ELECTRICAL SAFETY SYSTEM

CONTRACTOR’S PRE-QUALIFICATION & SELECTION

• CONTRACTOR’S SKILLS-REFERENCE RECORD.
• AVAILABILITY OF SKILLED WORKMEN
 WELDER QUALIFICATION
 CABLE JOINTER QUALIFICATION
 ELECTRICIAN / WIREMEN QUALIFICATION
• HAS THE OWNER / PARTNER / DIRECTOR OF THE COMPANY ANY EXPOSURE TO
HEALTH & SAFETY STANDARDS?
• HAS THE COMPANY ANY QUALIFIED HEALTH AND SAFETY OFFICER?
• HAS THE COMPANY ANY WRITTEN SAFETY PROCEDURES OR MANUALS?
• HAS THE COMPANY ANY PREQUALIFICATION PROCEDURES FOR SUB -
CONTRACTORS?
• HAS THE COMPANY ANY SYSTEM / PROCEDURE FOR PERIODIC TRAINING OF
ITS EMPLOYEES IN HEALTH & SAFETY?
• IS THE COMPANY A MEMBER OF ANY SAFETY ORGANIZATION?
• HAS THE COMPANY WON ANY SAFETY AWARDS?
• CAN THE COMPANY FURNISH A LIST OF SAFETY APPLICATIONS OWNED BY THEM?
• HAS THE COMPANY ANY SYSTEM / PROCEDURE FOR MANTENANCE OF PLANT /
TOOLS / EQUIPMENT?
• IS THERE ANY SYSTEM FOR INVESTIGATION & REPORTING ACCIDENTS, DISEASES
AND DANGEROUS OCCURRENCES?
• HAS THE COMPANY BEEN EVER PROSECUTED ON HEALTH & SAFETY GROUNDS?
• WEIGHTAGES CAN BE GIVEN TO ALL THESE QUESTIONS AND CONTRACTORS
MEETING CERTAIN MINIMUM MARKS SHALL BE SLECTED.
• EVEN IF CONTRACTORS ARE NOT FULLY EQUIPPED PRESENTLY, THEY WILL GEAR UP
IN COURSE OF TIME ONCE SUCH PREQUALIFICATION PROCEDURES ARE STRICTLY
ENFORCED.

OWNER’S RESPONSIBILITY
• PERIODIC TRAINING IN HEALTH & SAFETY TO ALL SUPERVISORS AND WORKMEN.
• PERIODIC AUDIT AND ENFORCEMENT OF ALL PROCEDURES AND SYSTEMS.

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• TO EMPLOY QUALIFIED & TRAINED WORKMEN FOR EACH JOB.

• TO HAVE “HEALTH & SAFETY MANUAL” AND MAKE IT EASILY ACCESSIBLE FOR ALL
STAFF FOR REFERENCE AND UPDATING THEIR KNOWLEDGE.
• TO ENFORCE “PERMIT TO WORK” SYSTEM.
• TO MAINTAIN A REGISTER FOR MAINTENANCE OF ALL TOOLS, TACKLES AND
INSTRUMENTS.
• TO MAINTAIN ADEQUATE SUPPLY OF SAFETY TOOLS & EQUIPMENT AND MAKE
THEM EASILY AVAILABLE TO STAFF.
• TO MAKE AVAILABLE FIRST-AID KITS, SHOCK CHARTS & SINGLE LINE DIAGRAMS IN
EVERY SUB-STATION.
• TO MAINTAIN DRAWINGS AND INSTRUCTION MANUALS FOR ALL SYSTEM /
EQUIPMENT.
• PERIODIC TESTING & MAINTENANCE TO BE ENFORCED FOR ALL ELECTRICAL
SYSTEMS AND EQUIPMENT.
• TO SELECT COMPETENT CONTRACTORS AND ENSURE THEY FOLLOW SAFE
PRACTICES.
• TO ENSURE PLANT SYSTEMS ARE UPDATED TO MEET SAFETY NORMS - SUCH AS
LOCKING FECILITIES, EARTHING, ELCB PROTECTION, AND LOG BOOK ETC.
• TO MAKE AVAILABLE IF RULE BOOK & BIS CODES. INSTRUCTIONS TO
CONTRACTORS SHALL BE CLEAR AND IN WRITING.
• WHILE IN COMPANY’S PREMISES, SHALL COMPLY WITH HEALTH & SAFETY.
• FOLLOW LEGISLATION & SAFETY REGULATIONS AS LAID DOWN IN THE CONTRACT.
• ENSURE THAT ALL SAFETY EQUIPMENT IS IN GOOD WORKING CONDITION.
• SHALL NOMINATE ONE OF HIS EMPLOYEES RESPONSIBLE FOR HEALTH & SAFETY.
• SHALL INSURE HIS WORKMEN.
• SHALL PROVIDE ADEQUATE LIGHTING ARRANGEMENTS AT VARIOUS LEVELS FOR
SAFE AND PROPER WORKING OPERATIONS
• SHALL PUT UP SAFETY NOTICES AROUND WORK AREAS AS REQUIRED BY
REGULATION / OWNER.
• SHALL PUT UP TEMPORARY FENCING OR SHIELDING AND ACCESS DENIED TO
UNSAFE AND HAZARDOUS AREAS.
• SHALL ENSURE SAFETY OF ALL WORKMEN, MATERIAL AND EQUIPMENT.

