Warning

This publication has been compiled as a training

document to aid the trainees and is not to be
treated as a service manual/book of reference

eValsura Publication
VP 200
Handbook of Electrical Hygiene &
Practices
 Handbook of Electrical Hygiene & Practices

VP-200
Handbook of Electrical Hygiene & Practices

Copyright Reserved
INS Valsura
All rights reserved. No part of this
publication may be reproduced, stored in
a retrieval system, or transmitted in any
form or by any means, electronic,
mechanical, photocopying, recording, or
otherwise, without the prior permission of
Commanding Officer, INS Valsura.

New Edition, 2004

Research & Compilation Team:

1. Cdr GS Jawanda
2. Lt KM Sudish

Edited By:
Faculty of Power Engineering
Electrical Technology School
INS Valsura

Produced By:
TRIM (Training Resource & Instructional Material) Section
Department of Training Design
INS Valsura

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 Handbook of Electrical Hygiene & Practices

Foreword

1. Good electrical hygiene and safe engineering practices are the

hallmark of a sound electrical professional. In case of a naval sailor, these
aspects are essential requirements for safety of men and material onboard
ships. Improper practices are dangerous, can seriously limit the performance
and efficiency of all electrical and electronic systems and in catastrophic form
be detrimental to the ship’s safety at sea. These issues therefore need to be
accorded the highest priority by all.

2. In order to control hazards, we must create a safe working

environment, and work in a safe manner. Ideally, it would be best to remove the
hazards altogether and create an environment that is truly safe. A safe work
environment is created by controlling contact with electrical voltages and the
currents they can cause. One must also work safely. Safe work practices help
control one’s risk of injury, which is also applicable while working on electrical
circuits or with electrical tools and equipment.

3. This handbook has been compiled by the officers and men of Electrical
Technology School from well established standards/publications on Electrical
Safety. This document is in synchronism with Valsura’s thrust of achieving
excellence through honing core skills with the aim of providing the our officers
and men the confidence and expertise to maintain utmost operational readiness
at all times onboard our ships.

Sd/-
(AS Sethi)
Captain
10 Jul 2004 Training Captain

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 Handbook of Electrical Hygiene & Practices

Preface

1. Electricity as is said is a good servant but a bad master, if used with

care and protection etc, it is an excellent companion. As an electrical
professional it is important that one is able to identify potential hazards and
practice safe procedures in order to prevent accidents to self and others.
2. Combinations of hazards increase your risk. Improper grounding and a
damaged tool greatly increase your risk. Wet conditions combined with other
hazards also increase your risk. You will need to make decisions about the
nature of hazards in order to evaluate your risk and do the right thing to remain
safe.
3. The handbook compiled by Electrical Technology School, is an attempt
to help you to recognize the “clues” that electrical hazards exist, evaluate the
seriousness of hazards. Decide if you need to take action. The handbook is
illustrated and is designed to convey the messages with clarity. It is therefore
felt that this will go a long way to create awareness amongst the trainees and to
practice safe in electrical works and prevent accidents which would otherwise
cause extensive damage to life and property.

(GS Jawanda)
Commander
Officer-in-Charge
10 Jul 2004 Electrical Technology School

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 Handbook of Electrical Hygiene & Practices

Contents

S. No Topic Page
1 Safety 4
2 Danger Signals 5
3 Electric Shock 6
4 Safety Precautions for preventing Electric Shock 8
5 Damage and Fire 10
6 Repair Safety 11
7 Portable and Temporary Electrical Equipment 12
8 Safety precautions with Batteries 13
9 Storage Batteries and Battery Banks 14
10 Personal Protective Equipment and Protective Clothing 15
11 Temporary Wiring 17
12 Grounding Basics 19
13 Grounding Guidelines 21
14 Training, Planning and Writing Procedures 22
15 Good Engineering Practices 23
16 Designing an electrical system – For safety 25
17 Bibliography 26

