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RISK ASSESSMENT FOR ELECTRICAL TESTING & PRE-COMMISSIONING OF PLANTS

HSE DOCUMENTS RISK ASSESSMENT FOR ELECTRICAL TESTING & PRE-COMMISSIONING OF PLANTS

HSE Documents provides a comprehensive Risk Assessment for Electrical Testing and Pre-Commissioning of Plants in an editable and ready-to-use Word format. Designed for HSE professionals, project managers, engineers, and supervisors, it ensures systematic hazard identification, risk evaluation, and implementation of control measures. This free resource supports compliance, enhances safety during high-risk electrical testing activities, and ensures a streamlined pre-commissioning process. Download this essential document to uphold workplace safety standards and facilitate safe and efficient project execution.


CONTENT

1.0. ACTIVITIES/ PROCESSES/EQUIPMENT/MATERIALS

2.0. HAZARD

3.0. RISKS

4.0. EXISTING CONTROLS

5.0. IMPROVED EXISTING CONTROLS / IMPLEMENTING NEW CONTROLS


1.0. ACTIVITIES/ PROCESSES/EQUIPMENT/MATERIALS

1.1. Obtain Permit to Work

1.2. Preparation of tools, materials and equipment

1.3. Mobilization of testing equipment to Substation building

1.4. Review of drawings and as-built plans for the planning of commissioning 

1.5. Visual check and inspection of all electrical equipment

1.6. Earth/Grounding survey and testing

1.7. Testing of inter-panel bus wiring, insulation testing using 500V Megger

1.8. Testing of Multi-Core cables and insulation resistance test using 1000V Megger

1.9. Check of batteries and chargers

1.10. GIS site test (conduct test by the work site test report)

1.11. Transformer site test and Shunt Reactor test


2.0. HAZARD

2.1. Unauthorized work to be performed within a defined location and boundary

2.2. Uncontrolled personnel entering a restricted location

2.3. Unidentified hazards with unplanned safety mitigating measures inadequate coordination and area control protocol

2.4. Contact with sharp edges

2.5. Improper use of personal protective equipment

2.6. Working in the awkward position

2.7. Unsecured tools, equipment & materials

2.8. Overspeeding

2.9. Adverse weather condition

2.10. Uneven surfaces

2.11. Workers struck by transport vehicle

2.12. Ergonomics hazards

2.13. Awkward positioning

2.14. Inadequate storage of materials

2.15. Opening of panel board

2.16. Pinch point

2.17. Caught in between panel board door

2.18. Slip, trip and fall on the same level

2.19. Poor visibility

2.20. Improper handling of testing equipment

2.21. Handling of tools, earth spikes, wiring

2.22. Slip, trip and fall

2.23. Struck by moving equipment and vehicle

2.24. Opening of panel door or back cover

2.25. Opening the wrong electrical equipment

2.26. Caught in between panel board door Congested headroom

2.27. Incompetent worker

2.28. Accumulation of hazardous/ toxic gas

2.29. Equipment failure

2.30. Overcharging

2.31. Alarm and Sensor monitoring system is not working

2.32. Poor supervision/ incompetency of personnel

2.33. Inappropriate tools

2.34. Inadequate PPE

2.35. Untrained personnel

2.36. Congested headroom

2.37. Overhead hazard

2.38. Shock hazard

2.39. Inadequate illumination

2.40. Sudden and startling loud sound

2.41. Exposure to SF6 gas through inhalation Environmental release of SF6

2.42. Exposure to pressurised vessel and its component

2.43. Struck by pressurized hose

2.44. Inadequate warning notification

2.45. Lack of information

2.46. Handling of tools

2.47. Contact with electricity

2.48. Energized electrical equipment/panel

2.49. Exposure to extreme environmental temperature (outside areas more than 50deg.C)

2.50. Use of the substandard elevated platform

2.51. Fall from the elevated platform

2.52. Improper manual handling/ lifting of equipment and material

2.53. Poor housekeeping

2.54. Undisposed waste materials

2.55. Unaccounted workers

2.56. Inadequate communication

2.57. Poor storage of chemical, flammable and combustible materials, etc.

2.58.Unattended unsafe condition Unsecured electrical equipment, energized equipment


