UNIT-III

RISKS DURING INSTALLATION OF ELECTRIC PLANT AND EQUIPMENT:

During the installation work, the main circuit is not yet energised and flow of
electrical energy is not yet established.
The main power circuits, bus bars and cables are not yet at high voltage. Hence risks
of electric shocks, flashovers, arcs, explosions in main equipment and auxiliary equipment
are negligibly small.
However risks of falling of objects, falling of construction workers from height, fires
due to welding sparks, fires during handling of flammable cases, liquids and solids are
particularly high and the risks are maximum when during installation work. Risks increases
several times due to simultaneously civil, erection and testing work are in progress.
The accidents during installation occur due to
-Unsafe Conditions at Site and/or Unsafe acts of negligence-Several cumulative
lapses culminate in a mishap. Behind one mishap there may be several chance misses.
Unsafe conditions during installation:
A. Civil and Mechanical Hazards
UNSAFE CONDITIONS
Open pits of civil foundations, open cable trenches,

CONSEQUENCES
Risk of fall of workers during

open pits in construction site, poor illumination at

installation.

site, unguarded openings from first/second floor, and

openings in slabs.
Unfinished civil works, uncured RCC

Risk of collapse of uncured RCC work

foundation/slab/walls/roof Windows

due to erection load. Sinking of

Uneven foundation

foundation when loaded.

Inclined unsafe structure, inclined

Mistakes in Civil layout

equipment.
Insufficient clearances, insufficient
space for movement unsafe condition
while shifting equipment to final

Roads not ready/no of adequate

location.
Accidents during transport/handling

strength/width/curvature
Crane, Lifter, Trucks without perfect control/brakes;

upto store/upto location

Accidents during assembly/dismantling

Wornout slings, D-schackles

Mechanical accidents during operational failure of to Risk to operators

weak parts, springs

High pressure Air system, high pressure/High

Risk of explosion.

temperature steam
B. Electrical and Fire Hazards:
Open flames, welding sparks
Welding
Loose bare wire connected to supply
Bare live conductor at accessible location
Temporary power supply for construction work

Risks of fires/explosions
Risk to welders eyes Risk of fires
Electric shocks/short circuits
Electric shocks/short circuits
Risk of fires due to loose connection,

through temporary switch board without

cable faults

fuse/proper material
Slippery surface on transformer tank, tower
Switching on the HT/LT supply inadvertently by

Fall of construction worker.

Shocks to construction worker at site

third person
Ungrounded structures, metal
Wet walls
Poor house keeping, garbage packing wood

during installation
Electric shock due to leakage
Electric shock due to leakage
Danger of fire during installation due too

collected near work place

Working in vicinity of live line/live equipment

welding sparks.
Danger of flashover shocks
Danger of induced current shocks

section clearance not adequate

C. Fire, smoke, poisonous gases and explosions

Handling/Processing/Storing of Flammable

Risk of fires/Explosions

Liquids/Gases/Solids/Filling in equipment e.g.

Hydrogen, Butane, Ammonia, Fuel oil, Transformer
oil
Filtration of Transformer oil.
Leaking gas/Oil/Fuel

Risk of fires and explosions

Risk of smoke and gases.
Risk of fire/explosion
Risk of Unconsciousness
Risk of Poisoning
Risk of eyes/lungs/skin/health

D. Chemical hazards:
Leakage of stored SF6 gas, CO2 gas in confined

Risk of suffocation.

space.
Poisonous gases, smoke, dust, released by chemical

Risk of damage to eyes, lungs, blood,

reaction let into atmosphere room.

Action of corrosive gases liquids, powders, solids

brain.
Risk of damage to eyes, lungs, blood,

on persons health.

brain.

