Safety in Electrical Testing

A Code of Good Practice

Revised and up<hced February 1991

.
Prepared for the electrical repair industry by
The Association of Electrical and Mechanical Trades
The representative body for the electrical repairer and merchant
IMPORTANT NOTE

This Code of Practice for Safety and Technical Advice which has been
prepared in consultation with the Health and Safety Executive should be
t·ead in conjunction with and does take precedence ove r the
t·equiremcnts of the Hea lth and Safety at Work etc Act 1974 and the
Electricity at Work Regulations 19 9.

The Code was first published in 1984 and has now been revised to take
account of experience in its use and especially to take account of
significant changes in legislation which have invalidated the origi nal
edition.

This document must not be copied in whole or in part except with the
express permission of the publishers.

Published by The Association of Elecuical and Mechanical Trades

( AEMT Limited by guarantee)
Reprinted March 1999

ISBN 0 9509409 0 9
 CONTENTS
PAGE

ACKNOWLEDGEMENTS IV

OBJECTIVES AND PRINCIPLES 1

EMPLOYERS' AND EMPLOYEES' DUTIES 1

SCOPE 1

WORK ON OR NEAR LIVE CONDUCTORS 2

PART I GENERAL REQUIREMENTS AND THE TESTING OF

LOW VOLTAGE EQUIPMENT

1.1 TEST AREAS 3

1.2 PERMANENTLY DESIGNATED TEST AREAS 5
1.3 TEMPORARILY DESIGNATED TEST AREAS 5
1.4 LOW VOLTAGE AC AND DC TEST SUPPLIES 6
1.4.1 TEST SWITCHBOARD CONSTRUCTION 6
1.4.2 DERIVATION OF TEST SUPPLIES 6
1.4.3 FUSING, BONDING AND EARTHING 8
1.4.4 CONTROL CIRCUITS 8
1.5 TEST SWITCHBOARD FITIINGS
1.6 TEST AREAS- DUTIES, TRAINING, SUPERVISION.
ACCESS AND RECORDS 11
1.7 AUXILIARY EQUIPMENT 12
1.8 INSPECTION MAINTENANCE 13
1.9 SAFE WORKING PRACTICE 14
1.9.1 GENERAL RECOlVIMEN DATlONS 14
1.9.2 DC TESTS 16
1.9.3 lNDUCED VOLTAGE TESTS 17
1.10 INSULATION TESTING OF LOW VOLTAGE
EQUIPMEl\TT 17
1.10.1 PURPOSE 17
1.10.2 I.R. TESTS 17
1.10.3 HV PRESSURE TESTS ON LV EQUIPMENT 18

PART2 TESTING OF ELECTRICAL EQUIPMENT WHOSE

RATED VOLTAGE EXCEEDS LOW VOLTAGE

2. 1 INTRODUCTION 21
2.2 LEGAL REQUIREMENTS 21
2.:3 COMPLIANCE 22
2.4 DERIVATION OF HV SUPPLIES 22
2.5 EQUIPMENT AND SAFETY PROCEDURES 24
2.6 I SULATION TESTrNG OF HIGH VOLTACE
EQU!Pl\1ENT 25
2.6. 1 1!\SULATION TESTS AND SAFETY PRECALITIONS 25
2.6.2 HV PRESSURE TESTS AND S PECIAL TESTS ON HV
COILS 26
2.6.3 SAFETY PRECAUTIONS 26
2.6.4 EARTHING AND OVERLOAD PROTECTION OF
PRESSURE TEST SETS 28
2.6.5 VOLTMETERS FOR HV MEASUREMENTS 28
2.6.6 TAN DELTA, DIELECTRIC LOSS ANGU: ANO
IMPULSE TESTS 29
2.6.7 ACCOMPANIED WORKING 29

II
PAGE

PART3 WORK ON SITE

3.1 INTRODUCTION 31
3.2 LEGAL REQUIREMENTS 31
3.3 SAFE WORKING PRACTICE ON SITE 31
3.3.1 GENERAL RECOMMENDATIONS 31
3.3.2 ELECTRICAL SAFETY PROCEDURES 33

APPENDICES

1 DEFINITIONS 35
2 REFERENCES 37
3 NOTE ON ACCOMPANIED WORKING 39
4 NOTES ON THE HEALTH AND SAFETY AT WORK ETC
ACT 1974 41
5 MECHANICAL HANDLING EQUIPMENT, MECHANICAL
AND OTHER RISKS ASSOCIATED WITH TESTING 42
6 EXAMPLES OF OTHER SAFETY, HEALTH AND WELFARE
CONSIDERATIONS APPLYING TO WORK ON SITE 43
7 ABBREVIATIONS 43
8 COMMUTATOR AND SLIPRING MAINTENANCE BY THE
USE OF HAND HELD STONES OR GRINDI NG TOOLS 44

