Port Dickson Refinery

Electrical Safe Work Procedure

(Revision 1 – Jan 2011)
1. PURPOSE:

This procedure covers the electrical safety-related work practices to be used when
performing work on or near electrical circuits and equipments. This procedure must
be used to ensure injuries are prevented.

Revision Tracking
Rev. 0
– Adopted from Singapore Electrical Safe Work Procedure with minimal changes to
reflect PDR practices and document numbering

Rev. 1 - Jan 2011 (This Revision)

– Revised to include comments during October 2010 Tier-1 BP Validation
– Introduce New Appendix (Appendix III) – the Arc Flash Warning Label Sticker
– Item 13 c) i) – emphasize of using 30mA ELCB and requirement to perform quarterly
audit of ELCB usage in the Refinery

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Electrical Safe Work Procedure
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INDEX

PAGE

A. Introduction. 5

B. Definitions 5

C. Personnel Qualifications and training requirements.

1. Scope. 12
2. Content Of training. 13

D. Basic Electrical safety precautions and requirements.

1. General. 14
2. Alerting Techniques. 15
3. Approved electrical devices. 16
4. Automatic Transfer systems, work on. 16
5. Batteries, work on. 17
6. Cable tray systems. 17
7. Conductive apparel. 18
8. Confined spaces, work or use of lights and power tools. 18
9. Current transformers. 19
10. Discharging of equipment. 19
11. Disconnect switches. 19
12. Drilling and tapping in electrical enclosures or panels. 20
13. Earth fault protection for workers or use of
earth leakage circuit breakers- cords and receptacles. 20
14. Earthing or grounding. 20
15. Electrical equipment in hazardous / classified area. 21
16. Electrical safety interlocks. 21
17. Equipment identification. 22
18. Fuses. 22
19. Heat tracing systems. 23
20. House keeping duties. 23
21. Insulated hand held ground sticks. 23
22. Job briefing and job safety analysis. 24

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23. Lighting or illumination. 24

24. Lights. 25
25. Motors and generators. 25
26. Portable ladders 25
27. Protective device ratings and settings. 26
28. Re-closing circuits after protective device operation. 26
29. Routine opening and closing of circuits. 26
30. Safety lockout locks. 26
31. Stored energy. 27
32. Switchgear and motor control center. 27
33. Substation. 28
34. Voltage back feed. 30
35. Work permit. 31
36. Miscellaneous. 31

E. De energizing circuits and equipment for electrical work.

1. De energizing or circuit and equipment isolation. 31

2. Verification of de energization. 32
3. Voltage testing - The three step voltage check. 33
4. Grounding or earthing of circuits and equipment for
the protection of workers. 33

F. Re energizing electrical circuits and equipment. 37

G. Working on or near exposed energized circuits and parts.

1. General. 38
2. Testing of circuits and equipment. 39

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Electrical Safe Work Procedure
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H. Portable Electric Equipment. 42

I. Personal and other protective equipment.

1. Introduction. 45
2. Body protection. 46
3. Hand protection (Table for voltage requirements
of rubber gloves). 46
4. Eye and face protection. 48
5. Head protection. 48
6. Insulating mats. 48
7. Insulated tools. 49
8. Personal protective equipment for work on batteries. 49
9. Fuse handling equipment. 49
10. Personal protective equipment for contractors. 50

J. Test instruments and equipment.

1. General. 50
2. Visual inspection of test instruments and equipment. 50

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Electrical Safe Work Procedure
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A. INTRODUCTION
This procedure covers the electrical safety-related work practices to be used
when performing work on or near electrical circuits and equipment. This
procedure is applicable for both qualified and unqualified persons and must be
used to ensure that injuries are prevented.

B. DEFINITIONS
• APPROVED ELECTRICAL EQUIPMENT
Acceptable, Approved, Certified, Labeled or Listed by an International
recognized testing laboratory such as UL, FM, CSA, etc; or designed
according to international standards like IEC or equivalent or endorsed by
the plant for the appropriate situation.

• ARC-FLASH HAZARD
A dangerous condition associated with the release of energy caused by
an arc that suddenly and violently changes material(s) into vapor.

• Authorized Person
A person authorized by the L.E.W. to perform specific tasks.

• BARRICADE
A physical obstruction such as tapes, cones, or metal structures intended
to provide a warning about and to limit access to a hazardous area.

• BARRIER
A physical obstruction that is intended to prevent contact with energized
lines or equipment or to prevent unauthorized access to a work area.

• CIRCUIT BREAKER
A device designed to open and close a circuit by non-automatic (manual)
means and to open the circuit automatically on a predetermined over-
current without damage to itself when properly applied within its rating.
The automatic opening means that it can be integral, direct acting with the
circuit breaker, or remote from the circuit breaker.

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• CONDUCTOR
Conductor carries the electric current
Bare Conductor: A conductor having no covering or electrical insulation
whatsoever.
Insulated conductor: A conductor encased within material of composition
and thickness that is recognized as electrical insulation. (Cables)

• CLEARANCE (BETWEEN OBJECTS)

The clear distance between two objects measured surface to surface.

• CLEARANCE (FOR WORK)

Authorization to perform specified work or permission to enter a restricted
area.

• DE-ENERGISED
Free from any electrical connection to a source of potential difference and
from electric charge; not having a potential difference from that of the
earth.

NOTE:
The term is used only with reference to current-carrying parts that could be Energised.

• ELECTRICAL EQUIPMENT
A general term including material, fittings, devices, appliances, fixtures,
apparatus, and the like, used as a part of, or in connection with, an
electrical installation.

• ELECTRICAL HAZARD
A dangerous condition such that inadvertent or unintentional contact or
equipment failure can result in shock, arc, flash burn, thermal burn, or
blast.

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Electrical Safe Work Procedure
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• ELECTRICAL WORK, TYPES:

a. HOT OR LIVE WORK OR WORKING ON ENERGISED CIRCUIT.

Any work that requires either intentional physical contact with an
insulated gloved hand, or the use of tools for the purpose of
manipulating, tightening or terminating exposed uninsulated
energized circuit conductors. Includes inserting and withdrawing
fuses, if fuse holder is live.

b. PROXIMITY WORK OR WORKING NEAR ENERGISED CIRCUIT.

Any work sufficiently close to exposed and unguarded energized
circuit conductors, such that, although it is not the intent to touch
energized conductors, there is the possibility of inadvertent contact.

Following table provides the minimum distances that are to be

maintained with reference to the voltage level from a live source, so
as to avoid proximity work.

Proximity Distance
For Electrical Work by Qualified Persons
Proximity Distance in Feet
System Voltage in V Includes Standard
Phase-to-Phase Inadvertent Movement Adder
300 V and Less Avoid Contact
300 V to 750 V 1 ft 0 in.
750 V to 2 kV 2 ft 0 in.
2 kV to 15 kV 2 ft 2 in.
15 kV to 36 kV 2 ft 7 in.
36 kV to 48.3 kV 2 ft 10 in.
48.3 kV to 72.5 kV 3 ft 3 in.

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c. TESTING ON ELECTRICAL CIRCUITS.

Using of an approved test equipment and leads for the purpose of
determining the magnitude of an electrical parameter.

d. WORKING ON DE-ENERGISED CIRCUITS AND EQUIPMENTS.

Work on electrical circuits or equipment that has been de-
energized.

• ELECTRICAL WORK PERMIT

It is a stand-alone work permit to carry out any electrical work. However
additional permits may be requested as appropriate to the job.