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3.0. RISKS

3.1. Significant property and appurtenances damage

3.2. Governmental violation

3.3. Sharp edges if not identified and isolated causes skin lacerations and cuts

3.4. Not observing proper posture could cause muscle spasms and body pain

3.5. Unsecured/ overloading could cause collapse or fall of materials

3.6. Overspeeding/ may cause damage to equipment, property/materials and injury to a person

3.7. Passing to uneven surfaces may cause the fall of materials and overturning of equipment

3.8. Vehicular accident resulting in significant damage to equipment and serious injury to the worker

3.9. Body sprain

3.10. Chronic musculoskeletal disorder

3.11. Loss or damage to property

3.12. Electric shock

3.13. Vehicular accident

3.14. Accident resulting in Injury to personnel

3.15. Property damage of adjacent structures or appurtenances

3.16. Damage to panel door and cover

3.17. Hand injury resulting from improper use of panel door key

3.18. Electrocution

3.19. Inhalation of fumes causes dizziness, irritation of the throat, passageway, chronic disease or fatality

3.20. Equipment failure will result in fire and explosion

3.21. Using inappropriate tools could cause short circuits and equipment failure

3.22. Wearing inadequate PPE may cause physical injuries

3.23. Mobilizing untrained personnel could cause accidents

3.24. Hand laceration or cut, bruise, contusion

3.25. Head injury or bruise

3.26. Eye strain

3.27. Visual impairment

3.28. Fall from a stationary position

3.29. Stress to worker

3.30. Difficulty in breathing

3.31. Asphyxiated

3.32. Accident resulting in serious injury

3.33. Property damage

3.34. Accident resulting in serious injury or death to other worker

3.35. Damage to assets and equipment

3.36. Inappropriate test result

3.37. Electric shock, skin burn

3.38. Injury to worker

3.39. Damage to property

3.40. Fire due to short circuit

3.41. Heat exhaustion

3.42. Heat cramps

3.43. Heat stress

3.44. Ill health of personnel

3.45. Body sprain or back injury

3.46. Accident resulting in injury to worker

3.47. Ill health

3.48. Muscular injuries (Back pain, strain, fractures)

3.49. Pinch/crash points resulting in hand injuries

3.50. Significant property and appurtenances damage Governmental violation

3.51. Environmental complaint

3.52. Loss of production

3.53. Accident resulting in serious injury or death to the worker

3.54. Significant cost due to damages

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4.0. EXISTING CONTROLS

4.1. Permit to Work shall be obtained as a pre-requisite to perform work

4.2. Work shall not be started until a duly approved Permit to Work is available at the site and that Safety Toolbox meeting was conducted

4.3. A safe work practice shall be implemented to reduce the possibilities of accident/incident

4.4. Permit Receiver and Permit Issuer shall visit together at the site to ensure that workplace hazards are adequately identified and mitigating measures shall be established

4.5. Permit to Work shall be displayed at the worksite

4.6. Permit Receiver shall not leave the area for the whole duration of work

4.7. Work shall not proceed without the presence of an approved Permit to Work with the Permit Receiver overseeing the activity

4.8. Permit Receiver shall account for all workers under his Permit to Work before the start of work

4.9. A valid permit to work should be obtained.

4.10. Toolbox talk should be conducted before the work commences.

4.11. Appropriate personal protective equipment should be available like coveralls, safety shoes, hand gloves, eye protection, etc.

