UNIT-03: SAFETY DURING INSTALLATION, TESTIING AND COMMISSIONING OPERATION AND

MAINTANCE

Preliminary Steps Before Installing :

 Site Preparation
 Parts Checklist
 Safety Requirements

These site preparations are required:

Location :The Equipment may be installed only in a RESTRICTED ACCESS LOCATION.

Space : deep to provide sufficient clearance around the cabinet to allow access to the front
and back.

Power : An AC or DC power source must be available within 6 feet (2 m.). A maximum

configuration for an AC-powered BPX switch might require up to 2333 VA (13 A at 180
VAC, 10 A at 230 VAC). A maximum configuration for a DC Equpiment might require up to
1680 Watts (40 A at -42 VDC, 35 A at -48 VDC).

Cooling :The site must be capable of maintaining an ambient temperature of 40°C

maximum (recommended range 20°C to 30°C) while the system is operating. A fully loaded
BPX switch may dissipate up to 7200 BTUs. It is extremely important that the BPX switch is
positioned to assure an unrestricted air flow through the enclosure.

Weight: A fully loaded, AC-version, BPX switch can weigh up to 213 pounds (97 Kgs). A
fully-loaded DC-version BPX switch can weigh up to 163 pounds (74 Kgs).

Basic Guidelines Follow these basic guidelines when working with any electrical equipment:

Locate the emergency power-OFF switch for the room in which you are working before
beginning any procedures requiring access to the interior of the BPX chassis.
Disconnect all power and external cables before removing or installing a chassis. Carefully
examine your work area for possible hazards such as moist floors, ungrounded power
extension cables, frayed power cords and missing safety grounds.

Never work alone when potentially hazardous conditions exist.

Never assume that power has been disconnected from a circuit; always check. Never
perform any action that creates a potential hazard to people or makes the equipment
unsafe.

Never install equipment that appears damaged. Any list of guidelines might not address all
potentially hazardous situations in your working environment so be alert and exercise good
judgment at all times.

These safety guidelines will help to ensure your safety and protect the equipment:

Keep the chassis area clear and dust-free before, during, and after installation. Keep tools
away from walk areas where you and others could fall over them.

Do not wear loose clothing or jewellery, such as earrings, bracelets, or chains that could get
caught in the equipment.

Wear safety glasses if you are working under any conditions that might be hazardous to
your eyes.

Never attempt to lift an object that might be too heavy for you to lift alone.

Always power OFF all power supplies and unplug all power cables before opening,
installing, or removing a chassis.

RISK OF PLANT AND EQUPIMENT DURING INSTALLATION:

Electricity is part of our daily lives, right from the time we wake up and throughout the day. We take it
for granted and have forgotten how powerful it is and can also be dangerous. While at home, we are
aware of the electrical risks and we follow safety rules such as unplugging unused devices, putting off
switches when not in use, no open or live wires lying around, using circuit breakers and various other
precautions.
While at our workplace, where most of the work tasks are done while sitting in a chair in an air
conditioned office building, would seem perfectly safe. However, a surprising number of hazards can be
present in an office setting. To keep you safe at your workplace, we have listed a few common
electrical hazards that you should be aware of and take necessary precautions.

Faulty or Damaged Wiring

Non-functioning wires or cables should be removed at once. Cables which are frayed, loose or have
exposed wires should be attended to and replaced. Damaged wires and cables can cause electric
shocks and fires.

Overloading Circuits

If too many devices are plugged into a circuit, the current will heat the wires to a very high temperature,
which may cause a fire. If the wire insulation melts, arcing may occur and cause a fire in the area where
the overload exists or even inside a wall.

Use of Extension Cords

Extension cords tend to develop cracks and other defects that can lead to shocks. And these problems
cannot be covered with electrical tape. Better to be safe and position your electrical devices within
reach of an electrical outlet rather than to use an extension cord.

Water Spill on Electrical Devices

No electrical equipment should be operated or even switched in case of contact with water.  Water
greatly increases the risk of electrocution especially if the equipment has damaged insulation. Switch
off the main power connection, then unplug all the wet or damp equipment. Make sure you dry them out
well. Have a certified electrician check the device  to confirm it is no longer a danger and can be
switched back on.

