SAFE WORK PRACTICES CORPORATE

FOR HSE
PROJECT SITES DEPARTMENT

SAFE WORK PRACTICES

FOR

PROJECT SITES
 ELECTRICAL SAFE WORK PRACTICES CORPORATE
FOR HSE
CONSTRUCTION SITES DEPARTMENT

INDEX

Section Content Pages

1. SCOPE AND PURPOSE 2-2

2. RESPONSIBILITY 2-2

3. PRACTICES 2-6

4. JOB RESPONSIBILITIES 9-10

5. CHECK LIST 10-10

6. APPENDIX A - CHECK LIST 11-21

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 ELECTRICAL SAFE WORK PRACTICES CORPORATE
FOR HSE
CONSTRUCTION SITES DEPARTMENT

1. SCOPE AND PURPOSE

This document defines the procedures to be followed for Electrical Equipments at Project sites.

The main goals are to follow safe practices for mobile electrical apparatus and equipment at Project site.
This document include the following:

a) Mobile Electrical Equipment Operation.

b) Electrical Forklifts
c) Power tools
d) Electrical Arc Welding Machine
e) Grinders
f) Temporary Electrical Installation for Construction
g) Cable Termination
h) Extension of LV Switchboard
i) Motor
j) Equipment in Hazardous Area
k) Earthing System
l) Lighting System

This Safe Work Practices includes Check List and have been written as one document for ease of reading. It
also describes the steps and measures to be taken in protecting workers from the hazards arising from the
work, and in reducing injuries and damage caused by electric shock.

2. RESPONSIBILITY

The responsibilities to execute any job at construction site are defined for following personal:

i. Job performer – Worker

ii. Construction Contractor
iii. Owner of the Project

It is the primarily duty of owner of the project of any industrial plant to ensure, the safety and health at work
of all agencies employed by him during construction phase in the industrial project. The owner including
contractor in industrial project should demonstrate the commitment in managing safety and health and bear
the final responsibility and accountability for the safety and health in any industrial project.

3. PRACTICES

3.1 MOBILE ELECTRICAL EQUIPMENT OPERATION

Employees must not operate any mobile equipment unless they:

 Possess the necessary certificates to operate such equipment

 Have received adequate instruction and training that they are able to operate the equipment
 Are familiar with the operating instructions pertaining to the equipment
 Have been authorized to operate the equipment
 Are familiar with the safe operation of the mobile equipment.

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Operators of mobile equipment are directly responsible for the safe operation of that equipment. They shall
maintain full control of the equipment at all times and comply with all the safety regulations regarding the
operation of the equipment.

3.2 ELECTRIC FORKLIFTS

Electrical Forklift operators must follow all applicable vehicle and mobile equipment safety rules which
includes following:

 Materials and equipment must be loaded on the forklift in a manner that prevents any movement of
the load, which could create a hazard to workers.
 All loads which could be subject to shifting during transportation must be restrained if such shifting
would result in the forklift becoming unstable.
 Carry loads as low as possible.
 Do not drive with arms, head or legs outside the confines of the forklift. Any operator who cannot
clearly see the load or off-load points and the full path of travel must use a signal person (see
Obstructed Vision).
 Sound horn and slow down when approaching pedestrians, doorways, ramps, and other forklifts.
 Observe and obey the load capacity of the forklift.
 When shutting a forklift down, level and lower the forks, apply the parking brake and put the controls
in neutral.
 Do not elevate anyone on the forks unless in an approved man cage that is secured to the forklift.
 Forklifts charging station should have the protection devices like ELCB/RCCB, MCB and Overload
Protective devices.

3.3 ELECTRICAL POWER TOOLS

Electrical Power Tool operator shall use any power tool, or similar type of equipment, unless they are familiar
with the use and operation of the equipment or has received instruction in its use and operation. Following
instructions to be followed for handling and maintenance of power tools:

 Only qualified or specially trained operator may alter, repair, or otherwise tamper with electrical
equipment or electrical tools.
 No workers will commence work on any electrical equipment until the equipment has been shut off
and locked out as per Lock Out procedure.
 Inspect tools, power cords and electrical fittings for damage prior to each use. Repair or replace
damaged equipment.
 Use only approved electrical tools and machinery.
 Do not wear gloves, loose clothing or jewelry while using revolving power tools.
 Switch tools off before connecting them to a power supply.
 Do not use electric tools unless tool is connected to a ELCB or RCCB for Earth Leakage Protection. .
 Ensure tools are properly earthed (three-point plug).
 Keep power cords clear of tools during use.
 Suspend power cords over aisles or work areas, when possible, to avert stumbling or tripping
Hazards
 Do not carry electrical tools by the power cord.
 Avoid multiple connections.