4.12. Observe proper posture and natural working position

4.13. Tools and equipment shall inspected by a competent person

4.14. Tools that will be used for the Test and Pre-commissioning shall be calibrated and certified by a third party as required

4.15. Observe the speed limit within the vicinity of the substation

4.16. Materials should be secured properly during mobilisation by providing adequate binder without damaging the equipment

4.17. Mobilization of materials in normal weather conditions

4.18. Use and pass in a stable access

4.19. Closed supervision by the engineer, supervisor or foreman must be observed

4.20. Unload equipment in a designated area

4.21. Designate a spotter or escort vehicle when transporting critical testing equipment

4.22. Guide workers at the location where the transport vehicle will pass Vehicle driver shall exercise defensive driving technique and shall not rush or exceed the proper speed

4.23. The contractor shall establish a war room where review of documents is undertaken

4.24. The war room shall be equipped with a table, ergonomic chair, storage cabinet, etc.

4.25. The commissioning Engineer shall be responsible for the proper storage of documents

4.26. Only a competent person shall open the panel board or electrical equipment

4.27. The commissioning team who will conduct the visual inspection shall not simultaneously check the same equipment to avoid contact with each other

4.28. Verify that equipment is safe to open without the requirement to wear arc flash-rated clothing

4.29. Workers shall wear appropriate PPE with clear safety glass, and hardhat when conducting a visual inspection

4.30. Electrical equipment to be inspected shall be provided with an adequate lighting system

4.31. Perform lockout/tagout to de-energized electrical equipment

4.32. Test the equipment, cable or wire for potential stored energy

4.33. Only authorized personnel shall open the energized panel

4.34. When using the stick, it shall be of non-conductor materials

4.35. Install barricade around the testing area including the earth matting being tested and provide adequate safety signs to communicate activity and hazards involve

4.36. Only a competent person shall conduct earth/grounding testing

4.37. The competent person shall closely communicate with the assistant to avoid contact with the electricity

4.38. Tools, earth spikes and wiring shall be handled in a manner to avoid damage and incurred injury

4.39. Wear appropriate hand gloves when installing earth spikes

4.40. Establish equipment access and shall be free from any obstruction

4.41. Designate parking area

4.42. Designate a location for unloading of materials

4.43. Designate a spotter and flagman to guide all equipment and personnel movement

4.44. Workers shall wear properly the high visibility vest

4.45. Taking or recording the heat index at the workplace Provide a drinking water cooler at the site

4.46. The commissioning Engineer shall identify the exact bus wiring and its exact extent of testing

4.47. Only a competent person shall open the panel board or electrical equipment using an approved tool

4.48. Verify right panel board is open with its label

4.49. Verify that equipment is safe to open without the necessary to wear arc flash-rated clothing

4.50. Use the right tool to open the back cover of the panel board

4.51. Workers shall wear appropriate PPE when removing the panel board back cover

4.52. Assign an adequate number of workers to manually lift the back cover

4.53. Adequate safety signs are to be posted on the adjacent equipment

4.54. A competent person shall closely communicate with the assistant to

4.55. Review the line diagram of bus wiring to ensure that only specific bus wiring will be energized during the insulation testing

4.56. Only a competent person shall operate the insulation tester

4.57. Review the line diagram of multicore cables to ensure that only specific cables will be energized during the insulation testing

4.58. Perform lockout/tagout on the equipment that might be energized during the testing

4.59. Test the equipment, cable or wire to ensure zero potential energy

4.60. Workers performing the battery charging shall be competent in doing the job

4.61. Regular document review and verification should be done

4.62. Closed supervision by the commissioning engineer, supervisor or foreman must be observed at all times while charging is ongoing

4.63. Interval battery test and measurement shall be done as per manufacturer’s recommendation

4.64. Worker conducting the test and measurement shall wear PPE as required by the manufacturer with arc flash-rated clothing

4.65. Check all wiring and connection of battery charger and make sure all are intact and properly secured

4.66. All equipment should have an emergency stop button

4.67. Special personal protective equipment must be observed like anti-static clothing, rubber gloves, respiratory equipment, clear goggles etc.