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Safety

1. Safety is an encompassing subject. Successfully completing of day to

day activities depends on their safe execution, the preparation and conduct
during these activities reflects on performance. In no other field is this more
significant than in the marine field.
2. Current is the measure of shock intensity. The passage of even a very
small current through a vital part of the human body can kill. At about 100
milliamperes (0.1 ampere), the shock is fatal if it lasts for one second or more.
Fatalities have resulted from voltages as low as 30 volts.
3. Conditions on board a ship add to the chance of receiving an electrical
shock. The body is likely to be in contact with the metal structure of the ship.
The body's resistance may be low because of perspiration or damp clothing.
Personnel must be aware that electrical shock hazards exist.
4. Accidentally placing or dropping a metal tool, ruler, flashlight case, or
other conducting article across an energized terminal can cause short circuits.
The resulting arc and fire, even on relatively low-voltage circuits, may
extensively damage equipment and seriously injure personnel.
5. Touching one conductor of an ungrounded electrical system while the
body is in contact with the hull of the ship or other metal equipment enclosures
could be fatal.

However a simple and trivial a job maybe, there is some

element of skill and basic knowledge needed for the
working personnel.

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 Handbook of Electrical Hygiene & Practices

Danger Signals.
6. Be constantly alert for any signs that might indicate a malfunction of
electrical equipment. When any danger signals are noted, report them
immediately to your superiors or electrical officer. The following are examples of
danger signals:

(a) Fire, smoke, sparks, arcing, or an unusual sound from an electric

motor or contactor.
(b) Frayed and damaged cords or plugs.
(c) Receptacles, plugs, and cords that feel warm to the touch.
(d) Slight shocks felt when handling electrical equipment.
(e) Unusually hot running electric motors and other electrical equipment.
(f) An odor of burning or overheated insulation.
(g) Electrical equipment that either fails to operate or operates irregularly.
(h) Electrical equipment that produces excessive vibrations.

Loose Connections increase temperature and gradually

produce visible sparks, and then audible sparks: ultimately they
burn the inflammable material in the vicinity

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Electric Shock
7. Electric shock is a jarring, shaking sensation. Usually it feels like
receiving a sudden blow. If the voltage and current are sufficiently high,
unconsciousness occurs. Electric shock may severely burn the skin. Muscular
spasms may cause the hands to clasp the apparatus or wire making it
impossible to let go.

While you switch off supply and proceed to do repairs in the

line or circuit, doubly ensure that no one else should be
able to switch it on.

Rescue and Care of Shock Victims

8. The following procedures are recommended for the rescue and care of
shock victims:
(a) Remove the victim from electrical contact at once, but do not
endanger yourself. Touching a shock victim who is still in contact with the
energized circuit will make you another shock victim. Help the shock victim
by de-energizing the affected circuit. Then use a dry stick, rope, belt, coat,

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 Handbook of Electrical Hygiene & Practices

blanket, shirt, or any other nonconductor of electricity to drag or push the

victim to safety.
(b) Determine the cardiopulmonary status of the casualty. (Start CPR
if spontaneous respiration or circulation is absent.)
(c) Once the person is stabilized, attend othe physical injuries as
they would normally be treated. Lay the victim face up in a prone position.
The feet should be about 12 inches higher than the head. Chest or head
injuries require the head to be slightly elevated. If there is vomiting or if
there are facial injuries that cause bleeding into the throat, place the victim
on his stomach with his head turned to one side. The head should be 6 to
12 inches lower than the feet.
(d) Keep the victim warm. The injured person's body heat must be
conserved. Cover the victim with one or more blankets, depending on the
weather and the person's exposure to the elements. Avoid artificial means
of warming, such as hot water bottles.
(e) Do not give drugs, food and liquids if medical attention will be
available within a short time. If necessary, liquids may be administered.
Use small amounts of water, tea, or coffee. Never give alcohol, opiates,
and other depressant substances.
(f) Send for medical personnel (a doctor, if available) at once, but do
not under any circumstances leave the victim until medical help arrives.

Do not take short cuts. Equipment are provided with interlocks

and safety device, they are for your safety.