Improper Grounding

Every electrical equipment, appliance or device must be Earthed or grounded to obtain a low resistance
path for dissipation of current into the earth. Ground fault current directly has an impact on human
safety, can cause fires and electrical shock. Additionally, ungrounded electrical systems can be
potentially hazardous to your electronics. This important safety feature takes the extra electricity away
from your device, which can save your electronics from damages.

Incorrectly placed Electrical Cords

Electrical cords should be installed in a proper manner and with safety in mind. They are mostly located
within or along walls. There should not be any loose wires as well. Also ensure that no electrical cables
run through high-traffic areas, under carpets or across doorways.

Loose Fitting Plugs

Plug for all electrical equipment’s should be firmly fitted in its socket. Be aware that loose-fitting plugs
can potentially cause equipment to overheat and catch fire. It may require periodic physical checks to
ensure that the plug has not loosened. Be wary when cleaning of work location takes place and
equipment is moved during cleaning, causing the plug to get loosen from the socket.

3. SAFETY PRECAUTIONS WHEN INSTALLING

THE ELCTRICAL EQUPIMENT:
1. The first step of electrical safety, avoid water at all times when working with electricity. Never touch
or try repairing any electrical equipment or circuits with wet hands. It increases the conductivity of the
electric current.

2. Never use equipment with frayed cords, damaged insulation, or broken plugs.

3. If you are working on any receptacle at your home then always turn off the mains. It is also a good
idea to put up a sign on the service panel so that nobody turns the main switch ON by accident.

4. Always use insulated tools while working.

5. Electrical hazards include exposed energized parts and unguarded electrical equipment which may
become energized unexpectedly. Such equipment always carries warning signs like “Shock Risk”.
Always be observant of such signs and follow the safety rules established by the electrical code
followed by the country you’re in.

6. Always use appropriate insulated rubber gloves and goggles while working on any branch circuit or
any other electrical circuit.

7. Never try repairing energized equipment. Always check that it is de-energized first by using a tester.
When an electric tester touches a live or hot wire, the bulb inside the tester lights up showing that an
electrical current is flowing through the respective wire. Check all the wires, the outer metallic covering
 of the service panel, and any other hanging wires with an electrical tester before proceeding with your
work.

8. Never use an aluminum or steel ladder if you are working on any receptacle at height in your home.
An electrical surge will ground you and the whole electric current will pass through your body. Use a
bamboo, wooden or a fiberglass ladder instead.

9. Know the wire code of your country.

10. Always check all your GFCI’s once a month. A GFCI (Ground Fault Circuit Interrupter) is a RCD
(Residual Current Device). They have become very common in modern homes, especially damp areas
like the bathroom and kitchen, as they help avoid electrical shock hazards. It is designed to disconnect
quickly enough to avoid any injury caused by over-current or short circuit faults.

Quality and safety of an electrical installation

In so far as control procedures are respected, quality and safety will be assured only if:

 The design has been done according to the latest edition of the appropriate wiring rules
 The electrical equipment comply with relevant product standards
 The initial checking of conformity of the electrical installation with the standard and regulation has been achieved
 The periodic checking of the installation recommended is respected.

Initial testing of an installation

Before a utility will connect an installation to its supply network, strict pre-commissioning electrical tests and visual
inspections by the authority, or by its appointed agent, must be satisfied.

These tests are made according to local (governmental and/or institutional) regulations, which may differ slightly from
one country to another. The principles of all such regulations however, are common, and are based on the observance
of rigorous safety rules in the design and realization of the installation.

IEC 60364-6 and related standards included in this guide are based on an international consensus for such tests,
intended to cover all the safety measures and approved installation practices normally required for residential,
commercial and (the majority of) industrial buildings. Many industries however have additional regulations related to a
particular product (petroleum, coal, natural gas, etc.). Such additional requirements are beyond the scope of this
guide.
 The pre-commissioning electrical tests and visual-inspection checks for installations in buildings include, typically, all
of the following:

 Electrical continuity and conductivity tests of protective, equipotential and earth bonding conductors
 Insulation resistance tests between live conductors and the protective conductors connected to the earthing
arrangement
 Test of compliance of SELV (Safety Extra Low Voltage) and PELV (Protection by Extra Low Voltage) circuits or for
electrical separation
 Insulation resistance/impedance of floors and walls
 Protection by automatic disconnection of the supply

Electrical Works – Personal Protective Equipment (PPE)

Basic PPE consists of:
 Cotton protective clothing with long sleeves
 Helmet or hard hat
 Goggles for eye protection
 Gloves (leather or rubber)
 Hearing protectors
 Safety footwear