FIGURES

1 SINGLE LINE DIAGRAM OF A TYPICAL LV AC AND DC

TEST SWITCHBOARD 7
2 OUTLINE DRAWING OF A LOW VOLTAGE AC AND DC
TEST SWITCHBOARD 7
3 SCHEMATIC DIAGRAM SHOWING CORRECT CONNECTION
OF BASIC CONTROL CIRCUIT COMPONENTS 9
4 A SWITCHFUSE WITH INTERLOCKED TERMINAL COVER 9
5 DC DROP TESTING 16
6 PRESSURE TESTING PROBE 18
7 BLOCK DIAGRAM SHOWING TYPICAL DERIVATION OF
HV TEST SUPPLIES 22
8 I3ASIC PRECAUTIONS DURING HV PRESSURE TESTING OF
HV MACHINE ON SITE 27

NOTE: Words and phrases which are in bold, non-italic type in the text (as distinct from
headings) are de fined for the purpose of this Code of Practice in appe ndix 1,
Defmi tions.
ACKNOW1EDGEMENTS

The AEMT wishes to acknowledge the assistance of all participants in

the preparation of this Code, and in particular:

C W Jenkins - Dowding & Mills (Southern) Ltd

KJ Larwood - Dowding & Mills (Southern) Ltd
WCAdams - Lewis DMR Ltd
J V Evans - Technical Consultant AEMT
AWDaw - The Health and Safety Executive

References in this document to "h e" and "his" a lso include "she" and
"hers".

Whilst every care has been taken in the preparation of t his document,
the AEMT does not accept responsibility for any omissions or any errors
contained herein.

iv
CODE OF PRACTICE:
SAFETY IN ELECTRICAL TESTING
OBJECTIVES AND PRINCIPLES

The purpose of this Code of Practice is t,o give guidance on the tes ting of
electrical machinery in the repair industries. The recommendations a rc
directed to employers, e mployees a nd oth er duty h olders in order to
facilitate safe testing in compliance with the requi rements of the Hea lth
and Safety at Work etc Act 1974 (the HSW Act) and the Electricity at
Work Regulations 1989 (the EA W Regulations). I n addition to this Code
a copy of the Memorandum of guidance on the EA W Regulations (see
a ppendix 2) should be available in premises where electrical repairs a nd
testing are undertaken. Manufacturers' test departments will a lso find
relevant safety advice in this Code.

The safely philosophy of t h e t:ecom mend a lion s is the preve nti on of

electr ica l danger by t.he co n s tru ction , protection and in s ulati on of
equipment a nd the adoption by trained and expet·ienced persons of a ll
practicable steps to prevent da nger and injury in t h e course of the ir
work. The ad vice given is founded upon the experience of the electrica l
machinery repai r a nd se rvice industry a nd lhe H ealth and Safety
Executive CHSE>. The practice of t he recommendations contained in this
Code s hould do much towards ensuring t hal the testing of electri cal
equipment a nd other plant is done safely. This is conditional upon a ll
those involved having a n appropriate level of technical knowledge a nd
experience, a nd upon l heir understanding of safety requirements and
their constant vigilance. The appendices form a n essential part of the
code.

EMPLOYERS' AND EMPLOYEES' OUTlES

Every employer (including self employed persons) and employee has a

duty to comply wilh the pr·o,risions of the Electricity at. Work Regulations
19 9 that relate to mattet·s within his control.

Additionally, employees have a to co-operate with their employers

in order to enable the Iauer to comply with duties imposed on them by
the Rc!,rulations.

Managers and supervisors a rc advised by AEMT to u se this Code of

Practice on safety in electrica l testing in ord er to supplement their
understanding and practical observa n ce o f lh e advice in lhc
Me morandum of guidance on the EAW Regulatio n s. NB: In the
l\Iemornndum t he persons on whom duties are imposed by the EA W
Regulations arc called duty holders.

SCO PE

Part I deals with common requirements and the testing of low voltage
electrital equipment (see Appendix 1J.
Part. 2 deals with high voltage electrical equipment (see Appendjx 1).

Part. 3 provides safely recommendations for work on site.

A thorough understanwng of Part 1 General Requirements and the

relevant appendices is recommended for compliance with common safety
concepts before referring to P arts 2 and 3.

Appendices to the Code include definitions, figures, references and notes

on some legal aspects.

WORK ON OR NEAR LIVE CONDUCTORS (EA W Regulation 14)

Rcgulat.ion 14, which will often apply to eleclrical testing especially

during diagnostic and site testing, is considered Lo be of such importance
and of such relevance to this Code that it. is quoted here in full, al the
beginning of this code:

No person shall be engaged in any work a ctivity

on or so near any live conductor (other than one
s uitably covered with insulating material so a s to
prevent danger) that danger may arise unless

a) it is unreasonable in all circumstances for it to

be dead; and

b) it is reasonable in all the c irc umstances for

him to be at work on or n ear if while it is live;
and

c) s uitable prec autions (in c luding where

n ecessary the provision of s uitable protec tive
equipment) are taken to prevent injury.

