Practical Electrical Substation Safety for

Engineers & Technicians

Technology training that works

 Overview
• Hazards of general nature in industrial installations
• Electrical hazards
– Direct and Indirect electric shock
– The deadly combination of heights and electric shock
– Hazards due to arcing/flashover
– Hazards from use of electrical equipment in explosive environment
– Hazards due to high temperature in electrical equipment
– Need for periodic inspection and maintenance for safe operation of
electrical equipment

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 Electrical Hazards
• Electric shock and associated effects
• Injuries by electric shock combined with fall
• Burns on skin at point of contact
• Internal organ damage due to passage of electricity through body
• Flash-over causing external burns

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 Mechanical hazards
• Injuries from moving parts of static machinery
• Injuries from moving vehicles
• Injuries from falling objects (including head injuries)
• Injuries from flying objects following an explosion
• Injuries to eye from moving particles
• Injuries to eye from prolonged exposure to bright light
• Loss of hearing due to prolonged exposure to noise

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 Hazards from toxic materials
• External contact on skin and eyes
• Ingestion
• Inhalation

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 Dealing with fire hazard
• Fire is often initiated by other hazards (electrical,
explosion due to hazardous gases present in the
environment etc.)
• Once initiated, it can be self sustaining
• Dealing with fire:
– Prevention is often the best way
– Alarm of incipient fire before it spreads
– Fire fighting measures as appropriate

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 Hot surfaces/liquids/gases
• Many electrical equipment have fairly high surface temperatures
• Many industries also handle materials at high temperatures
• Effects:
– Burns due to contact
– Explosions (e.g. molten steel and water)

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 Handling of cold liquids
• Burns due to contact
• Explosions (e.g. liquid oxygen)

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 Handling of corrosive liquids
• Acids and alkalis are corrosive
• Safety issues
– Burns/irritation due to contact with skin
– Loss of sight or serious injury of eyes
– Danger of ingestion
– Danger of inhalation (fumes)

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 Handling of explosive gases
• Explosion by formation of explosive mixtures of
combustible gases and oxygen in air
• Source of ignition is often electrical
• Effects
– Burns by fire accompanying explosion
– Injuries from flying objects following an explosion
– Damage to limbs/internal injuries
• Prevent
– Formation of explosive mixtures
– Ignition
– Damage due to explosion

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 Electric shock-Reasons
• An electric shock can happen
– Due to exposure to live parts (Direct contact)
– Due to exposure to parts that accidentally become live
(Indirect contact)
• Due to potential difference in the ground under certain
conditions

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 Electric shock-Effects
• Causes current flow through body
• Causes muscular contraction
• Can cause stoppage of heart/breathing
• A shock is often accompanied by a fall
– A non-fatal shock can result in a fatal fall
– While working on electrical systems at heights, adopt
preventive measures to avoid a fall

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 Burns
• An electrical short circuit is accompanied by arcing
• Extent of arcing depends on
– Fault energy level of the system (VA)
– Time of fault clearance
• High energy faults can cause melting of components
– Copper/aluminium conductors
– Steel parts of enclosure
– Results in deposition of toxic copper salts on the skin

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 Temperature hazards
• External surfaces of electrical equipment often
attain elevated temperature
– Example: Bus ducts can often attain surface
temperatures of over 60 Deg C
• Exposed conducting parts can attain even higher
temperatures
– Example: Bus bars often run at temperatures in excess
of 100 Deg C

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 Fire hazard
• An external fire can often result from an electrical
fault
– Example: A wiring short circuit and presence of
combustible substances in the vicinity
• Certain electrical equipment contain inflammable
substances and improper handling can result in fire
– Example: Large transformers with mineral oil for
cooling

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 Reasons for Electrical accidents
• Failure to isolate or inadequate or insecure isolation (60%)
• Poor maintenance and faulty equipment (30%)
• Insufficient information about the system being worked on
• Carelessness and lack of safe procedures

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 Summary of safety measures

• Safe design/installation of plant and equipment

• Safe operating and maintenance practices
• Appropriate knowledge on the part of workers
– Training
– Certification
• Warning signs at points of hazard
• Use of equipment/sensors to warn incipient problems
• Proper periodic inspection and prompt repairs

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 Structure of an electrical system
• Incoming circuit
• Step-down transformer
• Primary distribution
• In-plant generation (Primary)
• Step down transformer
• Secondary distribution
• In-plant generation (Localised/secondary)
• Local distribution centers (MCC/DBs)
• Uninterrupted power supplies to specific critical loads
• Loads on primary and secondary distribution system

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 Main components-1
• Generation equipment - (Captive generation in industry)
• Step-up/step-down Transformers
• Transmission lines (long distances)
• Cables (Medium distances)
• Bus ducts (Short distances)

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 Main components-2
• Distribution equipment
– Isolation equipment (for safety purposes)
– Bus bars
– Switching equipment (circuit breakers/contactors)
– Instrument transformers
– Protection equipment
• Loads
– Motive, Heating, Lighting
• Uninterrupted power supplies with battery

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 Potential hazards-1
• Generation equipment
– Electric shock, flash-over, mechanical hazards
• Transformers
– Electric shock, flash-over, fire hazard
• Overhead Transmission/distribution lines
– Electric shock, flash-over, fall from heights
• Cables
– Electric shock, flash-over, fire hazard

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 Potential hazards-2
• Bus ducts
– Electric shock, flash-over, thermal hazard
• Distribution equipment
– Electric shock, flash-over, thermal hazard, fire hazard
• Motive equipment
– Electric shock, flash-over, thermal hazard, mechanical hazards
• Heating equipment
– Electric shock, flash-over, thermal hazard

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 Potential hazards-3
• Lighting equipment
– Electric shock, flash-over, thermal hazard, fall from heights
• Uninterrupted power supplies with battery
– Electric shock, flash-over, hazards from corrosive liquids and
explosive gases

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