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 Wear safety glasses or goggles when using power tools for grinding, cutting and sanding operations.
 Chuck keys must not be taped to cords as electrocution might occur when insulation has worn
through.
 Operator shall impair, remove, render ineffective, any safeguards provided for the protection of
themselves or other workers.
 Operator responsible for placing equipment into service, are also responsible to ensure that
equipment guards are in place. If, due to damage or deterioration, the original guard provided on a
piece of equipment cannot be put in place, operator should use a temporary method, offering equal
or better protection, as approved by supervisor.

3.4 M ANUAL ELECTRICAL ARC WELDING M ACHINE - WELDING EQUIPMENT AND POWER SUPPLY

In manual electric arc welding operations, the major electrical hazard is electric shock. The exposed welding
electrode that becomes live when the welding equipment is in use poses obvious electric shock hazard to the
welding worker. Any defective welding equipment or improper electrical wiring also poses electric shock
hazard to the welding worker or other workers in the vicinity.

Prior to the installation of electric arc welding equipment, it is necessary to check that the capacity of the
power supply source is adequate to handle the load demand of the welding operation and the operator
should ensure following:

a) Frame of the welding equipment should be properly earthed

b) A suitable disconnecting switch or controller should be located near the welding equipment

c) The welding equipment should be protected by a suitable fuse or circuit breaker on a source panel.

d) The Earth Leakage Circuit Breaker (ELCB) or Residual Current Circuit Breaker (RCCB) installed at
the power source. It is to be noted that this device would give protection against electric shock that
occurs at the input side of the welding transformer only. If the electric shock incident occurs at the
output side of the transformer, e.g. the transformer output terminals, the welding cables, the
electrode holder, the welding electrode and workpiece etc., the ELCB/RCCB will not function
automatically to cut off the power supply due to the isolation effect of the transformer.

e) Welding equipment should conform to the appropriate national or international standards. In

particular, the following points should be considered:

I. Electrode holders should be properly insulated to avoid any undesirable exposure of live
conductor (other than the welding electrode) that can be inadvertently touched by the
welding worker.
II. Welding cables should be insulated, of robust construction and of sufficient size to carry the
welding current safely. Welding cables connections should be suitably insulated to avoid the
exposure of conductive parts.
III. In general, the welding return should be firmly connected to the workpiece as close to the
point of welding operation as possible to avoid any uncontrollable and undesirable stray
current flow that would cause electric shock hazard and fire hazard.

f) Operator in the workplace should be protected from making direct contact with the common bonded
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structure is required to prevent electric shock. He should not sit on or lean on the bonded structure
and the workpieces. Insulated mat/ stands should be provided and used as appropriate. He should
also wear insulated footwear and proper clothing

g) To prevent electrical fire hazard due to loose joint/ connection, the earthing, joints and connections of
the bonded structure should be maintained to ensure that the bonding is always secure, proper and
effective.

Typical Setup of Manual Electric Arc Welding Operation

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3.5 GRINDERS

Following instructions to be followed for handling and maintenance of power tools:

 Eye protection must be used when operating a grinder.