UNSAFE ACTS DURING INSTALLATION:

UNSAFE ACT
Installation work was ordered though civil

CONSEQUENCES
Risk of fall in Pits, fall from first/second

work was not yet complete

Safety Hat was not used
Safety belt/rope not used
Garbage not cleared form site
Person climbs on transformer tank for

floor
Head injury due to fallen bolt
Climber falls from structure
Garbage caught fire due to welding sparks
Fall from tank to ground head injury and

inspection without precaution

String insulator support not hooked in RCC

death
String insulator and flexible bus fall sown

of wall column but held in brick masonary

along with portion of wall
While filtering transformer oil, supervisor did Fire
not notice high temperature
Temporary switchboard with loose

Overheating of temporary cable and fire of

connection and solid bar in place of fuse

Fire fighting system not installed in store

switchboard
Small fire could not be extinguished, grew

Worn out slings used for lifting bushing

Welder did not used Dark Glasses
Unauthorised person switched on LV switch

into big fire

Sling was broken and bushing fell down
Eyes were injured
Persons working on LV system got electric

High pressure pipe connection was loose

Supervisor did not take work permit while

shock
The pipe flew off causing accident
The workers got electric shock due to

undertaking extension work of fence.

Person defeats Interlock/Protection/Alarm

flashover from nearest busbar

Very unsafe practice which may lead to

System etc., for temporary continuation of

serious accident/disaster.

plant.
SAFETY DOCUMENTATION FOR INSTALLATION:
The safety documentation for installation has three parts:
1. Safety System Document for the complete project coves the safety objectives, safety
organisation, safety procedures, safety rules, work permit system etc.
2. Plant Installation Document.
3. Equipment Installation Document.

FIELD QUALITY AND SAFETY DURING ERECTION:

Careless erection work results in unsafe conditions for testing commissioning and
operation/maintenance.
The Electrical Plant and Equipment consists of Main Circuit with current carrying parts
supported on insulation system. In addition to main circuit, there are protection systems,
control systems, measurement system, auxiliary supply systems, safety systems, etc. The
installation of each system must be done carefully and with excellence in quality.
Carelessness or weakness at any stage results in subsequent failure somewhere and unsafe
condition or accident.
Following aspects are important:
1. Current carrying paths in main circuit:
The function is to conduct load currents, overload currents without overheating.
The entire main power circuits should have low resistance. These paths include: terminal
connectors, busbar joints, rigid tublar busbars, power cable conductors, circuits
breaker/isolator poles, CT poles, terminal clamps for equipment etc, loose connections are
unsafe.
High resistance in main circuit results in overheating of conductors and may lead to
burning of adjacent insulation.
-

Joints in conducting path: the joints have mating surfaces. Air gap between two
mating surfaces results in formation of oxide layer on conductor surfaces. These oxide
layers are of high resistivity. The joints become progressively hot due to I^2Rt losses

and the joint may fail resulting in fault and mishap.

Loose hardware: the terminal connections, the joints etc are fastened by using
appropriate hardware. Absence of spring washer results in loose joint and over
heating/sparking. Over tightness of hardware results in shearing of threads of
hardware and failure of fastner. Each joint must be made carefully by using torque

spanner of appropriate recommended torque value.

Neutral point must be earthed by low resistance copper flexible or copper bar

connected between the neutral point and earth mesh.

2. Low voltage conductor system: Loose connections are not permitted. The screws,
connectors, terminals should be tight and secured. Neutral points must be firmly
established. Chassis earthing, shield-earthing should be as per recommendations.