 ENCLOSED OR CONFINED SPACE

A space which:
o Has limited openings for entry and exit, or rescue of workers
entering it
o Has limited ventilation or containing potentially dangerous air
contaminants. Is not suitable for continuous occupancy. Is not
normally entered by, or accessible to, personnel in the course
of their Is sufficiently surrounded by confining surfaces so as
to permit the accumulation of flammable or toxic vapors, or
oxygen deficient atmospheres.

 ENCLOSURE
The case or housing of apparatus, or the fence or walls surrounding an
installation to prevent personnel from accidentally contacting energized
parts, or to protect the equipment from physical damage.
• ENERGISED, HOT OR LIVE EQUIPMENT
Electrically connected to a source of potential difference, or electrically
charged so as to have a potential significantly different from that of earth
in the vicinity.

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• ENERGY ISOLATING DEVICE

A physical device that prevents the transmission or release of energy,
including, but not limited to, the following: a manually operated electric
circuit breaker, a disconnect switch, a manually operated switch, a slide
gate, a slip blind, a line valve, blocks, and any similar device with a visible
indication of the position of the device.
NOTE: Push buttons, selector switches, and other control-circuit-type
devices are not energy isolating devices.
• EXPOSED
(As applied to live parts) Capable of being inadvertently touched or
approached nearer than a safe distance by a person. It is applied to parts
not suitably guarded, isolated, or insulated.
• EARTH OR GROUND
A conducting connection, whether intentional or accidental, between an
electrical circuit or equipment and the earth, or to some conducting body
that serves in place of the earth.

• EARTH LEAKAGE CIRCUIT BREAKER (ELCB)

A device whose function is to interrupt the electric circuit to the load when
a leakage current through the insulation to earth or earth fault current
exceeds some predetermined value.
• GUARDED
Covered, shielded, fenced, enclosed, or otherwise protected by means of
suitable covers, casings, barriers, rails, screens, mats, or platforms to
remove the likelihood of approach to a point of danger or contact by
persons or objects.
• INSULATED
Separated from other conducting surfaces by a dielectric (including air
space) offering a high resistance to the passage of current.
NOTE:
When any circuit or equipment is said to be insulated, it is understood to
be insulated for the conditions to which it is normally subjected.
Otherwise, it is, within the purpose of this Standard, uninsulated.

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• ISOLATED
The disconnection and separation of the electrical equipment from every
source of electrical energy in such a way that this disconnection and
separation is secure.
• L.E.W.
Licensed electrical worker. A person licensed by the EC (Malaysia Energy
Committee) to perform specific tasks. List of L.E.W as in Appendix II. Also
known as Chargeman.
• OVERLOAD RELAY
A device that protects equipment and conductors from operating in excess
of rated current which, when it persists for a sufficient length of time, would
cause damage or dangerous overheating. This device may not be a
protection against a short circuit or earth fault.
• PROCEDURE
A procedure is a detailed and step-by-step written information or instruction
to be used to maintain, operate or test equipment or carry out a designated
task. This includes specific operating, maintenance instruction and
procedures based on the specific process such as operating limits, hazards
to be controlled, and any other safety, health and environment
requirements.
• QUALIFIED PERSON
Qualified Persons are intended to be only those who are well acquainted
with and thoroughly conversant in the electric equipment and electrical
hazards involved with the work being performed. He/she shall have a
minimum qualification of A0 in the electrical trade OR equivalent.

 SHALL
Indicates a mandatory requirement.

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• SHOULD
Indicates a recommendation or that which is advised but not
mandatory
• STANDBY PERSON, HAZARD WATCH
A Hazard Watch Standby Person is required for certain energized or hot
work, testing and proximity works. The Standby Person shall be a
Qualified Person.
Responsibilities of Standby Person are as follows:
a. Understanding the job scope and safety implications of the task to
be done. Ensure that permit scope of work not exceeded.
b. Keeping non-essential people out of the work area.
c. Knowing where and how to de-energise or switch-off the electrical
circuit or equipment if there is any sign of worker in distress.
d. Summoning qualified help via area radio, telephone, etc.
e. Standby Person shall wear and use the same personal and other
protective equipment as used by the Qualified Person performing
the work.
f. Stand-by person may assist the person who carries out the work
however for complex Electrical tasks like Motor starter rack in /
Rack out and Live testing work he shall not perform any work or
assist the worker instead he needs to monitor and identify potential
hazards. During switching, he shall be out of the arc-flash
boundary.
g. Being prepared to de-energize relevant energized wire or
equipment, if need be. The Standby Person should not risk
touching the person, should only grab with Gloves or use Hot
Sticks to pull/push away, but should not wrap arms around.
• SYSTEM
An electrical system in which any of the electrical equipment is or may be
electrically connected to a common source of electrical energy and
includes such source and such equipment.

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• VOLTAGE, NOMINAL.

A nominal value assigned to a circuit or system for the purpose of

conveniently designating its voltage class (e.g., 240 volts, 6.6 kV). The
actual voltage at which a circuit operates can vary from the nominal within
a range that permits satisfactory operation of equipment.

For the purpose of Refinery lock & tag procedure (SHE Infobank : IBPDR-
SWPM-10429) & to explain the intent of the practice, voltages are
classified as follows:
Up to 50 V AC is considered as Safety extra low voltage.
From 50 V AC to 600V AC and 120V DC is considered low voltage.
Any voltage above 600V AC and 120V DC are considered high voltages.

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C. PERSONNEL QUALIFICATIONS AND TRAINING REQUIREMENTS
1. SCOPE
Electrical work as defined in this procedure shall be done only by
Qualified Persons who are properly trained to do such work. They
shall be trained in and familiar with the safety-related work practices,
safety procedures, and other safety requirements that pertain to the
respective equipment and job assignments.

NOTE:
Other persons such as welders, machinist, painters, riggers and others, who may
face a comparable risk of injury due to electric shock or other electrical hazards
deemed to be unqualified persons, should be trained.

2. CONTENT OF TRAINING
a. QUALIFIED PERSONS
Qualified persons (i.e., those permitted to work on or near exposed
energized parts) shall, at a minimum, be trained in and familiar with
the following:
(i) The qualified person shall be trained for the specific electrical task
to be performed.
(ii) He/she shall have minimum qualifications of A0 EC Certificate or
equiv.
(iii) The clearance distances specified in the procedure and the
corresponding voltages to which the qualified person will be
exposed.
(iv) Precautionary techniques and the proper use of personal
protective equipment, insulating and shielding materials, and i
nsulated tools for working on or near exposed energised parts
of electric equipment.
(v) Qualified persons shall also be trained in and familiar with the
safety-related work practices required by this procedure that
pertain to their respective job assignments.
It is recommended that Qualified Persons should be trained in the
following:
(i) Cardiopulmonary Resuscitation (CPR) and,
(ii) First Aid.

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b. UNQUALIFIED PERSONS

Unqualified persons are not allowed to enter into the substations or near
any work area where electrical hazards are present. In case unqualified
persons needs to enter substations / work area where electrical hazard
are present, he / she shall undergo tool box training conducted by a
qualified person which emphasizes the following aspects:
(i) Hazards associated with electricity.
(ii) Proper use of portable plug-connected tools and extension
cords.
(iii) Electrical hazards (i.e. flash protection boundaries)
associated with one’s respective job assignment.
(iv) Emergency exit location / route from substation.