 Remove jewellery, confine long hair and roll up sleeves.
 Adjust and tighten wheel guards in place.
 If a spark guard is installed, adjust it to the correct place.
 Do not use electric tools unless tool is connected to a ELCB or RCCB for Earth Leakage Protection.
 Check to ensure that blotters and wheel flanges have been used to mount the wheels onto the shaft.
 Adjust and tighten the tool rest to within 1/8" from the wheel.
 Inspect the wheels to ensure they have a speed rating greater than or equal to the grinder's speed
rating and that they are in good condition. Cracked or chipped wheels must be replaced.
 Do not stand in line with the wheel when starting the grinder.
 Do not use the side of the wheel when grinding; use the face only.
 Use pliers or a vice grip to hold small items.
 If the wheel vibrates, dress it (on the face only); replace it or replace the shaft bearings if they are
worn.
 Allow the object you were grinding to cool before handling it.
 Unplug or lockout the grinder before doing repairs.
 Never leave a grinder unattended while the wheels are turning

3.6 TEMPORARY ELECTRICAL INSTALLATION FOR CONSTRUCTION

Following instructions to be followed for temporary electrical installation for construction:

 Load drawn for temporary installations is well within capacity of temporary installations power
requirement.
 The number of welding machines connected from individual outlet shall not exceed the rating of the
outlet.
 Properly sized plug socket are used to cater the load requirements.
 Earthing is provided for all portable/static equipments.
 MCB/HRC fuses shall be used for all outlet power circuit.
 Local power isolation is at accessible distance with phase and neutral isolation is done
simultaneously.
 All Portable equipment are moved only after power is disconnected.
 electrically.
 All portable equipment are provided with ELCB

3.7 CABLE TERMINATION

Following instructions to be followed for termination of power and control cables:

 Tags number identification is provided at both ends of the cable.

 The tag size shall be sufficient enough in size so as to accommodate to contain all required details.
 Proper type and size of crimpling lug is used for cable termination.
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 For termination of Alluminium conductor cable on copper busbar shall be done by using copper
aluminium Bi-Metal lugs.
 Cable termination of power cable is done by using tubular lugs and proper size and type of crimping
tool is used with appropriate crimping die.
 Lug size matches with cable core and material of lug is suitable for application.
 All termination is done with torque wrench to ensure proper tightness.
 Mechanical protection for the cable is available. If pipe is used for mechanical protection then ensure
that both ends are sealed.

3.8 EXTENTION OF LV SWITCHBOARD

Following instructions to be followed for termination of power and control cables:

 The size and type of Switch board is matching with existing switchboard
 The connecting bus bar is matching in dimension and overlapping area.
 The control Voltage supply is tapped from existing switchboard
 The clearances around panel are as per Indian Electricity Rule and approved drawings.
 Switchboard is firmly bolted to the base plate which is there is no gap between new panel and
existing panel.
 Phase Neutral and Earth Bus Bar are firmly connected with suitable size and type of bolts with
existing panel without any gap and connection is tightened with torque wrench
 Danger board has been provided.
 Insulated floor mats have been provided in front and rear side of new switchboard..
 Insulation resistance value of bus bars is checked after connection to new switchboard and isolating
the mains Power supply.
 Safety Shutter of vertical bus bar tapping is in working condition.
 Unused holes are plugged properly to make panels vermin proof.

3.9 MOTOR

Following instructions to be followed for replacement of existing motor or installation of new motor:

 Insulation resistance value between phase and earth and between phases are as per Indian
Standard
 Insulation Resistance is measured before cable connection.
 Cable entry hole for flameproof motors are not modified to accommodate the cable.
 Flameproof motors are connected to internal earthing with fourth core of cable,
 Double external earthing with proper earth conductor size is done.
 If pump and motor are not in the same base plate, both are independently earthed.
 Correct type and size of cable glands are used.
 The space heater is connected with the space heater cable.
 Canopy is provided.
 Shaft movement is checked by hand for freeness of shaft and bearing.
 No load running of motor is done and direction of rotation is checked before connecting to
mechanical equipment like Pump, Compressor, and Conveyor etc.
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3.10 HAZARDOUS AREA ELECTRICAL EQUIPMENT

Following instructions to be followed for any electrical equipment in hazardous area like Local Control
Station, Control Panel, Junction Box, Lighting Fixtures, Motors etc.:

 Apparatus is appropriate to area classification.

 Enclosure, glass and gasket are without any sign of damage.
 Machined surfaces of flamepath are free from corrosion pitting, ingress of dust and paint.
 Unauthorised alteration of Flameproof enclosure like drilling of extra hole for cable is not done
 All the cover fixing fasteners are in position and fully tight.
 Cable glands and stoppers are fitted tight with all threads engaged..
 The enclosure gaskets fixed at place and are without any deformation or damage is satisfactory.
 Wherever compound filling is required, it should be with soft compound.
 Apparatus is properly protected against corrosion, fall of material, vibration and any other adverse
factors.