3. Solid insulators: Insulators support the conductors. Some insulators also enclose the
conductor system and components. Primary requirement of insulators is to provided
insulation and to withstand voltage. External surfaces of solid insulators must be
clean, glazed, without cracks/blisters/chips. If cracks/blisters/chips more than 1cm
dia are found during erection, the insulator should be replaced. Solid porcelains
designed for vertical position must not be subjected to bending, tensile loads during
installation. The insulator suddenly breaks. A 220 kv Circuit breaker was being
shifted by crane in assembled condition. The support insulators got shattered during
the handling. Cementing between flange and porcelain should be strong. Flanges
should be free from cracks. Insulator surfaces must get washed during rains. In some
highly polluted are artificial washing of insulators may be necessary.
4. Hollow porcelain insulators: The hollow porcelain insulator assemblies with top
and bottom cemented flanges are used for
-Bushing porcelains, CT chambers, Circuit breaker chambers, Surge arreste chambers
etc. The functional requirement includes voltage withstand, creepage, clearance and
also air tightness/gas tightness. The porcelain assemblies must withstand internal gas
pressure/air pressure and overpressure. Sealing is provided by neoprene rubber orings squeezed between the groove in the flange and the ground surface of porcelain.
5. Corona rings: These are located around high voltage terminals for modifying electric
field and reduce voltage stress on insulator near live terminals. The racking of dust along
insulator surface at live end is reduced. Corona around conductor is also reduced.
6. clearances: During and after installation, the clearances between conductor and nearest
earthed part must be checked against recommended minimum value. It is possible that some
stray construction at site has encroached within the clearance zone.
7. Earthing of structures: Each structure must be positively earthed by connecting to earth
mesh via earthing conductor. It is for safety of operation and maintenance staff.
8. Oil Immersed equipment: Extra precaution is necessary while filling oil, filtering oil and
operating and maintaining oil filled equipment. Temperature should never exceed specified
limit. Moisture entry is dangerous. Oil quality should be checked periodically. Poor oil leads
to faults and possible explosions.
9. Oil leakage: Oil leakage must be quickly attended. Oil leaks are unsafe as they can lead to
failure of main equipment and fire hazard.
10. Gas filled equipment: Special precautions, facilities are essential while handling gases,
installation of gas filled equipment. Gases used in equipment are of two types:

1. inslulating gases like SF6 , N2.

2. flammable gases like hydrogen for generator cooling ammonia for flue gas
neutralising, propane for oil burner initiation etc.
11. Interlocks, sequence systems, protection, alarm monitoring systems: Installation of
these systems is as important as the installation of main systems. Electrical energy must be
controlled. Several automatic safeguards are provided to ensure safety of operators and
equipment against wrong operations and unsafe operating conditions.
12. Completeness: Before handling over the plant to testing and commissioning manager, the
erection of main equipment, auxiliaries, control and protections systems, monitoring system,
communication system, fire fighting system, earthing system, lighting protection system, etc
must be checked for completeness and quality.
SAFEGUARDS FOR OPERATIONS SAFETY:
Operator should be safeguarded from electrical, mechanical, environmental hazards.
Safeguards are provided in the plant and equipment to prevent injury to operator.
Safety provisions for operators safety:
1. Bare live conductors are either placed out of reach of operator or enclosed in earthed
metallic enclosures.
2. Cabinets, enclosures, structures, metallic bodies are earthed.
3. Air insulated high voltage equipment are mounted on earthed metallic structures of
minimum height 2.55M above ground level.
4. Earthed Metallic Screens are provided around high voltage equipment not having
sufficient ground clearance.
5. Substation switchyards are fenced, entry is possible only through doors which must be
normally closed and locked.
6. Doors with limit switches: High voltage testing laboratories, high voltage installations
with insufficient ground clearances etc. are provided with limit switches interlocked
with circuit breaker on supply side such that doors can be opened only when the
supply is removed.
7. Prohibited zone: Fixed barriers, enclosures, awareness barriers are provided for plant
and equipment to prevent entry of authorised and casual person in protected zone.
8. Rotating parts, reciprocating parts, high temperature parts, electrically live parts are
provided with safety guards to prevent accidents and injury to operators. Operators
hands/fingers do not pass through the safety guard over a fan.
9. Danger notices must be placed. Only authorised personnel are permitted entry.

5.

Protection against injurious

forces and circumstances.

Air or water under

pressure/vacuum, body parts
under strain.