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• SHALL PROVIDE ENOUGH FIRE FIGHTING / PROTECTION EQUIPMENT OF THE TYPES

AND NUMBERS AT OFFICE, TEMPORARY STRUCTURES, LABOUR COLONY AREA ETC.
• SHALL ENSURE USE OF PROPER VOLTAGE EQUIPMENT AS FOLLOWS:
- 24V FOR HAND LAMPS
- 110V FOR HAND TOOLS
- 240V / 415V FOR WELDING.
• ALL ABOVE VOLTAGE SOURCES SHALL HAVE ELCB PROTECTION.

RECOMMENDED MINIMUM LEVELS OF ILLUMINATION:

INTERIOR MOVEMENT ONLY 5 LUX

GENERAL MOVEMENT 5 LUX
HANDLING MATERIALS, UNLOADING 10 LUX
EXTERIOR GENERAL 10 LUX
CLEARING SITES, GENERAL ROUGH WORK- 15 LUX
INTERIOR WORKING PLACES 15 LUX
INTERIOR REINFORCING AND CONCRETING 50 LUX
BRICK LAYING (EXCEPT FACINGS) 100 LUX
BENCH WORK , FACING BRICKWORK AND
200 LUX
PLASTERING

INTERIOR WORKSHOPS 400 LUX

FINE CRAFTWORK 400 LUX

DRAWING BOARDS 600 LUX

THE TERM INTERIOR LIGHTING COVERS THOSE PARTS OF STRUCTURES WHICH MAY
NOT HAVE CLADDING DURING ERECTION, BUT WHICH WILL BECOME INTERIORS WHEN
THE WORK IS FINISHED.

DISTRIBUTION VOLTAGES RECOMMENDED ARE:

FIXED PLANT 415V, 3 PHASE

MOVABLE PLANT SUPPLIED BY TRAILING
415V, 3 PHASE
CABLE

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SITE OFFICES, STORES, DRYING ROOMS,

24OV, 1 PHASE
ETC.
FIXED FLOODLIGHTS 240V, 1 PHASE
LIGHT MOVABLE PLANT, 1 - 2 HP 110V, 3 PHASE

PORTABLE HAND HELD TOOLS, UPTO 1 HP 110V, 1 PHASE

SITE LIGHTING (NOT FIXED) 110V, 1 PHASE

PORTABLE HAND LAMPS (GENERAL USE) 24V, 1 PHASE

SPECIAL
PORTABLE HAND LAMPS (DAMP OF
CONSIDERATIONS
CONFINED AREAS)
APPLY

REDUCED VOLTAGES ARE OBTAINED BY:

• 110V, 3 PHASE - USING A DOUBLE WOUND TRANSEFORMER WITH THE NEUTRAL
POINT OF ITS STAR-CONNECTED SECONDARY WINDING EARTHED SO THAT THE
NOMINAL VOLTAGE TO EARTH IS APPROXIMATELY 55V.
• 110V, 1 PHASE - USING A DOUBLE WOUND TRANSFORMER WITH THE CENTRE TAP OF
THE SECONDARY WINDING EARTHED SO THAT THE NOMINAL VOLTAGE TO EARTH IS
55V.
• 110V, 3 PHASE - USING PORTABLE GENERATOR SET PROPERLY EARTHED IN
ACCORDANCE WITH CP 1017.