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D. BASIC ELECTRICAL SAFETY PRECAUTIONS AND REQUIREMENTS

1. GENERAL
a. Safety-related work practices shall be employed to prevent electric
shock or other injuries resulting from either direct or indirect
electrical contacts, when work is performed near or on equipment
or circuits which are or may be energized. The specific safety-
related work practices shall be consistent with the nature and
extent of the associated electrical hazards.
b. Live parts to which an employee may be exposed shall be de-
energized before the employee works on or near them, unless that
de-energizing is infeasible due to equipment design or operational
limitations.
c. All electrical equipment must be considered live or energized until it
is proven de-energized. No person must begin work on de-
energized parts until this verification has been completed.
d. All electrical work shall comply with the Malaysian Standards.
e. No person should commence any electrical work until that person
fully understands the instructions received and in no circumstances
should that person exceed those instructions. Should any person
consider that the instructions given could not be carried out safely,
that person refers the matter immediately to the electrical
supervisor.
f. No person should interfere with earth or ground connections, locks,
tags, danger or warning signs, safety barriers, flags or other safety
devices.

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2. ALERTING TECHNIQUES
The following alerting techniques shall be used to warn and protect all
persons from hazards that could cause injury due to electric shock, burns,
or failure of electric equipment parts:

a. Safety signs, safety symbols, or accident prevention tags shall be

used where necessary to warn employees about electrical hazards
that may endanger them.
b. Barricades shall be used in conjunction with signs where it is
necessary to prevent or limit individual access to work areas
exposing individuals to un-insulated energized conductors or circuit
parts. Conductive barricades shall not be used where they might
cause an electrical contact hazard.
c. If signs and barricades do not provide sufficient warning and
protection from electrical hazards, an attendant shall be stationed
to warn others to prevent entering the work area.

3. APPROVED ELECTRICAL DEVICES

Electrical devices including test equipment, portable tools, that are
brought into process areas must be approved and meet the electrical
classification for the area in which they are used. Any (camera, notebook
computers and pagers are some examples) device not approved but
intended to be used in classified area shall requires use of LEL monitor
with appropriate permit to work.

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4. AUTOMATIC TRANSFER SYSTEMS, WORK ON.

This section covers the basic precautions to be taken when planning to
work on automatic electrical transfer systems. These systems include
primary and/or secondary selective systems, standby emergency
generators, alternate power supplies, battery systems, etc.
a. All appropriate process personnel should be notified about the work
involved and consequences of any inadvertent actions.
b. Qualified persons planning to work on the transfer system or
transfer associated equipment must know how the system works,
including how to temporarily defeat and restore the automatic
transfer mechanism, etc.
c. If it is not safe to work on the system without defeating or disabling
the automatic transfer system, consequences of the action should
be discussed with and permission obtained from process personnel
prior to starting the work.
d. Prior to start of work on the automatic transfer systems ensure all
alternate power supplies are available. If it is not possible, make
arrangements to provide alternate power supplies.

e. Before restoring the automatic transfer system equipment,

ensures the integrity of fuses. A blown fuse in the transfer circuitry
may result in automatic transfer of the power sources.

5. BATTERIES,WORK ON.
The following requirements cover work on vented batteries.
a. Chemical safety goggles shall be used when measuring storage
battery specific gravity or handling electrolyte.
b. Acid resistant face-shield, gloves, boots and aprons shall be worn
for protection against spattering when battery acid is handled.
c. Emergency eye wash facility shall be available within 25 feet of
battery handling area.
d. Employees assigned to work with storage batteries shall be
instructed in safe handling of acids as dealing with accidental acid
spills. In case of contact, proceed to eyewash and seek medical
attention.

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e. Electrolyte (acid or base, and distilled water) for battery cells shall
be mixed in well ventilated room. Acid or base shall be poured
gradually, while stirring, into the water.
f. Electrolyte shall never be placed in metal containers nor stirred
with metal objects.
g. When taking specific gravity readings, the open end of the
hydrometer shall be covered with an acid resistant material while
moving it from cell to cell to avoid splashing or throwing the
electrolyte. Any spillage shall be thoroughly cleaned.
h. Insulated tools shall be used while working on battery terminal.
Any other metallic objects shall be kept away from the top of
uncovered batteries.

6. CABLE TRAY SYSTEMS

Following precautions should be taken when any work near or on cable
trays is to be done. These precautions are intended to ensure the safety
of workers, cables and trays. Cable trays may contain any or all voltage
level power, control and instrumentation cables.
a. Ensure the integrity of cable tray grounding system prior to start of
any work on the cable tray or cables in the tray.
b. Ensure cable trays and cables are mechanically protected from any
falling objects or inadvertent movement of non-electrical equipment
on the area.
c. Ensure the workers are provided with safe and firm support or
platform to work on cable trays and their cables. Man-lifts may also
be used for work on cable trays and their cables.
d. Note: Use of ladders is permitted for inspection only. Ladders
should not be used if any work other than inspection is to be
carried out.
e. Cable tray should not be used for walking or supporting any
conduits or structures whether for temporary or permanent use.
f. Cable trays should not be used as platforms for work on cable
trays, cables or nearby equipment.

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g. Consideration should be given to safeguards against damage to
other cables in the tray by "isolation" means such as blanketing,
etc., particularly if such cables are energized.
h. When splicing cables in the trays provide mechanical protection to
the rest of the cables and use insulating blankets to eliminate any
shock/harm if any cables in the tray experience electrical faults.

7. CONDUCTIVE APPAREL.
When performing electrical work, personnel shall remove jewellery from
hands and wrists example watches and rings etc. Also remove metal
objects from coverall pockets to prevent short circuits caused by
accidentally dropping or touching metal objects on exposed energized
live.

8. CONFINED SPACES, USE OF LIGHTS AND POWER TOOLS.

a. LIGHTS
Approved 12 V or less hand lamp or approved flashlight shall be
used when entering a process drum, tank, vessel, etc; for
inspection or test of combustibles. Certified 24V portable electric
lighting and 110V centre-tapped and grounded transformer lighting
system can also be used.

b. POWER TOOLS
(i) Only approved power tools and electrical equipment with earth
leakage circuit breaker protection shall be used. It is the onus of
owner and user of the power tool and electrical equipments to
ensure that their tools and equipments are certified safe for use.
General Services section (tool room) keeps a record of all
certified tools and equipments.
(ii) Certified 24V portable power tool and 110V centre-tapped and
grounded transformer powered tool can also be used.

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9. CURRENT TRANSFORMERS
Opening the secondary winding of an energized current transformer can
produce extremely high and lethal voltages. The secondary of a current
transformer shall not be opened while the associated circuit is energized.
If the primary of the current transformer can not be de-energized before
work is performed on a relay, meter or other section of a current
transformer secondary circuit, the circuit shall be shorted through shorting
links.

10. DISCHARGING OF EQUIPMENT

Prior to start of the work on and before testing (megger, high potential,
etc.) of the electrical buses, cables, switches, motors, capacitors, etc., all
equipment should be appropriately discharged by grounding the
equipment. The equipment should also be discharged after the completion
of testing and prior to their re-energization.

11. DISCONNECT SWITCHES

a. Disconnect switches shall not be opened unless they are rated for
such duty and their source of power and loads are known.
b. Switch-off or isolate all secondary loads before attempting to open
disconnect switches.

12. DRILLING AND TAPPING IN ELECTRICAL ENCLOSURES OR

PANELS
Drilling and tapping into electrical enclosures with live circuits or
equipment should be avoided. If such drilling and tapping is necessary,
then a detailed procedure shall be written highlighting the hazards
involved and instruction to take necessary precautions prior to start of
work.

13. EARTH FAULT PROTECTION FOR WORKERS OR USE OF

EARTH LEAKAGE CIRCUIT BREAKERS - CORDS AND RECEPTACLES
a. GENERAL
All portable tools/lights/cords shall have an ELCB for workers
protection
(i) Portable lights and tools (110V and above)
(ii) Fixed field electric power tools and machines powered by
13, 15 or 20-Amp, 240 V receptacles.