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Safety Precautions for Preventing Electric Shock

9. Observe the following safety precautions when working on electrical

equipment:

(a) When work must be done in the immediate vicinity of electrical

equipment, check with the senior engineer responsible for maintaining the
equipment to avoid any potential hazards. Stand clear of operating radar
and navigational equipment.
(b) Never work alone. Another person could save your life if you receive
an electric shock.
(c) Work on energized circuits only when absolutely necessary. The
power source should be tagged out at the nearest source of electricity for
the component being serviced.
(d) Keep covers for all fuse boxes, junction boxes, switch boxes, and
wiring accessories closed. Report any cover that is not closed or that is
missing to your senior responsible for its maintenance. Failure to do so
may result in injury to personnel or damage to equipment if an accidental
contact is made with exposed live circuits.
(e) Discharge capacitors before working on de-energized equipment.
Take special care to discharge capacitors properly. Injury or damage to
equipment could result if improper procedures are used.

Do not assume things before undertaking repairs in electrical

systems. Make yourself doubly sure by asking as many people
as possible in case of even a small doubt.

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(f) When working on energized equipment, stand on a rubber mat to

insulate yourself from the steel deck.
(g) When working on an energized circuit, wear approved electrical
insulating rubber gloves. (The rubber gloves used with NBC suits are not
acceptable.) Cover as much of your body as practical with an insulating
material, such as shirt sleeves. This is especially important when working in
a warm space where you may perspire.
(h) If possible, de-energize equipment before hooking up or removing test
equipment.
(j) When working on energized electrical equipment, work with only one
hand inside the equipment. Keep the other hand clear of all conductive
materials that may provide a path for current flow.
(k) Wear safety goggles. Sparks could damage your eyes. The sulfuric
acid contained in batteries and the oils in electrical components can cause
blindness.
(l) Ensure that all tools are adequately insulated when working on
energized electrical equipment.
(m) Never work on electrical equipment while wearing rings, watches,
identification tags, or other jewelry.
(n) Never work on electrical equipment while wearing loose-fitting
clothing. Be careful of loose sleeves and the battle dress uniform (BDU)
shirttails.
(p) Ensure all rotating and reciprocating parts of the electric motors are
adequately protected by guards.
(q) Remain calm and consider the possible consequences before
performing any action.

CAUTION

Do not operate faulty equipment. Stand clear of

any suspected hazard, and instruct others to do
likewise.

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Damage And Fire

1o Never enter a flooded compartment that has a generator actively
producing power. Transfer the load and secure the generator before entering.
Secure power to the affected circuits if there is an electrical fire in a
compartment. If critical systems are involved that prevent power from being
secured (determined by the chief engineer), extinguish the fire using a
nonconducting agent, such as dry chemical, carbon dioxide (C02), or halon.

WARNING
The use of water in any form is not permitted.

11.
Carbon dioxide is the choice for fighting electrical fires. It has a
nonconductive extinguishing agent and does not damage equipment. However,
the ice that forms on the horn of the extinguisher will conduct electricity.

12. Burning electrical insulation is toxic and can kill in a matter of

moments. Use the oxygen breathing apparatus (OBA) when fighting electrical
fires.

Whenever temporary wiring is carried out for short durations,

supply system must be checked for all possible accidents or
fire hazards

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Repair Safety
13. Before Starting any electrical work, secure the power to the circuit and
affix a temporary warning tag to the affected circuit breaker or power source.
Check the de-energized circuit with a multimeter. If you must leave the repair
and return at a later time, always ensure that the circuit is de-energized before
resuming work.

14. When you are engaged in electrical repairs on board a ship, always
work in teams of two or more. Never start working on an electrical system until
the electrical officer has been informed. A unit's operational status reflects the
vessel's operational status and its ability to get under way. All ship’s systems
are interrelated. What may appear to be a minor repair may ultimately
determine whether or not the ship is fully operational.

If one contact is spoiled, do not give through Use correct and insulated tools. These will
connection, change the switch. help you to do the task efficiently and safely.

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 Handbook of Electrical Hygiene & Practices

Portable and Temporary Electrical Equipment

15. Ensure all electrical extension cords are approved by either the chief
engineer or the electrical officer. Never use an extension cord or power hand
tool without it being properly grounded. Regularly inspect all extension cords
and portable electrical equipment. Ground all metal multimeters and test
equipment to the hull.

WARNING
An ungrounded portable power tool can kill.