4.68. A first aid kit should be available with an adequate quantity of medicines

4.69. Only non-sparking tools must be used inside the battery room

4.70. Ensure fire suppression equipment is working and readily available in strategic locations at all times

4.71. Limit the duration of stay of personnel inside the battery room

4.72. Frequent rotation of workers

4.73. Check visually the physical appearance of the battery case for signs of bulging, or spillage before allowing anyone to touch or open

4.74. Check for air concentration inside the battery room before allowing personnel to enter

4.75. Use calibrated and appropriate gas testing equipment

4.76. Test the battery as per manufacturer’s recommendation

4.77. Observe the “use the right tool” rule

4.78. Appropriate personal protective equipment should be observed like coveralls, hand gloves, eye protection, etc.

4.79. Only certified and competent personnel will engage in the job

4.80. Provide an adequate and safe standing platform to reach the battery for specific gravity and other testing to be conducted

4.81. Workers shall wear appropriate PPE when going to congested areas

4.82. Assign an adequate number of workers to manually lift the cable

4.83. Hardhat and Safety glass shall be worn as mandatory PPE when opening the panel board

4.84. Electrical equipment to be tested shall be provided with an adequate lighting system

4.85. Electrical spaces without permanent lighting shall be installed with temporary lighting

4.86. Workers shall only wear clear safety glass, dark glass is not allowed inside the substation

4.87. Ensure that neighbouring workers present in the area are aware of the testing activity that generates loud sound

4.88. Maintain barricade around the affected equipment being tested

4.89. Exposed workers shall wear adequate hearing protection. If sound exceeds 110 dB, the exposed worker shall wear double hearing protection

4.90. Worker shall be aware of the signs of SF6 leakage and take necessary action to stop the leakage

4.91. Provide a force ventilation blower and make it ready in case SF6 gas leaks

4.92. Use approved method to conduct air and gas leakage tests for SF6 and another pressurized vessel

4.93. Limit exposure of workers to the pressure vessels

4.94. Ensure that all fittings are intact and installed properly

4.95. Workers shall wear appropriate eyes and face protection when exposed to compressed air systems

4.96. Other workers shall maintain a safe distance away from the pressurized vessel

4.97. Activity shall be disseminated to all affected workers the day before the actual testing

4.98. Only competent and qualified persons shall be involved in the testing activity

4.99. The commissioning Engineer shall identify the exact location where the testing equipment be installed

4.100. The affected area shall be adequately barricaded with safety signs to communicate the activity and hazards involved

4.101. The commissioning Engineer shall closely communicate with the assistant to avoid contact with the electricity

4.102. Implement proper cable management to avoid dangling, short circuits, damage to wires and tripping accidents

4.103. Use hand hand-held radio when communicating with workers from other locations of the equipment being tested

4.104. Review the line diagram and discuss accordingly with the testing and pre-commissioning team to ensure that only specific cables will be energized during the insulation testing

4.105. Perform lockout/tagout on the equipment that is not involved and might be energized during the testing

4.106. Test the equipment, cable or wire to ensure positive isolation with zero potential energy

4.107. Notify affected personnel when performing lockout/tagout

4.108. Adequate safety signs shall be posted on the adjacent equipment

4.109. Personnel shall not touch energized equipment

4.110. The commissioning Engineer shall ensure that there shall be no unnecessary personnel within the affected area during the testing

