
GENERAL SAFETY PRECAUTIONS
S.N DOs S.N DO NOTs
1 Preach and practice safety at 1
all the time. Good work can
be spoiled by an accident.
Place Safety Tagging or 2
2
other warning boards on
main switch before
commencing work.
Before working on any 3
3
circuit or apparatus, make
sure that the controlling
switches are open and
locked.
4 Always treat circuit as live 4
until you have proved them
to be dead, the insulation of
the conductor may be
defective.
Do not wear loose clothing,
metal watch straps, bangles
or finger rings while working
on appliances. Do not hang
clothes and such other things
on electric fittings.
Do not close any switch,
unless you are familiar with
the circuit which it controls
and know the reason for its
being open.
Do not touch or tamper with
any electrical gear or
conductor, unless you have
made sure that it is dead and
earthed. High voltage
apparatus may give leakage
shock or flash over even
without touching.
Do not work on live circuit
without the orders of the
authorized person. Make
certain that all safety
precautions have been taken.
 16.0 Dos and Dont s
GENERAL SAFETY PRECAUTIONS
S.N DOs S.N DO NOTs
Points That counts 5 Cultivate the habit of 5
turning your face away
whenever the flash or an
arc may occur.
Clear doubt of your
mind 6 Guard against arcs as well 6
as high voltage; remember
before starting job that burns from arc are
very severe.
7 See that all the splices and 7
connections are securely
For Safety do not made.
Believe any body
8 Use extreme care when 8
breaking an inductive
circuit as dangerously high
Do not touch one who is voltage is likely to result.
Working in electrical
panel 9 Thoroughly discharge to 9
earth all cables before
working on cores.
57
ELECTRICAL SAFETY HANDBOOK
Do not disconnect earthing
connection or render it
ineffective of the safety
gadgets installed on mains
and apparatus.
Do not expose your eyes to
an electrical arc. Painful
injury may result even with
short exposure.
Do not tamper with the
meter board and cut-outs,
unless you are authorized
to do so.
Do not touch the circuit
with bare fingers or hand
or other makeshift devices
to determine whether or
not it is live.
Do not place any part of
your body in circuit either to
ground or across the
terminal when making a
connection or doing
operation.

10
Points That counts
11
Be safe and help other to work safely
12
Do not be Over confident
13
Do not go for short-cut
Remove metallic body like watch, ring
before working in electrical panel
58
ELECTRICAL SAFETY HANDBOOK
Test safety gloves 10
periodically.
Place insulating mats in front 11
of electrical switchboard.
Before replacing a lamp or 12
handling a fan, make sure
that the supply is switched
off.
Work deliberately and 13
carefully. Haste causes many
accidents. Be sure of what
you are doing.
Do not touch an electrical
circuit when your hands are
wet, bleeding from a cut or
have an abrasion.
Do not work on energized
circuit without taking extra
precautions, such as the use
of safety gloves. Do not use
metal case flash light around
apparatus which is energized.
Do not connect single pole
switch or fuse in a neutral
circuit, but always connect in
the live or phase wire.
Do not work on pole or any
elevated position if there is a
live part on it, without the
safety belt and safety gloves
and unless the authorized
person stand nearby to direct
operation and give warning.
 14
Points That counts
Do not believe what you see
15
If you find any abnormal
sound in electrical equipment
Check it may lead to failure
16
Foresight Power to visualize
59
ELECTRICAL SAFETY HANDBOOK
Always obey the safety 14
instructions given by the
person in-charge.
Always report immediately 15
to the person in-charge or
to any other proper
authority of any dangerous
condition or a practice,
which you may observe.
Ensure that all portable 16
appliances are provided
with 3 pin plug and socket
connections. Also the
metal work of the
apparatus is effectively
earthed.
Do not use a ladder
without a lashing rope,
otherwise the ladder
should be held firmly by
another person. Do not
remove Safety Tags or
other signs or interface with
safety barriers or go
beyond them.
Do not bring naked light
near battery. Smoking in
the battery room is
prohibited. Do not allow
visitors and un-authorized
person to touch or handle
electrical apparatus or
come within the danger
zone of high voltage
apparatus.
Do not use a lamp in a
metal holder fixed to the
end of a loose flexible wire
as a portable hand lamp.
Do not disconnect a plug
by pulling the flexible cable
or when the switch is on.
 Safety is an
on-going
learning.
THANK YOU
Keep updated
Keep safe
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ELECTRICAL SAFETY HANDBOOK