 Helmets normally need be worn only when working on outdoor switchgear, where they serve to
protect against falling objects and collisions with solid objects at head height. Outdoor
 substations should always be considered ‘safety helmet’ areas and helmet wear made
compulsory.
 Hearing protectors are only required when the in a noisy situation, that can occur during
construction works.
 Eye protection should be worn when working with hazardous fluids, particularly mineral oil, to
prevent splashes into the eye. They should always be worn when washing down the internal
parts of oil circuit breakers.
 Safety footwear should be routinely worn in all working areas and the shoes or boots should
incorporate steel toe-cap and non slip soles.
Specific works require specific protective equipment.
 Safety harness should be worn when working at any height greater than 1.5 m above ground
level and a full harness equipped with a connector is preferred. Fall arrest equipment may be
necessary when working at high level. Harnesses should be chosen that are suitable for their
intended application and should be of a design that will support the user in the correct position.
A harness should be comfortable, allowing adequate movement of the user and the unhindered
operation of other devices within the system.
 Depending on the conditions of the work a sit harnesses may be necessary; sit harness has
lateral and central attachment points and are designed primarily to be used for work in
suspension, although they may also be used for work restraint purposes.

 Respirators can also be necessary when a leakage of SF6 is suspected. Although SF6 is not toxic, it
degrades under the heat of arcing to gases.
 When performing energized works or switching operations insulated gloves and dielectric
shoes are required.
 The gloves must be tested and suitable for the working voltage. Labelling chart for insulated
gloves according to ANSI/ASTM (ANSI: American National Standards Institute. ASTM:
American Society for Testing and Materials) Standard  D120

Safety Clearance Notice:

 Isolation Point - An Energy Isolation Point is any piece of equipment that is used to isolate an employee or work
site from hazards associated with the servicing or maintenance on machines, equipment, or systems as a part of
this procedure.

3.6 Tag out - A written warning utilizing a Danger Do Not Operate tag on an energy isolating device to indicate
that the operation of that equipment is prohibited. Tag outs are to be utilized only when it is not physically
possible to lockout the equipment. Tag outs identify the date, equipment, energy isolation point, position, name
of the primary authorized employee and the safety clearance number.

3.7 Lockout - The placement of a lock or locking device on an energy isolating device, in accordance with this
procedure, to ensure that the energy Issuing Authorities are the only employees authorized to issue a Safety
Clearance. An employee can not be the Issuing Authority and Primary Authorized Employee on the same Safety
Clearance. A lockout can not be performed without the signature of a knowledgeable Issuing Authority.

3.5 Energy isolating device and the equipment cannot be operated until the lock or locking device is removed.
Lockouts are to be utilized as necessary to ensure that the equipment being serviced or repaired can not be
physically restarted or operated. Lockouts are to be used in conjunction with a Danger Tag (DANGER DO NOT

OPERATE).

SAFE GUARDS FOR OPERATORS-SAFETY:

Requirements for Safeguards

Safeguards must meet these minimum general requirements:

 Prevent contact: The safeguard must prevent hands, arms, and any other part of a operator's body from
making contact with dangerous moving parts. A good safeguarding system eliminates the possibility of
the operator or another worker placing parts of their bodies near hazardous moving parts.
 Secure: Operators should not be able to easily remove or tamper with the safeguard, because a
safeguard that can easily be made ineffective is no safeguard at all. Guards and safety devices should
be made of durable material that will withstand the conditions of normal use. They must be firmly
secured to the machine.
 Protect from falling objects: The safeguard should ensure that no objects can fall into moving parts. A
small tool dropped into a cycling machine could easily become a projectile that could strike and injure
someone.
 Create no new hazards: A safeguard defeats its own purpose if it creates a hazard such as a shear
point, a jagged edge, or an unfinished surface that could cause a laceration. The edges of guards, for
instance, should be rolled or bolted in such a way to eliminate sharp edges.
 Create no interference: Any safeguard that impedes an operator from performing the job quickly and
comfortably might soon be overridden or disregarded. Proper safeguarding may actually enhance
efficiency since it relieves the operator's apprehensions about injury.
 Allow safe lubrication: If possible, workers should be able to lubricate the machine without removing the
safeguards. Locating oil reservoirs outside the guard, with a line leading to the lubrication point, will
reduce the need for the operator or maintenance operator to enter the hazardous area.