Divers suits, trousers,

bandages, elastic
stockings, safety ropes
and belts, hair nets.

SELECTION OF PPE OF HAZARDOUS CONDITION

Selection of PPE as per parts of the body to be protected

sl.no
1.

2.

3.

Part of body
head

face

eye

Equipment to be used
(i)fiber helmet

Protection against
Fall of objects, hitting against falling
objects(during erection or handling)

(ii)electrical resistance
helmet

Shock when working on electrical lines.

(iii)welders leather cap

Falling of molten slag during overhead

welding and splashing of liquid
Liquid chemical splashing, striking of
dust particles.

(i)plastic face shield

(ii)welding helmet and
shield
(iii)asbestos hood

Welding fumes, sparks, ultra violet

rays(during arc welding)
Radiation of heat in furnace work.

(i)panorama goggles with

plastic visor.

Oil and paint splashes,dusts,chip entries.

(ii)leather mask goggles

Foreign bodies entering the eyes and

against smoke.

(iii)spectacles type

Foreign bodies entering the eyes while

4.

5.

6.

7.

ear

Nose

body

Hand

goggles with plain shatter

proof lens.

working on machines and reflected arc.

(iv) panorama goggles

with green plastic visor.

Reflected arc during arc welding.

(v)gas welding goggles

gas welding and gas cutting.

(vi)acid and alkali proof

rubber goggles
(i)ear plugs

Splashes of corrosive substance like acid,

alkalies, chemical substances.
High noise level above 95 dbs

(ii)ear muff

High noise level

(iii)both plug and muff

(i)dust proof respirator

Very high noise level above 110dbs

Against dust and powder particles
(entering lungs through nose)

(ii)heavy fumes mask

Against acid fumes, vapours and gases

(0.1%)

(iii)canister mask
(i)leather apron

Against acid fumes, vapours and

gases(0.2%)
Falling of hot chip, slag sect.

(ii)asbestos gloves

Heat radiation

(iii)PVC apron

Splashing of chemicals

(iv)lead apron

X-rays and gamma rays9

(v)safety belts
(i)leather gloves

Falling of persons from height

Cuts due to handling

(ii)asbestos gloves

Heat radiation

(iii)acid and alkali proof

rubber gloves

Splashing of chemicals

(iv)electrical resistance
gloves

Burns due to handling of acids

(v)canvas gloves

Electrical shock.

(vi)hand sleeves

Contact with oil, greas, and other drit in

the crane ladders rung

(vii)lead gloves

Falling of hot slag during over head

welding

8.

Leg

(viii)protective barrier
cream

Skin diseases.
Sun-burns of face.

(i)leg guard

welding sparks

(ii)leather safety boots

Striking against objects, struck by

moving objects, fall of objects from
height, stepping on sharp and ho objects.

(iii)asbestos safety boots

Heat radiation, stepping on sharp and hot

objects, striking against stationary
objects, struck by moving objects or full
of objects from height.

(iv)gum boots

Mud ,dirty floor, chemical liquids.

SAFETY CLEARANCE NOTICE (SCN) BEFORE ENERGIZING

This is issued by the authorized person (e.g. site manager) after completion of erection,
equipment tests and subsystem tests and before energizing the electrical plant for the first
time and putting in regular operations and also before energizing the plant after completion of
annual maintenance. The SCN is issued only with the agreement between the following :

Plant manager
Site manager
Contractor
Testing incharge
Electrical safety inspector(of the owner)

All the other construction staff (civil, mechanical, structural general) must vacate the safety
clearance zone, control room and the areas should be cordoned and closed.
SCN is initiated by site manager and is countersigned by the safety inspector. All the work
must be completed before applying for the SCN.
Each contractor (Civil, Mechanical, and Electrical) receives a copy of SCN and signs the
acknowledgement copy. Contractor must ensure that his personnel, tools, equipment are
removed from the are