For all portable equipment three pin and three core cables
should to be used and earthing ensured. Do not have temporary
joints in the cables

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 Handbook of Electrical Hygiene & Practices

Safety Precautions with Batteries

16. Observe the following safety precautions when working with batteries
(a) Handle all types of batteries with care.
(b) Never short the terminals of a battery.
(c) Use carrying straps when transporting batteries.
(d) Wear chemical splash-proof safety glasses when maintaining
batteries.
(e) Wear protective clothing, such as a rubber apron and rubber gloves
when working with batteries. Electrolyte will destroy everyday clothing such
as the battle dress uniform.
(f) Do not permit smoking, electric sparks, or open flames near charging
batteries.
(g) Take care to prevent spilling the electrolyte.

(j) Never install alkaline and lead-acid batteries in the same

compartment.

Acids not only eat away the clothes, not only cause injury to the
skin, but also eat away the wood etc. Provide protective covers

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 Handbook of Electrical Hygiene & Practices

Storage Batteries and Battery Banks

17. In the case of rechargeable batteries used as a source of electrical

energy, the hazards are not limited to batteries of a particular voltage and
energy rating, since the nature of the associated electrical hazards is similar
without regard to battery size; the severity of the hazard increases as the
battery ratings increase.

Types Of Hazards
18. Some of the types of hazards associated with storage batteries and
battery banks are listed as follows:

(a) Accidental grounding of one polarity of a battery bank can

create a hazardous voltage between the ungrounded polarity and
ground.
(b) Accidental shorting of the exposed terminals or cables of a
battery can result in severe electric arcing, causing burns and electric
shock to nearby personnel.

(c) Hydrogen gas generated during battery charging can create

fire, explosion, and toxicity hazards.

(d) Exposed terminals in a battery bank present electric shock

hazards.

(e) Batteries, particularly sealed-cell batteries, can explode if they

are shorted or if they are charged at excessively high rates.

(f) Electrolytes can be highly corrosive and can produce severe

burns to personnel on contact.

19. Battery design forces the

electrolyte to explode upwards. Never
service batteries without proper eye
protection. If battery electrolyte gets in
your eyes, flush them immediately for
15 minutes and seek medical
attention. EXIDE

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Personal Protective Equipment and Protective Clothing

20. All Personnel should wear appropriate personal protective equipment

and protective clothing to protect them from hazards of high-voltage apparatus.

(a) Shoes. Personnel should wear shoes or boots of proper standards.

No metal parts should be present in the sole or heel of the shoes where
nonconductive shoes are required.

(b) Safety Hat. Personnel should wear approved hardhats when working
aboveground on poles, structures, or buildings or in trees. Personnel
should wear hardhats when working on the ground near poles, structures,
buildings, or trees in which work is being done. Personnel should wear
hardhats when visiting or observing in areas where overhead work is being
done.

(c) Eye Protectors. Whenever eyes are in danger of being injured,

personnel should wear safety goggles or other eye protectors meeting
proper standards. When the work being performed dictates, personnel
should wear nonmetallic and nonconductive eye protection.

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(d) Metal Fasteners. Personnel should not wear articles such as loose
chains, keys, watches, or rings if such articles increase the hazards
associated with inadvertent contact with energized parts or can become
caught under or snagged while climbing off or on structures, equipment or
vehicles.

(e) Work Gloves. When insulated gloves suitable for high-voltage are
not required, otherwise suitable work gloves should be worn while handling
materials and equipment to prevent the possibility of slivers, cuts, and skin
irritation.

(f) Work Clothes. Work clothes should be made of natural materials,

such as cotton and should have full length sleeves. Sleeves should be
rolled down for greatest protection. Dungarees are designed to provide you
full protection.

(g) Rubber Gloves. These should be of appropriate voltage rating for the
work being performed. Rubber gloves issued for service should be tested
at appropriate voltage levels at intervals not exceeding 6 months.

Any broken switch or any exposed live points at lower

reachable heights should not be neglected but should be
repaired at once.

Disconnect cords by grasping the plug (Don't Pull them Out).

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Temporary Wiring

21. Temporary electrical installations should be allowed only during the

periods of construction, remodeling, maintenance, repair, such as refit work.
However, such temporary installations are not substitutes for permanent
installations and should be removed as soon as the special need is completed.