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b. INSPECTION AND TESTING OF ELCB
(i) Inspect the ELCB for any crack, damage or abnormality, etc;
before each use.
(ii) The ELCB device shall be tested daily by pressing the ‘Test’
button. The ELCB will disconnect the circuit or power to the
receptacle. After testing of ELCB, restoration is done by
switching ON the ELCB.
c. ELCB FOR TEMPORARY SUPPLY (e.g FOR WORK ON
CONFINED SPACE, METAL ENCLOSED VESSEL, etc)
(i) 30mA ELCB shall be used. Electrical Engineer/Supervisor
shall perform a round check every quarterly.
(ii) ELCB shall be tested daily prior starting the work.

14. EARTHING OR GROUNDING

Grounding or earthing is necessary as a prelude to handling potentially
live parts. The purpose of equipment grounding is to:
a. Dissipate any electrical charge. This may be due to long lengths of
cables, motors, capacitors, etc., and electrical testing (megger,
high potential, etc.) done on the equipment.
b. Prevent/minimize the effect of inadvertent recharging of the
equipment after its isolation. There are a number of ways; voltages
may reappear on a dead or switched-off circuit or equipment.
e.g. Back-feeds from control or potential transformers.
Alternate power sources or undocumented or unknown alternate
power supplies.
Circuit or equipment not energized or working at the time of voltage
checks.
Lightning, induced voltages energized line contacting a de-
energized line.
Insulation failure (extension cord, etc.), etc.

15. ELECTRICAL EQUIPMENT IN HAZARDOUS/CLASSIFIED AREA

Only equipment certified/suitable for use in classified area shall be used in
classified area. A hot work permit is required for equipment/testing
equipment/portable tools that are not certified for the classified area.
Electrical equipment with arcing devices must not be opened in classified
area unless power to the arcing devices has been switched-off. Electrical
equipment with arcing devices can be opened in the classified area with
electrical work permit with use of Non-IS equipment check box is checked.
LEL monitor shall be worn.

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16. ELECTRICAL SAFETY INTERLOCKS.

Electrical Safety Interlocks are mechanical linkages or other devices which
prevent exposure to energized parts or circuits when starter/breaker doors are
opened. These interlocks may be defeated or rendered inoperative so that tests
or maintenance work can be done.

(i) Only a qualified person may defeat electrical safety interlock, and then
only temporarily while he or she is working on the equipment. The
interlock system shall be returned to its operable condition when this work
is completed.
(ii) Where Electrical interlocks needs to be defeated or disabled, it is to be
clearly stated and identified in the Job Hazard Check list and shall be
approved by a second engineer / FLS.

NOTE:
If interlocks at starter/breaker doors are defeated to perform inspection
or electrical work at the starter/breaker, precautions and personal
protective equipment as applicable to the voltage level shall be used.

17. EQUIPMENT IDENTIFICATION

All equipment identifications must be legible and permanently fixed.

18. FUSES
When fuses are installed or removed with one or both terminals
energized, applicable fuse pullers or fuse-handling equipment shall be
used.
Fuses shall be checked for continuity and proper rating and type before
putting them in service. A blown fuse can cause single phasing to
electrical motors, automatic transfer of power sources, etc.

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19. HEAT TRACING (ELECTRIC) SYSTEMS
1. All appropriate process personnel should be notified about the work
involved and consequences of any inadvertent actions.
2. All non-electrical work (insulation work, working on valve & pipe,
etc.) on electrically heat traced equipment, should not be done
without reviewing the work with the area electrical maintenance
group. The power supply to the associated heat tracing circuit
should be switched off while non-electrical work is in progress.
3. Care should be taken that thermostat / controller settings not be
disturbed.
4. Only electrical maintenance group can remove the electric heat-
traced lines.
5. After completion of insulation work, electrical group shall reinstate
back all warning labels and line identification labels.

20. HOUSEKEEPING DUTIES

a. Where live parts present an electrical contact hazard, employees
may not perform housekeeping duties at such close distances to
the parts that there is a possibility of contact, unless adequate
safeguards (such as barriers) are provided. Electrically conductive
cleaning materials (including conductive solids such as steel wool,
metalized cloth, and silicon carbide, as well as conductive liquid
solutions) may not be used in proximity to energized parts unless
procedures are followed which will prevent electrical contact.
b. Materials for work in areas outside the substations should not be
stored in the substations.
c. Eating, drinking and smoking in the substations and MCC
rooms are not allowed.

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21. INSULATED HAND-HELD GROUND STICKS

Insulated hand-held ground sticks with voltage rated gloves and eye
protection shall be used when discharging the electrical equipment after
removal of their power source and applying grounds on and removing
grounds from the equipment. If it is not feasible to use the insulated hand-
held ground sticks because of space constraint, ground wire with voltage
rated gloves may be used for discharging the equipment.

22. JOB BRIEFING and JOB SAFETY ANALYSIS

a. GENERAL
Please refer to PDR JSA PROCEDURE (SHE Infobank : IBPDR-
SWPM-10427)

23. LIGHTING OR ILLUMINATION

a. Employees shall not enter spaces containing exposed energized
parts, unless lighting or illumination is provided that enables the
employees to perform the work safely.
b. Whenever natural light is insufficient to illuminate the worksite,
artificial lighting shall be provided to enable the individual to perform
the work safely.
c. Please refer to Confine Space Procedure (SHE Infobank : IBPDR-
SWPM-10435)

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24. LIGHTS
a. FLASHLIGHTS
Flashlights having Underwriters Laboratory (UL), Factory
Mutual (FM) or equivalent agency approvals are the only type
permitted for use in hazardous (classified) locations.

b. PORTABLE LIGHTS
Approved portable lights suitable for the area classification
must be used.
(i) Do not remove vapor-proof globes except for
cleaning, repairing or replacing lamps.
(ii) Only Qualified Person shall open explosion-proof
fixtures.

25. MOTORS AND GENERATORS

Motors and Generators shall be de-energized before any work to
commerce on them. Voltage testing shall be performed before
disconnection of cables from the terminals. If the end covers needed to
be removed, the space heater power shall be isolated. When any motor is
re-installed after repair, the grounding connection shall be made first.

26. PORTABLE LADDERS

Portable ladders shall have non-conductive side rails if they are to be used
where the employee or the ladder could contact exposed energized parts.
Use of fiber glass ladders is recommended. Note that wooden ladders
may absorb moisture and chemicals.
Use of all metal ladders is prohibited.
Portable ladders shall be visually inspected prior to use for damage.
Portable ladders shall be inspected periodically.

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27. PROTECTIVE DEVICE RATINGS AND SETTINGS

Fuse rating, type and relay settings including over current and earth
protection of circuits, conductors and equipment shall not be modified
without a management of change (MOC) process.

28. RECLOSING CIRCUITS AFTER PROTECTIVE DEVICE

OPERATION
After a circuit is de-energized automatically by a circuit protective device,
the circuit shall not be electrically or manually re-energized until it has
been determined that the equipment and circuit can be safely energized.
The repetitive manual re closing of circuit breakers or re-energizing
circuits through replaced fuses is prohibited.

NOTE:
When it can be determined from the design of the circuit and the
over current devices involved that the automatic operation of a
device was caused by an overload rather than fault condition, no
examination of the circuit or connected equipment is needed
before the circuit is re-energised.

29. ROUTINE OPENING AND CLOSING OF CIRCUITS

Load rated switches, circuit breakers, or other devices specifically
designed as disconnecting means shall be used for the opening,
reversing, or closing of circuits under load conditions. Fuses, terminal
lugs shall not be used for such purposes.