3.11 EARTHING SYSTEM

Following instructions to be followed for any earthing system.:

 The earthing installation has been done as per approved earthing drawing and specifications .
 The main earth grid is laid below ground level as per standards.
 Earthing strip is protected against mechanical damage in operating area
 Earthing conductor is running along cable trays.
 The earthing for equipment is tapped from the main earth grid conductor and not from adjacent
equipment earthing or the cable tray structure.
 All joints on earth strip below ground is permanently done with lap welding and protected by applying
two coats of bitumen or zinc rich paint
 All joints above ground are by means of connector/lugs. Minimum of two bolts of adequate size is
used for this purpose.
 Earth pit is identified by permanent markers and Earth Resistance value is written on it.
 Earth electrodes are tested for earth resistance by means of 4 Point Earth Megger.
 The electrodes is galvanised and of clean surface and not covered by paint or grease
 All earth pits are so located avoiding interference with road,building foundation, column etc.
 The earthing for conveyors is with the earth strip runs along the entire length of conveyor.
 Disconnect facility is provided for the individual earth pits to check their earth resistance periodically
without isolating the equipment earthing..
 All 3 Phase Electrical equipment is doubly earthed in connecting two points on equipment to a main
earthing grid.
 The cable armour will be earthed through the cable glands for L.T. cables. For HT cable, the Pipes
are bonded and earthed on entering the battery limit of the process area.
 Paint, scale, and enamel is removed from the contact surface before the earthing connections are
made.
 Hardware used for earthing installations is hot dip galvanised or zinc passivated.
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 In Hazardous Area lighting fixture and other electrical equipment are internally earthed through the
extra core provided in the cable for this purpose.

3.12 LIGHTING SYSTEM

Following instructions to be followed for any lighting system.:

 No unauthorised site modification is done on flameproof Lighting Fixture, Lighting JB or Lighting DB

 Outdoor lighting panel are weather protection of IP :55 degree of protection and is provided with
canopy.
 Gaskets for Lighting Fixture, Lighting JB or Lighting DB are in position.
 Cable glands are properly fitted with all threads engaged..
 Earthing bus bar and cable earthing connections inside the Lighting DB is proper.
 The equipment external earthing from the earthing grid is made properly.
 Extra core of the cable is connected to internal earthing terminal inside the lighting fixture.
 Unused entries for Lighting Fixture, Lighting JB or Lighting DB are blocked with Flameproof Plug.

4. JOB RESPONSIBILITIES

4.1 OPERATOR

 Operator to follow the Work Instruction and Check List

 All the operating Tools and Machines must be approved by supervisor and owner’s safety person
before use
 Any maintenance and repair of defective Operating Tools and Machines must be done outside the
work premises and to ensure that it is taken back to working site only after approval by supervisor
and owner’s safety person before use

4.2 CONTRACTOR SUPERVISOR

 Supervisor to ensure that operator is following the Work Instruction and Check List before use of any
Tools and Machine
 All the operating Tools and Machines must be approved by supervisor before obtaining owner’s
safety person approval
 Supervisor to ensure that maintenance and repair of defective Operating Tools and Machines should
be done by appropriate experience person and not by operator and must be done outside the work
premises. He should ensure that it is taken back to working site only after his approval and owner’s
safety person approval before use

4.3 OWNER’S SAFETY SUPERVISOR

 Owner’s Safety Supervisor to ensure that operator is following the Work Instruction and Check List
before use of any Tools and Machine

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 All the operating Tools and Machines are approved by contractor supervisor and are checked for all
the functional and safety aspect.
 Supervisor to ensure that maintenance and repair of defective Operating Tools and Machines should
be done by appropriate experience person and not by operator and must be done outside the work
premises. He should ensure that it is taken back to working site only after his approval and owner’s
quality person approval before use
All the records of above tasks completion shall be maintained by owner’s safety supervisor for traceability
and management review.

5. CHECK LIST

The Check List for all the above operations mentioned under Section 3. are as given under APPENDIX A

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APPENDIX A – CHECK LIST

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