(a) Wet Locations. Conductors with non-rated weather-proof insulation

should not be enclosed in metal raceways or used for wiring in tanks,
penstocks, or tunnels. Receptacles used in damp or wet locations should
be approved for the purpose. When a receptacle is installed outdoors
(outdoors is considered a wet location), it should be contained in a
weatherproof enclosure, the integrity of which would not be affected when
an attachment plug is inserted.

(b) Supports. Bare or open conductors should be insulated from

their supports. This requirement prevents arcing, sparking, or flash-over to
grounded objects.

(c) Lighting. All lamps for general illumination should be protected from
accidental contact or breakage. Metal-case sockets should be grounded.
Temporary lights should not be suspended by their electric cords unless
cords and lights are designed for this means of suspension. Temporary
lighting used in damp, wet, or hazardous areas shall be marked as suitable
for use in those locations.

Do not loop the power supply from one machine to another. It

may become fateful to somebody who is not aware of it.

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(d) Conduit. Temporary wiring installed in conduit should have bushings at

all outlets and terminals to prevent abrasion and damage to the insulation.

(e) Confined Spaces. When temporary wiring is used in tanks or other

confined spaces, an approved disconnecting means (identified and
marked) should be provided at or near the entrance to such spaces for
cutting off the power supply in emergencies.

(f) Exposed Sockets And Broken Bulbs. Exposed empty light

sockets and broken bulbs should not be used. This is required to protect
personnel from accidentally contacting the live parts in the socket and
being shocked.

(g) Feeder Conductors. Feeders are the conductors that transmit

power from the service equipment to the distribution panelboard or
between the main disconnect and the branch circuit over current devices
(circuit breakers, fuses). Feeders for temporary wiring should originate
inside a proper distribution box, that is rated for the voltages and currents
the system is expected to carry. Some equipment is manufactured
specifically for temporary use.

Electrical markings essential for identifications. Make sure these are not
removed and if missing must be replaced.

Always turn the appliance OFF before unplugging.

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Grounding Basics
22. Most electrical tools and equipment are required to be grounded.
Grounding makes equipment safe by:
(a) Providing a low-impedance path for any unintended voltage that is
present on a metal parts of the equipment.
(b) Facilitating operation of an overcurrent device (fuse or circuit breaker),
when internal wiring contacts the equipment case. This is called a Fault.

Metal Housing Grounded

23. During normal operation, the current follows the circuit pathway and
returns to the transformer. Note that the transformer, transformer enclosure,
and equipment enclosure are bonded together and coonnected to ground at the
transformer location.

24. A fault has occurred in the equipment, energizing the equipment

enclosure to 120 volts. However, the equipment ground provides a pathway for
the circuit to return to the transformer. Since there is little resistance in this path,
the current is great enough to trip the circuit breaker, removing the voltage.

Keep power off while assembling your computer.

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 Handbook of Electrical Hygiene & Practices

25. Without an equipment ground, the fault current seeks a pathway back
to the transformer. Unfortunately, it is through the person who happens to touch
the equipment enclosure. Since there is much resistance in the earth, the
current cannot get high enough to trip the breaker, but is high enough to
seriously injure or even kill the person.

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 Handbook of Electrical Hygiene & Practices

Grounding Guidelines

(a) Never alter or remove a grounding connection.

(b) Never use equipment which has had the ground wire altered or
removed.
(c) Never cut off the 3rd pin on a plug or extension cord.
(d) Equipment may be grounded by more than one method, but the
original ground with the circuit wiring must not be removed or isolated.
(e) Supplemental grounds associated with capacitor discharge hooks,
wands, high power de devices, and large metal objects, such as laser
tables, should be constructed of #2 braided copper in clear insulation.

Do not ignore even minor items. Occasionally check the screws

of the terminal covers and tighten them

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Training, planning, and writing procedures.