4.111. Adjust work timing and exposure of the workers to extreme environmental temperature

4.112. Allow frequent rest time if needed

4.113. Provide rest shelter with shade near the workplace

4.114. Provide supplemental hydration powder or liquids

4.115. Reminds to drink plenty of water

4.116. Taking or recording the heat index at the workplace

4.117. Provide a drinking water cooler at the site

4.118. Use a standard ladder when accessing elevated spaces

4.119. The ladder to be used shall not electrical conductor

4.120. The ladder shall be capable of carrying 4x the weight of the user

4.121. The ladder shall be used by one person at a time

4.122. A ladder or working platform shall be adequate to reach the area for inspection

4.123. Full body harness shall be worn if personnel is exposed to a fall of more than 1.8 meter

4.124. Anchor lanyard on a fixed structure with a strength of more than 5000 lbs.

4.125. Ensure to plan correct manual lifting procedures and body positioning before the actual lift.

4.126. Only 20 kg is allowed for lifting by an individual. Use the buddy system if the load exceed.

4.127. Use hand protection (cotton gloves minimum) during the handling of materials.

4.128. Keep hands away from pinch/crash points Ensure safe and clear pathways before lifting.

4.129. Permit Receiver shall ensure that housekeeping is done before, during and after the work

4.130. All waste materials generated from the work shall be disposed of properly and shall not be left unattended at the worksite

4.131. Mobile equipment shall be properly parked on a designated equipment laydown

4.132. All materials used at the site such as chemicals, and flammable and combustible materials shall be stored at the designated storage at the end of each day

4.133. Electrical equipment shall be properly secured, distribution board closed and padlocked


5.0. IMPROVED EXISTING CONTROLS / IMPLEMENTING NEW CONTROLS

5.1. The Site Manager, Supervising Engineer, and Foreman shall designate a Permit Receiver competent enough to take responsibility for securing the Permit to Work

5.2. Permit Receiver shall be trained and authorized by the Manager to receive a Permit to Work

5.3. Permit Receiver shall be responsible to oversee for the safety of all workers under his Permit to Work

5.4. The manager, Supervisor, Foreman and all workers shall adhere to all requirements outlined in the Permit to Work, Risk Assessment, Method Statement, Job Safety Procedure and other relevant safety practices and standards

5.5. All workers shall attend the toolbox meeting daily conducted by the Supervising Engineer, Foreman and Permit Receiver

5.6. All workers attending the toolbox meeting shall sign on the attendance sheet attached to the specific Permit to Work

5.7. Tool, materials and equipment shall be identified and selected before the actual Testing and Pre-commissioning

5.8. The foreman shall take the lead in the selection of tools and materials

5.9. All tools and equipment to be used shall be in good working condition and inspected by a competent person

5.10. Provide trained flagman/ banks man to guide vehicles used to mobilize testing equipment

5.11. Install barricade around the vehicle when unloading the equipment

5.12. When the equipment weighs more than 30 kg, lifting equipment shall be used

5.13. The commissioning Engineer shall be responsible for ensuring that the driver will transport the testing equipment in the safest manner

5.14. Only authorized personnel can enter the war room

5.15. Make a borrower’s log book to monitor the loaned documents

5.16. The commissioning Engineer shall closely monitor the personnel performing a visual inspection

5.17. Limit the number of personnel who will conduct visual inspection

5.18. Lighting shall be installed the day before the actual inspection date

5.19. Toolbox meetings shall be conducted by the competent person daily emphasizing the risk involved in the activity and its mitigating measures to eliminate or minimize the impact Tools, earth spikes and other equipment shall be inspected by the competent person before using the sit

5.20. Site management plan shall be prepared, approved and implemented to avoid property damage and personnel accident

5.21. Panel board back cover shall be stored safely without obstructing access

5.22. Tools and other equipment shall be inspected by a competent person before use on the site

5.23. The commissioning Engineer shall closely monitor the testing of inter-panel bus wiring

5.24. The safety Officer shall monitor compliance and provide advice to the pre-commissioning team as necessary

5.25. Tools, earth spikes and other equipment shall be inspected by a competent person before use at the site

5.26. Notify affected personnel when performing lockout/tagout

5.27. Workers involved shall be trained by the manufacturer or vendor and certified to conduct charging and discharging of battery

5.28. Supervising Engineer and Foreman shall ensure that workers performing the job are competent and certified by the manufacturer