30. SAFETY LOCK-OUT TAG-OUT

Electrical lockout tag out procedure (SHE Infobank : IBPDR-SWPM-10429)
shall be followed for safety lockout

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31. STORED ENERGY

a. STORED ELECTRIC ENERGY

Stored electric energy, which might endanger personnel, shall be
released. Capacitors shall be discharged and high capacitance
elements shall be short-circuited and grounded, if the stored electric
energy might endanger personnel.
Allow sufficient time (Minimum 15 minutes) to discharge the
charged energy after de-energizing the power supply before starting
the work.

b. STORED NON-ELECTRICAL ENERGY

Stored non-electrical energy in devices (e.g. closing spring) that
could reenergize electric circuit parts shall be blocked or relieved to
the extent that the device could not accidentally energize the circuit
parts.(e.g. by mechanically closing and opening the breaker after
switched off the control power supply).

32. SWITCHGEARS AND MOTOR CONTROL CENTERS

a. Work on switchgears or Motor Control Centers (MCC) shall be
performed only by Qualified Persons.( Except switching and rack-
in/out)
b. Even if a breaker or starter module is drawn out to test position, the
component or module can be energized through D.C./A.C. control
power and/or space heater supply. Special consideration shall be
given to these wires/terminals.
c. For low voltage MCC, live vertical bus is exposed once the starter is
drawn out in some designs. Barriers shall be used, once the starter
is drawn out.
d. Multimeter shall not be used at switchgear or MCC bus to check
voltage unless these are equipped with fused terminals. Neon
voltage detector shall be used for high tension.

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e. Voltage back feed possibilities shall be evaluated before any work
on switchgears and MCCs and necessary precautions shall be
taken.
f. For any work on bus, double point isolation should be achieved.

33. SUBSTATIONS
This section provides requirements for substations and for work
performed in them.
a. ACCESS AND WORKING SPACE
Sufficient access and working space shall be provided and
maintained about electric equipment to permit ready and safe
operation and maintenance of such equipment.
At least two gates shall be kept open for any work inside
transformer yard or substation cellar.
b. OUTDOOR SWITCHYARD SUBSTATION FENCES
Conductive fences around substations shall be grounded. When a
substation fence is expanded or a section is removed, fence-
grounding continuity shall be maintained, and bonding shall be
used to prevent electrical discontinuity.
c. GUARDING OF ROOMS CONTAINING ELECTRIC SUPPLY
EQUIPMENT
(i) There shall be no exposed live parts operating at greater
than 24 volts to ground located inside the room or space

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(ii) Except for fuse replacement and other necessary access by
qualified persons, the guarding of energized parts within a
compartment shall be maintained during operation and
maintenance functions to prevent accidental contact with
energized parts and to prevent tools or other equipment
from being dropped on energized parts.
(iii) When guards are removed from energized equipment,
barriers shall be installed around the work area to prevent
personnel who are not working on the equipment, but who
are in the area, from contacting the exposed live parts.
d. ENTRY TO SUBSTATIONS/TRANSF YARD
1. General Guideline :
(i) Only L.E.W are allowed to hold the substation/LOTO key.
List of L.E.W as attached in APPENDIX II.
(ii) For any entry for work the relevant work permits from
electrical FLS is required
(iii) Keys shall be obtained from Electrical maintenance.
Only EM and EMR are authorized to withdraw the substation
keys. Operation shall not issue any key to non-operation
personnel.
(iv) For situations where other work is in progress, the
EM/MR/worker shall check with the other parties there about
existing conditions affecting the safety of the workers.
(v) All doors shall be locked after work
(vi) No eating, drinking, smoking and sleeping allowed
2. Contractors :
(i) For visual inspections, inform electrical FLS. No additional
permit for entry required.
(ii) All work shall be supervised by EM/EMR.

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List of EMR shall be submitted to Electrical Maintenance for
authorization. There shall be 2 categories of EMR.
(Cat 1-electrical work, Cat 2-non electrical work)

3. Employees
(i) Entry for LOTO purposes do not require additional
electrical permit for entry and do not need to inform elect
FLS. All other parties need to inform elect FLS.
(ii) Entry for visual inspections by IEA maintenance and
operation do not require additional electrical permit for entry
and do not need to inform elect FLS. All other parties need
to inform elect FLS.

36. VOLTAGE BACKFEED

a. Prior to start of any work on electrical circuits or equipment, it is
essential that the possibilities of voltage back feed to the circuits
and equipment to be worked on are thoroughly evaluated and
necessary precautions taken to ensure the safety of personnel and
equipment.
b. To ensure no back feed from the upstream, downstream and
parallel sources of power and the equipment, one, more or all of the
following may be required:
(i) Remove potential and control power transformers’ primary
and secondary fuses.
(ii) Isolate the DC control power source.
(iii) Open, lock and tag out the source and alternate breakers
that if inadvertently closed may energize the equipment or
circuit isolated for work.
(iv) Ground the equipment and circuit for the safety of the
personnel.
(v) Isolate, discharge and ground the capacitors.

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37. WORK PERMIT
a. For all electrical work including house keeping a work permit is
required.
b. No work should be done outside the work area defined by the
permit and or the safety warning devices that may include area
barricades.
38. MISCELLANEOUS
a. Never touch a piece of apparatus under test with which you are not
directly concerned.
b. Beware of injury from mechanical action of electrical equipment.
c. Remove any water around electrical tools or machines.
d. Always replace and tighten all bolts on an electrical housing after
servicing.

E. DE-ENERGIZING CIRCUITS AND EQUIPMENTS FOR

ELECTRICAL WORK
The following requirements shall be met before any circuits or equipment can be
considered de-energized and worked on by a qualified person

1. EQUIPMENT OR CIRCUIT ISOLATION / DE-ENERGISING

a. For isolation, refer to OIMS6.2 LOTO Procedure (SHE Infobank :
IBPDR-SWPM-10429).
b. Interlocks for electric equipment shall not be used as a substitute
for lockout and tag out procedures.
c. Stored electric energy that might endanger personnel shall be
released. Capacitors shall be discharged and high capacitance
elements shall be short-circuited and grounded, if the stored
electric energy might endanger personnel.
d. Stored non-electrical energy in devices that could reenergize
electric circuit parts shall be blocked or relieved to the extent that
the device could not accidentally energize the circuit parts. (E.g.
spring charging mechanism in circuit breaker)

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2. VERIFICATION OF DE-ENERGISATION
a. If any work to be carried out on the de-energized electrical
equipment or any equipment driven by electric motor then
verification of de-energization is required.
b. Test equipment shall be used to test the circuit elements and
electrical parts of equipment to which the employees will be
exposed and shall verify that the circuit elements and equipment
are de-energized.
c. The test shall also determine if any energized condition exists as a
result of inadvertently induced voltage or unrelated voltage back
feed even though specific parts of the circuit have been de-
energized and presumed to be safe.
d. Where built-in grounding facility is not available or where it cannot
be ascertained positively that the circuit is de-energized a qualified
person shall prove that the circuit is de-energized before they apply
grounds or begin “hands-on” work using the “Three Step Voltage
Check” listed below.
e. Testing instruments and equipment shall be visually inspected for
external defects or damage before using to determine de-
energization.

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3. VOLTAGE TESTING - THE THREE STEP VOLTAGE CHECK
The three-step voltage check shall be performed with an approved
circuit tester to test the circuit to which they will be exposed to verify that
the equipment parts are de-energized. The circuit tester shall be
checked for proper operation immediately before and immediately after
this test according to the following procedure:
a. Prove the integrity of the voltage tester by testing it on a known live
circuit or power source.
b. Check that the nominal voltage is absent on the de-energized
equipment between all phases and between each phase and
ground. Do not assume that the equipment is “dead” and safe to
touch or install grounds until the next step is completed.
c. Reprove the integrity of the voltage tester by testing it on a known
live circuit or power source.