These conditions have to be me t in order to satisfy

the legal requireme nts for safety if live parts are
not first made d e ad and i solated in orde r to
remove danger.
 PART I
GENERAL REQUIREMENTS AND THE TESTING OF
LOW VOLTAGE EQUIPMENT
1.1 TEST AREAS

INTRODUCTION Test a reas, if not designed and managed safely, can be a source of
danger. It is important, therefore, for careful thought be given to every
aspect of a test ar ea, from its initial design to its management and to the
operation of safe working procedures, whether in the works or on site.

Danger in a test area can t·es ult not only from voltages capable of
causi ng electric shock but also from circuits carrying high currents,
under normal or fault condition s, that could cause burns due to arcing or
overheating. It should be noted also that, in addition to electrical danger,
equipmen t under test may also be a source of danger from acciden tal
contact with moving parts.

A safe lest area will result from good design a nd strict management of
safe working practice to ensure that:

a) Lest engineers oper a te with in a sa fely equi pped well mana ged
environment;

b) persons in t he tes t a rea and the vicinity are not exposed to danger
when equipment is under test; and

c) the test area is clea rly recognisable by all persons as a separate

entity from the wot·k place, with its own supervision and safety
procedures.

Test a reas a re defined as permanent or temporary but, in both cases,

adequate precautions s hould be taken to restrict access to authorise d
pe r sons. If it is necessary for other persons to en ter, for exam ple in
training or to witness testing, t h ey s hould be under t he close supervision
of an a uthorised p e rson .

ADEQUATE Test areas s hould a ll ow free and unrestri cted movemen t to the test
SPACE engineers in the performance of t heir duties. There s hou ld be adequate
s pace around equipment for persons to gain safe access to the test
switchboard controls at all times.

The entrance s hould be controlled and so managed t h at a ny person

enLering will have full view of the area a nd therefore be aware of the
work in ha nd.

Il is also important that any person entering s hould be pl ain ly visible to

lhe lcsl engineer at work.

GOOD It is the responsibility of t he person in charge of a test area to ensure

HOUSEKEEPING that the area is tidy and free fr om unnecessary obstructions. Test leads
nnd power cables to the equ ipment under test s hould be routed to
minimise risk.

LIGHTING Particular attention s hould be paid lo both general and local lighting in
OF TEST the test a rea. A level of 500 lux at work s urfaces is recommended. Work
AREAS s urfaces s hould not glare Lobe a problem for the lest engineer (sec
appendix 2).

3
 Positioning of the test area general lighting s hould be so arranged as to
minimise shadows. Account s hould be taken of overhead cranes or other
passing traffic that may cause lighting problems for the test engineer.

Local or temporary lighting should not cause obstructions for the test
engineer and lights should be placed where they are not lia ble to damage.

The stroboscopic efTecl of fluorescent lighting on moving parts should be

taken into account. This type of lighting, if in rows, s hould be fed by
alternate phases. AJternatively, light fittings of the high frequency type
or twin fittings with lead/lag devices can be used.

Further advice oo l ighting may be obtained from the Chartered Institute

of Building Surveyors- Code for Intet;or Lighting- (see Appendix 2).

It is recommended that the lighting in the test area should, so far as is

reasonably practicable, be free from supply interruptions.

FLOOR The floor where testing is carried out, and in front of switchboards,
SURFACES should be dry, firm and even and kept free from obstructions.

RUBBER MATS When the safety precautions and working practices recommended in this
Code are adopted, rubber mats should not generally need to serve as a
primary protection against the risk of electric s hock in the course of
djagnostic, proving and performance tests undet·taken by r·epai rers. For
example, the majority of enclosures of equipment under lest, the
installed test equipment and faciliti es \viii be at earth potential and
indiscriminate use of rubber mats would serve little, if any, purpose.

However, as an additional safeguard, lhe use of rubber mats is a d vised:

(a) in the immediate working area in front of test switchboards which

include provis ion for temporary outgoing power cables and not
simply control, indication etc facilities;

Cbl in the immediate working area in front of test benches which have
a non-conducting work surface;

(c) in other s iluations where, in the judgement of the duty holder,

their use will form a substantial contribution to safety as a part of
the approprinle precautions adopted in order to comply wilh EA W
Regulation 14.

BENCH Benches used for Lc>sting should be of sound construction with durable
CONSTRUCTION non-conduc.ting work s urfaces. Thet·e s hould be adequate separation
bel-ween adjacent a reas.