5.29. Company requires full supervision by the Commissioning Engineer at all times while the activity is ongoing Company’s requirement: Battery charging and discharging shall not be allowed without the presence and supervision of the commissioning engineer or Engineer in charge for the whole duration of the activity

5.30.  Any source of naked flames and sparks should be prohibited, prevented inside the battery room

5.31. Ensure no power interruption during the whole operation

5.32. Ensure the required and sufficient room temperature, lighting, ventilation and exhaust system as per manufacturer's design

5.33. Regular training should be given to personnel

5.34. Close supervision by the engineer or foreman should be observed

5.35. Rotation of personnel shall be done especially at night

5.36. Workers rendering a maximum of 10 hours of duty shall be relieved and will be allowed to work the following day

5.37. Arrange testing equipment in a manner that the worker maintains its natural back curve and does not over bending down the floor

5.38. The foreman or Commissioning Engineer shall closely monitor the activity

5.39. Place testing equipment on a table fitted ergonomically to the workers

5.40. Worker shall avoid repetitive motion and awkward body posture

5.41. Ergonomic Safety shall be conducted to

5.42. Tools and other equipment shall be inspected by a competent person before use at the site

5.43. Post adequate safety signs on the adjacent equipment so that other workers will be warned

5.44. Lighting shall be installed the day before the actual testing date

5.45. Lighting shall be adequate to provide illumination to the point of visual inspection

5.46. The flashlight can be used during the inspection of some congested spaces

5.47. If possible, there shall be no other workers in the area except the testing and pre-commissioning personnel only

5.48. Place adequate safety signage on the doors of the building to aware other workers

5.49. Workers shall be trained on the hazards involved in exposure to SF6 and measures to avoid the risk

5.50. Exposed workers shall wear an Oxygen gas badge to determine if oxygen is at a low concentration

5.51. Conduct toolbox meetings and discuss hazards involved in working with pressurized vessel

5.52. Unnecessary workers shall stay away from the area

5.53. The commissioning Engineer shall be responsible for proper information dissemination

5.54. The warning notice shall be posted on a strategic location of the building the day before the actual testing indicating the start and end date, the exact location of the testing indicated on a floor plan

5.55. Toolbox meetings shall be conducted by a competent person daily emphasizing the risk involved in the activity and its mitigating measures to eliminate or minimize the impact

5.56. Tools and other equipment shall be inspected by a competent person before using the site Post adequate safety signs to the adjacent equipment so that other workers will be warned

5.57. When opening an electrical panel board of more than 600V AC, qualified personnel within a limited approach boundary shall wear arc-rated clothing as recommended by NFPA 70E

5.58. Assess the approach boundary before allowing personnel to come closer to electrical equipment

5.59. Conduct Lockout/Tagout training for all workers involved or who might be the affected person to have a common understanding of the system to be implemented

5.60. Provision of air-conditioned shelter if needed

5.61. Provide appropriate clothing during hot weather Establish a complete heat illness prevention program

5.62. Safety awareness/training related to heat stress, etc.

5.63. Conduct housekeeping on the area to be inspected the day before the activity

5.64. Remove obstruction and unnecessary materials on the access and on the equipment to be inspected

5.65. The ladder or working platform used in energized equipment shall be adequately grounded or earthed

5.66. Provide material handling equipment for the transport of heavy and large materials/equipment.

5.67. Inspection of Material Handling equipment before use

5.68. Provide Manual handling Training to the workers.

5.69. Permit Receiver shall account for all workers under his Permit to Work and ensure all have signed out on the attendance sheet and clear of the area

5.70. The Supervising Engineer and Foreman shall adhere to the proper housekeeping and storage of materials at the designated location

5.71. The Site Manager shall be responsible for the effective implementation of the Permit to Work

5.72. Permit Issuer shall visit the work location to verify good housekeeping was conducted before closing the Permit to Work


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