Low Voltage Test with nearby known live source.

Proximity

By keeping the voltage selector at 230 V test with a known source

Type

before proceeding to test for rated voltage.

High voltage

By pressing the test button

contact
Direct

type

4. GROUNDING OR EARTHING OF CIRCUITS AND EQUIPMENT

FOR THE PROTECTION OF WORKERS
a. GENERAL
For the employees to work on equipment or circuits as “de-
energized”, the equipment or circuits shall be de-energized and
shall be earthed or grounded. However, if the installation of an
earth or ground is impracticable or if the conditions resulting from
the installation of a ground would present greater hazards than
working without grounds, the lines and equipment may be treated
as de-energized provided all of the following conditions are met:

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(i) The equipment and circuits have been de-energized
following the lockout/tag out procedures.
(ii) There is no possibility of contact with another energized
source.
(iii) The hazard of induced voltage is not present.

b. PURPOSE OF GROUNDING OR EARTHING

Grounding or earthing is necessary as a prelude to handling
potentially live parts. The purpose of temporary protective
grounding is to:
(i) Dissipate any electrical charge. This may be due to long
lengths of cables, motors, capacitors, etc., and testing
(megger, high potential, etc.) done on the equipment.
(ii) Prevent/minimize the effect of inadvertent recharging of the
equipment after its isolation. There are a number of ways,
voltages may reappear on a dead or switched-off circuit or
equipment,
 Back feed from control or potential transformers,
 Alternate power sources, undocumented or unknown
alternate power supplies,
 Circuit or equipment not energized or working at the time of
voltage checks,
 Lightning, induced voltages, energized line contacting a de-
energized line, insulation failure (extension cord, etc.),

c. PROVEN METHOD OF EARTHING

 Via circuit breaker with integral earthing.
 Via circuit breaker with bolt-on earthing.
 Via an earthing truck.
 Portable earths applied by means of insulated sticks.
 Portable earths applied manually.

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d. LOCATION OF GROUNDS
(i) Temporary protective grounds should be placed at the work
location. However, if the installation of temporary protective
grounds at the work location is infeasible, grounds should be
installed at switchgear end from where the power is fed. E.g.
Upon power cable disconnection from the motor, all three
phase wires shall be shorted and grounded.
(ii) All temporary grounds shall be logged and "circuit grounded'
indication shall be placed at the ground and switchgear
location.

e. PROTECTIVE GROUNDING EQUIPMENT

(i) Protective grounding equipment shall be capable of
conducting the maximum fault current that could flow at the
point of grounding for the time necessary to clear the fault.
This equipment shall have an ampacity at least equal to that
of 70 mm² copper cable or the ampacity of the phase
conductor of the system.
(ii) Protective grounds shall have the impedance to ground low
enough to permit prompt operation of protective devices in
case of accidental energising of the lines or equipment
(iii) Always make sure the connections to ground are properly
secured (e.g.; use C-clamp grounding equipment).
(iv) Grounding leads shall be applied by means of insulated
sticks or manually with use of voltage rated insulating rubber
gloves.
(v) Grounding leads or cables should be properly maintained
and always examined immediately prior to use.
(vi) Grounding leads or cables shall be connected to all phases,
even if work is to be carried out on one phase only.

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f. TESTING
Before any ground is installed, lines and equipment shall be tested
and confirmed for absence of voltage, unless a previously installed
ground is present.

g SEQUENCE OF CONNECTING GROUNDS

When grounds are to be attached to lines or equipment, the
ground-end connection shall be attached first, and then the other
end shall be attached by means of live-line tools or manually with
use of voltage rated insulating rubber gloves.

h. SEQUENCE OF REMOVAL OF GROUNDS

When a ground is to be removed, the grounding device shall be
removed from the line or equipment using a live-line tool or
manually with use of voltage rated insulating rubber gloves before
the ground-end connection is removed.

i. REMOVAL OF GROUNDS FOR TEST

Grounds may be removed temporarily during tests. During the test
procedure, the supervisor shall ensure that each worker uses
insulating equipment and is isolated from any hazards involved,
and the supervisor shall institute any additional measures as may
be necessary to protect each exposed worker in case the
previously grounded lines and equipment become energized.

j. ADDITIONAL PRECAUTIONS
(i) When work is performed on a cable at a location remote
from the cable terminal, the cable may not be grounded at
the cable terminal if there is a possibility of hazardous
transfer of potential should a fault occur. Therefore, ground
as close to the work location as practical.
(ii) DOORS OF GROUNDED EQUIPMENT
Doors of the grounded equipment, where possible, practical
and applicable, should be left open for the duration of the
work until the work is completed and grounds are removed

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(iii) GROUND INSTALLED SIGNS
 Circuit Earthed signs should be placed on the door of the
equipment that has been grounded and also at the
MCC/switchgear . This is intended to remind the workers
that the grounds are to be removed before re-energizing
the equipment.
 Circuit Earthed signs shall be of weatherproof material.

F. RE-ENERGISING ELECTRICAL CIRCUITS AND EQUIPMENT

These requirements shall be met, in the order given, before circuits or equipment
are re-energized, even temporarily.
1. A qualified person shall conduct tests and visual inspections, as
necessary, to verify that all tools, electrical jumpers, shorts, grounds,
cover, guards and other such devices have been removed, and control
fuses are all in place so that the circuits and equipment can be safely
energized.
2. Employees exposed to the hazards associated with re-energizing the
circuit or equipment shall be warned to stay clear of circuits and
equipment (when the circuits and equipment are re-energized).
3. Removal of locks/tags shall follow electrical lock/tag procedure( See SHE
Infobank : IBPDR-SWPM-10429).
4. There shall be a visual determination that all employees are clear of the
circuits and equipment.
5. Before a draw-out circuit breaker or contactor is inserted into a cubicle, it
shall be verified that the device is in the “open” position and control power
is switched off and make sure that there is no active close signals /
remote on signals.
6. Notify process or control centre before the switching to restore the system
begins and after the switching is completed

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7. Wherever available, use remote controls, to operate switchgear breakers.
8. Doors shall be properly closed when operating the switchgear breakers.
9. Always stand to the side of the cubicle and face away when operating a
circuit breaker.
10. Do not operate energized electrical equipment with its cover off except in
test position and use appropriate PPE.
11. Establish effective communication between the workgroup involved before
the re-energization.

G. WORKING ON LIVE EQUIPMENTS OR IN CLOSE PROXIMITY TO LIVE

EQUIPMENTS
1. General
a. All work shall be considered live except verification /measurements
of voltages/currents.

b. For live work at 380V (3phase /DC) nominal and above - SOC
approval is required
c. For live work below 380V (3phase/DC) nominal - I/E FLS approval
is required.
d. All live work shall be done in pair.
e. Work shall be done by qualified persons.
f. Approved PPE/insulated tools/test equipments shall be used

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2. TESTING OF CIRCUITS AND EQUIPMENT

a. GENERAL
Use of proper testing procedures and equipment is required to
insure personnel and equipment safety.
(i) Prior to starting work and discharging the circuits and
equipment, voltage tests shall be made to ensure that electrical
voltages are not present.
(ii) Persons testing circuits shall use Approved Personal
Protective Equipment.
(iii) Inspect test equipment for external defects prior to use. If a
defect is found, take it out of service until repairs and tests
have been made.
(iv) Test equipment, devices and leads shall be approved, rated
for the voltage and suitable for the electrical area
classification.
(v) Test equipment, devices and leads must be used per
manufacturer’s instructions.