IDENTIFICATION COLOURS

OPERATING VOLTAGE A.C. COLOUR

25 VIOLET
50 WHITE
110 YELLOW
220 / 240 BLUE
380 / 415 RED
500 / 650 BLACK

ISOLATION AND SWITCHING

SWITCH BOARD
HV & LV SWITCHBOARDS SHALL HAVE LOAD BREAK FAULT MAKE ISOLATORS OR
CIRCUIT BREAKERS AS INCOMER FOR ISOLATING POWER SUPPLY TO SWITCHBOARD

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MERE FUSES ARE NOT ADEQUATE. PT's IN HV SWITCHBOARDS SHALL BE ON DRAWOUT

MODULE WITH HV FUSES AND AUTOMATIC EARTHING ON DRAWOUT.

TRANSFORMERS
WHERE HV SWITCHGEAR AND TRANSFORMER ARE IN TWO DIFFERENT BUILDINGS FAR
AWAY, A LOAD BREAK SWITCH WITHIN 15m DISTANCE OF TRANSFORMER IS
RECOMMENDED

MOTORS
ALL MOTORS SHALL HAVE LOAD BREAK POWER ISOLATOR CLOSE TO MOTOR WITHIN
VISIBLE DISTANCE

SWITCHYARD EQUIPMENT
CIRCUIT BREAKER SHALL HAVE ISOLATOR ON EITHER SIDE FOR CIRCUIT BREAKER &
CT MAINTENANCE. PT's SHALL HAVE ISOLATORS OR DROPOUT FUSE FOR THEIR
MAINTENANCE.

OVERHEAD LINES
ALL OVERHEAD LINES SHALL HAVE ISOLATOR ON BOTH ENDS FOR THEIR
MAINTENANCE.

CONTROL AND RELAY PANELS

ISOLATORS SHALL BE PROVIDED IN EACH PANEL FOR AC/DC POWER SUPPLIES.

PROCEDURES FOR CHARGING LINE:

• OBTAIN DOCUMENTARY APPROVAL FROM COMPETENT AUTHORITY.
• WRITTEN WARNING FOR UNAUTHORISED PERSONS TO STAY AWAY.
• REMOVAL OF TEMPORARY EARTHING, TOOLS AND TACKLES TO BE THOROUGHLY
CHECKED.
• CLOSURE OF ALL OPENINGS TO BE ENSURED, SUCH AS GLAND PLATES, BACK
SHEETS OF PANELS, GUARDS, INSPECTION COVERS ETC.
• SEQUENCE SHALL BE FROM SOURCE TO LOAD.
• DURING INTIAL COMMISSIONING AND AFTER PROLONGED SHUTDOWN SWITCHING
SHALL BE DONE AFTER PERFORMING ALL PRECOMMISSIONING CHECKS SUCH AS :-

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 MEGGER TEST
 CONTINUITY TEST
 DUCTOR TEST ( FOR JOINTS )
 FUNCTIONAL TEST

EMERGENCY SWITCHING
HV / LV CIRCUIT BREAKERS
SHALL HAVE MECHANICAL AS WELL AS ELECTRICAL TRIP PBs IN PANEL

HV / LV ISOLATORS
INCOMER ISOLATOR FEEDER SHALL HAVE ELECTRICAL TRIP PB FOR TRIPPING SENDING
END CIRCUIT BREAKER OR MCCB

MOTORS
• LOCAL ISOLATORS SHALL BE OF LOAD BREAK TYPE.
• TRIP PUSH BUTTON SHALL ALSO BE PROVIDED.
• THE ABOVE WILL CATER FOR EITHER SWITCH OR CONTACTOR CONTACT WELDING.

TRANSFORMER
A TRIP PUSH BUTTON OUTSIDE THE TRANSFORMER ROOM SHALL BE PROVIDED FOR
EMERGENCY TRIP OF SENDING END BREAKER.