26.
(a) Provide training. An important aspect of electrical safety is training. To
be qualified, personnel need to be trained on the tasks and procedures that
are essential to conducting their work in a safe manner.
(b) Plan every job. Take the time to prepare a work plan that considers all
possible eventualities. Before starting the job, think about each step and try
to visualize the potential for hazards.
(c) Anticipate unexpected results. When thinking about a job, break each
task into small steps. Understand that plans can change, so be ready to
modify the plan. Make sure that everyone involved in the job is working
according to the same plan. Whenever work is required near an electrical
hazard, a written plan is needed to outline the scope of the job.
(d) Use procedures as tools. Procedures are the best way to help you
prepare, execute, and complete a job. Like any tools, make sure
procedures are maintained.
(e) Identify the hazard. After your work plan is complete, review each step.
Consider that the equipment might be perfectly safe under normal
conditions and very unsafe when systems are not working properly. Also
consider potential hazards that may be unrelated to electrical energy.
(f) Assess people’s abilities. Any person assigned to tasks associated
with electrical energy must be qualified and trained for the job at hand. He
or she must be able to identify electrical hazards, avoid exposure to those
hazards, and understand the potential results of all action taken.

Before testing rotary machinery, ensure they are mechanically

stable and do not move by vibrations

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Good Engineering Practices

27. No amount of safety can help if one does not adhere to good engineering
practices, these have to be second nature and followed unconsciously. A few of
the common practices are given below:
(a) Use wires with plugs/ lugs. instead of naked wires with matchsticks in
a socket.
(b) Use of correct tools
ƒ Instead of using hammer, people use the tool located nearest to
them
ƒ Use of right size spanner, rather than a big spanner with a screw
driver to fill the gap.
(c) Reapplication of rack grease after defectation.
(d) Putting back all the screws/ bolts of the rack/ module/ sub-assembly
post defectation to avoid vibration and loose contacts.
(e) Strictly adhering to ‘Switching On’ and ‘Switching Off’ procedures.
(f) Using lead lamps with proper shields.
(g) Cleaning of the wire tips and use of flux before undertaking soldering
of components.
(h) Adhering to “Red Fuse Drill’.

Indications, indicating instruments and identification

of names and numbers of panels are very important.
Ensure there is no supply before commencing tests
and repairs in panels, to avoid accidents.

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(j) Deckheads and Bulkheads pierced for passing cables should be

suitably filled post cabling.
(k) Use of proper rating fuse wire while replacing fuses.
(l) Use of filtered and smoothed DC supply for running equipment.
(m) Replacing/ Fitting back the earthing and bonding straps post receiving
the equipment from dockyards.
(n) Storage/ Transportation of PCBs and static charge sensitive
equipment in proper packing/ carry bags.
(o) Sensitive Elements of the gyros are to be transported in their wooden
casing without tilting.
(p) Switching ON of sensitive equipment only on availability of stabilized
supply.

When replacing fuses. Ensure the equipment is deenergised,

and use fuse extractors.

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Designing an electrical system - for safety

28. It is not enough to focus just on work practices and the maintainer. The
first step in providing a safer work place is designing and retrofitting the
electrical system with specific safeguards. There are a number of things that
can be implemented including the following:
(a) Isolate the circuit. Electrical systems must be designed to support
preventive maintenance, with easy access to the equipment. Designers
need to make it easy to isolate equipment for repair with a disconnecting
means that provides for proper implementation of procedures.
(b) Cover exposed components. Equipment must be “Safe" where
possible to avoid potential contact with energized conductors. It is not
always possible to de-energize the equipment before working on it.
(c) Limit the energy. Circuits should also be designed to limit the available
arc-flash energy. The use of current limiting over current devices can help
to reduce the flash energy. This will provide for improved protection for both
equipment and personnel. Use current-limiting fuses or current-limiting
circuit breakers.
(d) Retrofit the fuses. If the electrical system is an existing fusible system,
upgrade the fuses to the most current-limiting fuse types. This measure
provides a greater degree of current-limitation if an arc-flash incident
occurs.

Avoid Overconfidence. Before shorting terminals ensure you

are shorting the correct ones.

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Bibliography

1. Publications.
(a) Introduction to the Basics of Electrical Grounding for Power Systems -
Harry J. Tittel, E.E. Florida Electrical Resources.
www.teamworknet.com
(b) Electrical Safety, Safety & Health for Electrical Trade, National Institute for
Occupational Safety and Health, DHHS (NIOSH) Publication No. 2002-123

2. Standards.
(a) NFPA 70, National Electric Code
(b) OSHA General Industry Standards, Subpara S, Electrical

3. Cartoon & Illustrations.

(a) A Practical Book on Electrical Safety, CIMI (Central Instructional Media
Institute), Chennai

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