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b. EXAMPLES OF TESTING
Following are a few typical examples of Testing Work:
i) Voltage testing both on live or potentially live circuits or
equipment.
ii) Current testing including secondary injection test.
iii) Phasing Check.
iv) Insulation resistance testing.
v) High-Potential testing.

c. VOLTAGE OR CURRENT TESTING

This section details requirements for voltage testing, and current testing
or measurements at non-insulated conductors or bus bars.
i) Certified voltage and current testing equipment and leads shall
be used.
ii) Qualified Persons shall perform voltage or current tests on
electric circuits, parts or equipment.
iii) Voltage Rated Rubber Gloves shall be used.
iv) Work shall be done in pair.

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d. INSULATION RESISTANCE TESTING OF CIRCUITS AND
EQUIPMENT
i) Prior to start of testing insulation resistance of
electrical busses (switchgear, MCC, etc.), ensure all
associated control power transformers and potential
transformers are disconnected from the circuit. This
is achieved, where applicable, by removing their
primary and secondary fuses.
ii) If motors are to be tested for insulation resistance,
make sure the capacitors used for starting the motor,
power factor correction or surge suppression are not
in the circuit.
iii) Use of insulation resistance tester in hazardous or
classified locations requires a ‘Hot Work Permit’.
iv) In additional to standard PPE, appropriate voltage
level gloves shall be used.
v) Guard against persons coming into contact with
circuits and apparatus while they are being tested.
Refer Alerting Techniques.
vi) After insulation testing, residual voltage shall be
discharged by means of ground cables. Connect
ground cable at the ground side followed by
equipment side.
e. HIGH-POTENTIAL TESTING OF CIRCUITS AND
EQUIPMENT
i) Prior to start of high-potential testing of electrical
busses (switchgear, MCC, etc;), ensure all associated
control power transformers and potential transformers
are disconnected from the circuit. This is achieved,
where applicable, by removing their primary and
secondary fuses.

ii) Approved Personal Protective Equipment shall be

used.

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iii) Test power disconnects are clearly marked and
readily available in an emergency.
iv) Protect all persons from energized parts using
Alerting Techniques. ( refer to Section D.2)
v) Ensure high potential test equipment is grounded to
the system ground grid prior to its use.
vi) After high potential testing, ground the tested circuits
and equipment to drain off static charges.

H. PORTABLE ELECTRIC EQUIPMENT

This section applies to the use of cord and plug-connected equipment, including
flexible cord sets (extension cords).
1. GENERAL
a. All portable equipment shall be inspected/ tested by an appropriate
LEW before its use. All portable equipment shall have a valid
approved sticker.

b. Flexible electric cords connected to equipment may not be used for

raising or lowering the equipment.

c. Flexible electric cords may not be fastened with staples or

otherwise suspended in such a fashion as could damage the outer
jacket or insulation.
d. Do not tie flexible electric extension cords in knots nor tie them to a
support.

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e. Avoid routing flexible extension cords through doorways, under
mats, under carpet or other pinch points. If such routing is
necessary, provisions should be made to protect the cord.
f. Do not lay extension cords across roads or walkways unless
protected by a conduit or a rigid metal frame for complete width of
the road or walkway. Whenever possible, run extension cords
overhead to prevent damage to insulation.
g. All cords should be positioned to eliminate tripping hazard. If it is
not feasible, then place `caution’ sign(s) or barrier(s) as needed to
alert the people in the area.
h. When using a pigtail the normal plugs are to be connected prior to
the connection of the explosion-proof plug.

NOTE:
Only qualified persons are authorised to replace or repair any
electrical equipment. This includes, but is not limited to, the plugs
and caps on extension cords or tools.

2. VISUAL INSPECTION

a. Portable and cord and plug-connected equipment and flexible

cord sets (extension cords) shall be visually inspected before use
for external defects (such as loose parts, deformed and missing
pins, or damage to outer jacket or insulation) and for evidence of
possible internal damage (such as pinched or crushed outer jacket).

b. Do not use defective or modified equipment.

c. Do not use spliced extension cords.

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3. GROUNDING-TYPE EQUIPMENT
a. For those electrical portable equipment having earth pin / terminal
shall be effectively grounded to the source earth by earthing
conductor of suitable size
b. Attachment plugs and receptacles shall not be connected or altered
in a manner which would prevent proper continuity of the
equipment grounding conductor at the point where plugs are
attached to receptacles.
e. Do not remove, defeat or modify in any way the grounding prong or
grounding conductor on tools, receptacles or extension cords.
f. All 3-wire electric powered tools shall be grounded or earthed
before using.
4. CONDUCTIVE WORK LOCATIONS
a. Portable electric equipment and flexible cords used in conductive
locations (such as those inundated with water or other conductive
liquids), or in job locations where employees are likely to contact
water or conductive liquids, shall be approved for those locations.
b. Do not stand in water when using electrical equipment.

c. Always use earth leakage circuit breakers.

5. CONNECTING ATTACHMENT PLUGS
a. Wet Hands
Employees’ hands shall not be wet when plugging and unplugging
flexible cords and cord- and plug-connected equipment, if
energized equipment is involved.
b. Wet Plug or Connection:
Energized plug and receptacle connections shall be handled only
with insulating protective equipment if the condition of the
connection could provide a conducting path to the employee’s hand
(if, for example, a cord connector is wet from being immersed in
water).
c. Locking-type connectors shall be properly secured after
connection.

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6. PORTABLE AND VEHICLE MOUNTED GENERATORS
a. The non-current carrying metal parts of equipment and the
equipment grounding conductor terminals of the receptacles shall
be bonded to the generator frame.
b. In the case of vehicle-mounted generators, the frame of the
generator shall be bonded to the vehicle frame.
c. Any neutral conductor shall be bonded to the generator frame.
d. Generator frame shall be grounded to the ground grid. Grounding
shall be done with stranded copper conductor sized at least half of
the power cable with 70mm² maximum.
e. The generator feeders shall be equipped with earth leakage circuit
breakers.
f. An approved flame spark arrestor shall be mounted at the generator
exhaust.

I. PERSONAL AND OTHER PROTECTIVE EQUIPMENT

1. INTRODUCTION
Employees working in areas where there are potential electrical hazards
shall use electrical protective equipment that is appropriate for the specific
parts of the body to be protected and for the work to be done. Please refer
to Appendix I - PPE Table For Electrical Tasks for the specific PPE
requirements.

All persons shall be safeguarded from injury and shock by protective

equipment appropriate for the work to be performed. All personal and
other protective equipment shall be of safe design and construction for the
specific part(s) of the body to be protected and for the work to be
performed.

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2. BODY PROTECTION

For any live or proximity or testing works on electrical system, protection

of the body is required. Please refer Appendix I - PPE Table For Electrical
Tasks for the specific PPE requirements.

3. HAND PROTECTION
a. Worker's hands shall be protected from electrical burns and shock.
Appropriate voltage rated gloves shall be used when hand
protection is required specified in the procedure.
b. The purpose of leather protectors is to provide mechanical
protection only for the rubber gloves and rubber mittens. The
leather protectors shall not be used for electrical protection.
c. The protector glove shall be sized and shaped so that the
insulating glove shall not be deformed from its natural shape.
d. Leather glove protectors shall be worn over rubber insulating
gloves.
e. Gloves or sleeves shall not be bundled together with tape.
f. Gloves shall be stored in their natural shape. Gloves may be kept
inside of protectors or in a bag, box, or container that is designed
for and used exclusively for them.
g. Gloves shall be wiped clean of any oil, grease, or other damaging
substance as soon as practicable.
h. Gloves may be washed with mild soap and water and air-dried.
Extra care is needed in the visual examination of the gloves and in
the avoidance of handling sharp objects.