REMOTE SUPERVISORY INSTRUMENTATION & CONTROL

a) EQUIPMENT MUST FAIL TO SAFETY i.e.
 EVERY REMOTE INDICATOR MUST GIVE THE CORRECT INDICATION OR NO
INDICATION.
 EVERY OPERATING HANDLE MUST CAUSE THE CORRECT OPERATION OR
NO OPERATION.
 EVERY INTERLOCK MUST ALLOW ONLY SAFE OPERATION, OR PREVENT
ALL OPERATION.
 ANY FAILURE TO FUNCTION CORRECTLY MUST BE MADE IMMEDIATELY
APPARENT.
(b) EVERY INDICATOR OR INTERLOCK SHOULD SPAN THE COMPLETE EQUIPMENT
AND OPERATION IN TIME AND SPACE.
 EVERY IMPORTANT INDICATION SHOULD BE SELF CHECKING AND IT IS AN
ADVANTAGE TO INCLUDE THE OPERATOR IN THE CHECK.

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 IMPORTANT INCOMING SIGNALS SHOULD NORMALLY TAKE PRECEDENCE

TO OUTGOING INTRUCTION, WHERE THE SAME CHANNEL OR TERMINAL
EQUIPMENT IS USED, SO THAT ACTION MAY BE TAKEN BASED ON LATEST
INFORMATION.

GUARD

TYPE FUNCTION
PREVENTS ACCESS TO DANGEROUS
FIXED GUARDS
PARTS
MOVE IN ADVANCE OF EACH
AUTOMATIC GUARDS OPERATION OR STROKE TO SWEEP OR
PUSH OPERATORS ARM
MUST BE IN CORRECT ADJUSTMENT
INTERLOCKED GUARDS BEFORE DANGEROUS OPERATION CAN
COMMENCE
STOPS THE MACHINE AUTOMATICALLY
TRIP GUARDS WHEN DANGER ARISES (SIMPLE LIMIT
SWITCHES)
ANOTHER FORM OF FIXED GUARD
POSITIONAL GUARDS WHERE OPERATOR IS KEPT AT SAFE
DISTANCE
GUARDS OPERATING ON
LIGHT BEAM &
PHOTOELECTRIC OR
ELECTRICAL INDUCTION
PROXIMITY EFFECT TO PREVENT
GUARDS
OPERATION OR TRIP THE MACHINE

INTERLOCKS
SEQUENCE
FOR MATERIAL HANDLING SERVICES (LIKE COAL HANDLING PLANT).
• START - LAST CONVEYOR FIRST / FIRST CONVEYOR LAST.
• STOP - FIRST CONVEYOR FIRST / LAST CONVEYOR LAST.

GENERATOR
• NO. OF GENERATORS OPERATE IN PARALLES IN SOLIDLY EARTHED SYSTEM.
• ENSURE EARTHING ISOLATOR CLOSED AND MORE THAN ONE ISOLATOR ARE NOT
CLOSED (RELAY LOGIC OR CASTLE KEY INTERLOCKS).

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TRANSFORMER
HT BREAKER TRIP TO TRIP LT BREAKER. LT BREAKER CLOSES ONLY ON HT BREAKER
CLOSING.

FEEDER
FOR UNIDIRECTIONAL POWER FLOW - DOWN STREAM BREAKER INTERLOCK WITH
UPSTREAM BREAKER FOR CLOSE AND TRIP.
SWITCHGEAR
• EARTHING TRUCK CAN BE INSERTED IF ASSOCIATED BUS OR CABLE DEAD BREAKER
CAN BE CLOSED IF ASSOCIATED EARTH TRUCK NOT INSERTED.
• ENSURE TWO ASYNCHRONOUS SOURCES ARE NOT PARALLELED.
INCOMER TO CLOSE IF OTHER(S) OPEN OR SHORT TIME PARALLELING THROUGH
SYNCHRO CHECK FACILITY.
• CHANGEOVER OF SUPPLY BREAKER ON U / V; FIRST BREAKER OPENS AND SECOND
BREAKER CLOSES IF SOURCE VOLTAGE PRESENT.
• ON BUS U / V, TRIP MOTOR FEEDERS.

MOTOR
• START / TRIP INTERLOCK WITH GUARD LOCAL ISOLATOR.
• PROVIDE SPEED SWITCH IF START TIME MORE THAN LOCKED ROTOR WITHSTAND
• TIME (NORMAL FOR HIGH INERTIA MOTORS).

BKR - ISOLATOR
• BREAKER TO CLOSE ONLY IF ISOLATOR IS CLOSED.
• ISOLATOR TO CLOSE OR OPEN ONLY IF BREAKER IS OPEN.

GENERAL
PROVIDE HAND RESET TYPE LOCKOUT RELAY. BREAKER TO CLOSE ONLY IF LOCK OUT
RELAY IS RESET.

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