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i. Gloves and sleeves with any of the following defects shall not be
used and shall be returned to an electrical testing facility for
inspection and electrical retest:
(i) Holes, tears, punctures, or cuts.
(ii) Ozone cutting or ozone checking.
(iii) Imbedded foreign objects.
(iv) Texture changes: swelling, softening, hardening, and
becoming sticky and inelastic
(v) Other defects that damage the insulating properties.
j. Insulating gloves shall be given an air test by rolling the cuff tightly
toward the palm in such a manner that air is entrapped inside the
glove. The glove shall be examined for punctures and other
defects. Puncture detection may be enhanced by listening for
escaping air or holding the gloves against the worker’s cheek to
feel for escaping air.
k. Gloves shall be air-tested before every use and at times if there is
a cause to suspect any damage.
l. Low voltage gloves shall be replaced annually or when damaged.
High voltage gloves shall be replaced when damaged.
m. Cloth gloves may be worn inside of insulating gloves for warmth in
cold weather and to absorb perspiration in hot weather.

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4. EYE AND FACE PROTECTION
a. Safety glasses with side-shields shall be used.
b. Protection of eyes and face from electric arcs or flashes. (Refer to
Appendix I - PPE Table For Electrical Tasks for the specific PPE
requirements.
5. HEAD PROTECTION
a. Employees shall wear non-conductive and approved head
protection wherever there is danger of head injury from electric
shock or burns due to contact with exposed energized parts.(Refer
to Appendix I - PPE Table For Electrical Tasks for the specific PPE
requirements.)
b. Earmuffs with metal frame or connecting strip attachment shall not
be worn while working near energized electrical equipment.
6. INSULATING MATS
Insulating mats or di-electric boots shall be used to provide additional
protection to the worker. Insulating mats may be removed temporarily to
facilitate installation or removal of the de-energized medium voltage
starters or breakers from their enclosures or housings. Rubber insulating
mats should remain flexible for use through normal temperature ranges

Voltage Requirements for Insulating Mats - ASTM D 178-93

Nominal Max.
Class of Use Voltage D-C Proof-
Insulating Phase-Phase A-C Proof-Test Test Voltage,
Mats AC- rms, Max Voltage, rms V Avg, V
0 1,000 5,000 20,000
1 7,500 10,000 40,000
2 17,000 20,000 50,000
3 26,500 30,000 60,000
4 36,000 40,000 70,000

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7. INSULATED TOOLS
When working near exposed energized conductors or circuit parts, each
employee shall use insulated tools or handling equipment if the tools or
handling equipment might make contact with such conductors or parts. If
the insulating capability of insulated tools is subject to damage, the
insulating material shall be protected.

Insulated tools shall never be relied upon for total protection from electric
shocks. Insulated tools with other appropriate and applicable personal
protective equipment (gloves) shall be used to provide protection from
electric shocks.

NOTE: Tools with plastic-dipped handle shall not be used on or near

energized circuits or equipment. The plastic dipped handles are for
comfort and a firmer grip and are not intended for protection against
electric shock.

8. PERSONAL PROTECTIVE EQUIPMENT FOR WORK ON

BATTERIES
While working on or near batteries, there is a potential for exposure to
corrosive liquids. Use of Chemical splash proof Goggles and Face-Shield,
Gloves, Aprons is mandatory.

9 FUSE HANDLING EQUIPMENT

Fuse handling equipment, insulated for the circuit voltage, shall be to remove
or install fuses when fuse terminals are energized

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.
10 PERSONAL PROTECTIVE EQUIPMENT FOR
CONTRACTORS
a. For contractors providing their own protective equipment, the
contractor shall be responsible to assure its adequacy, including
proper maintenance, and sanitation of such equipment.
b. All personal and other protective equipment shall comply with the
requirements of this procedure and all applicable standards.

J. TEST INSTRUMENTS AND EQUIPMENT

1. GENERAL
Only qualified persons shall perform testing work on electric circuits or
equipment. All electrical testing and measurements shall be done with
approved or manufacturer's certified test instruments and equipment. Test
instruments and equipment and all accessories shall be rated for the
circuits and equipment to which they will be connected, and shall be
designed for the environment in which they will be used.

2. VISUAL INSPECTION OF TEST INSTRUMENTS AND EQUIPMENT

Test instruments and equipment and all associated test leads, cables
power cords, probes, and connectors shall be visually inspected for
external defects or damage before they are used. If there is a defect or
evidence of damage that might expose an employee to injury, the
defective or damaged item shall be removed from service, and no
employee shall use it until repairs and test necessary to render the
equipment safe have been made.

** End of Procedure **

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APPENDIX I - PPE TABLE FOR ELECTRICAL TASKS

The following PPE table is included for reference and use by all sites. Each site is responsible for
performing a site-specific and equipment-specific PPE analysis. Equipment type and incident energy
exposure may require more or less stringent PPE requirements, precautions and procedures.
Nominal Voltage (AC or DC) (Note 4)
<130V 130V to 300V 300V to >1000V
Task 1000V
Live Work (Note 1) A, B A, B, D, F A, B, C, D, F Not Permitted

Proximity Work A, B A, B, D, F A, B, C, D, F Not Permitted

Voltage Testing to A, E A, E A, E A, C, D, E, F
Prove 'Dead'

Testing/Measurement A, E A, D, E A, D, E, F A, C, D, E, F
on Live Equipment
Application of N/A N/A A, C A, C
Temporary Grounds or
Discharging of Power
Cables after Voltage
Checks
Rack In/Out of N/A N/A A, C, D** A, C, D**
Equipment From
Energized Bus-bars
Consult Consult BP Consult BP Consult BP
Other activities BP details for details for details for
details for guidance guidance guidance
guidance

Code PPE and Equipment Description

A Voltage Rated Gloves
B Approved insulated tools and/or insulating barriers, blankets, shields or guards
C Arc Flash Gloves, ATPV Rated or -
2
Incident Energy < 8 Cal/ cm : Leather Gloves
2
Incident Energy > 8 Cal/cm : Class 2 Voltage Rated Gloves with Leather
Protectors
D Appropriate PPE including Arc Flash PPE where required - **Arc Flash PPE may not be
required when racking in or out with approved arc-resistant switchgear (See Section
9.3.2.3)
E Voltage Rated Test equipment
F 2nd Person Required
N/A Not Applicable
Notes:
1. Live work shall not be permitted unless it is unreasonable in all the circumstances to de-
energize the equipment and reasonable in all the circumstances to work 'live'
2. 'Basic PPE' applicable for all tasks is long sleeved fire retardant shirt/pants or coverall,
safety glasses with side shields, safety shoes/boots.
3. Hearing protection should be considered when the calculated incident energy exposure
is greater than 1.2 cal/cm2
4. All voltages are represented as the highest exposure voltage for the work being done,
whether that is line-to-line or line-to-ground.

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APPENDIX II
EC Licensed Electrical Worker

EC Work Authorization
Name
Certificate 11kV 3.3kV > 1kV
Mustafa Mahbut 33kV-B4 √ √ √
Foo Dai Hing 33kV-B4 √ √ √
Haron Masani 11kV-B0-1 √ √ √
Mohd Khalid Mohd Sah 11kV-B0 √ √ √
Kholil Osman 11kV-B0 √ √ √
Rashid Ismail A0 √

Note*: Only EC Licensed Electrical Worker are allowed to hold substation key

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APPENDIX III
Arc Flash Hazards Warning Label

! WARNING !
Arc Flash Hazards
Appropriate PPE Required
65 cal/cm2 Flash Suit, Face-Shield, Hood
Flash Protection Boundary – Outside
Substation
cal/cm2 Flash Hazard at 450mm

Location :

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