A non-conducting worktop s upported on a metal fram e s hould have

sufficient overhang to minimise the likelihood of a person at work
making contact wtth the m e tal frame. Dependi n g on the b e n c h
construction, the fr·onl of metal support legs may need screening with
insulaling material. Metal storage drawers or cabinets s hould be located
to the s ide of the normal work a rea.

MACHINE Test beds, comprised of, for example, g rid irons, tee s lots or s lide rails
TEST BEDS mounted on a fixture, s hould be of sound construction and suitably
designed for the "''ork tn hand. Adequate working space s hould be
provided around the Lest bed lo e nable the test engineer unimpeded
access to the machme under test. (see also second para of 1.4.:!)

4
 1.2 PERMANENTLY DESIGNATED TEST AREAS

The test a r ea s hould be separated from other parts of the premises by

permanent fencin g of s ufficient height and a dequate cons truction to
prevent the careless or unintentional entry of persons or materials.
Fixed chain link or s teel mesh fencing lo a height of at least one metre is
suggested and the fencing s hould be constructed so that persons wor king
in t he test area are within sight of other persons on the premises.
Notices should be pe rmanently dis played on the fence to warn against
unauthorised entry. Metallic fencing s hould be earthed. Test areas
s hould be located where they a r e not overhung by galleries or walkways
e xcep t those reserved for person s s upervi s ing the testing or for
instruments and controls used for the purpose of the test. Open mesh
fencing should not be used adjacent to switchboards or termi nals where
sources of danger lo pe rsons may exist outside the test a rea from li ve
conductors near the perimeter.

The number of doors, gates or hatches giving access to a Lest area should
be kept to the minimum consistent with safe means of entry and exjt of
the testing staff and the safe handling of materials. Where reasonably
practicable doors and gates should open outwards and be made self-
closing. Means should be provided to enable doors, gates and hatches
which give access to a permanently designated test area Lo be secured
when it is necessary for reasons of safety to conduct a test from an
e xLe rnal posi tion:

SIGNS AND All safety signs should comply with the Safety Sign Regulations 1980
NOTICES obtainable from Government B ookshops and BS5378 obtainable from
BSI (see appendix 2 ).

Copies of the following notices should be displayed:

In the lest a rea:

Instructions as to the treatment of persons suffering from elect1;c s hock -

obtainable from ROSPA and the publishers of "E lectrical Times .. and
··Electrical Review•·.

The location of F irst Aid Station, Company First Aider and emergency
services numbers.

Clear identification of e m e rge n cy t rips, supply isolation switches a nd

the location of fire extinguis hers.

A COPY OF T HIS AEMT CODE SHOULD BE AVAILABLE AT ALL

TIMES INSIDE THE TEST AREA.

Atlhe entrance ln the lest area:

"Authorised Persons Only" notice.

Notice indicating ·'Testing in Progress" when approp1iale.

1.3 TEMPORARILY DESIGNATED TEST AREAS

ll is preferable to carry out electrica l testing in a per man e ntly

dc-signated and dedicated area but lhcre 'viii be occasions when testing
has to be carried out. elsewhere. When this is necessary a temporarily
designated test area should be established with the necessary safet.v
mensures an d sepnrl"lted from other working a r ea s by effecti,•e

5
 temporary barriers and warning notices . Such an area s h ould be
dismantled as soon as possible after the test has been completed.

Temporary baiTiers may include por table fencing or firmly secured tapes
or ropes but the use of the latter will require a correspondingly higher
degree of test area supervision. When setting out a tempora r ily
designated test area the authorised person shoul d ensure safe
clearance distances of plant and test equi pment including any live
conductors from adjacent working areas, depending on the test to be
undertaken. If metallic fencing is used it should be earthed.

1.4 LOW VOLTAGE AC AND DC TEST SUPPLIES

1.4.1 TEST SWITCHBOARD CONSTRUCTION

REGULATIONS Fixed test switchboards should be located in a permanently designaLed

test area. Switchboards should be constructed and arranged so as to
comply with statutory requirements and good engineering practice. The
electrical.installation s hould also comply where possible with the
requirements of the edition of the lEE Regulations current at the time of
the design (see appendix 2).

ENCLOSURE The use of enclosed LV test switchboards having no bare live conductors
which can be touched is strongly recommended. Enclosed switchboards
should be installed whenever older equipment is replaced. When open
type switchboards are still used in test areas, then a barrier or railing at
a height of approximately one met re s hould be erected one metre in front
of s uch s witchboards with bare live conductors, for example knife
switches and terminals, in order to prevent accidental contact with live
parts. Su itable precautions should also be taken to prevent s imilar
contact at the rear of switchboards e.g. by enclosur·e.

Rubber mats (see appendix 2) s hould be laid in front of open type

switch boards.

1.4.2 DERIVATION OF TEST SUPPLIES

Test switchboards should have their own s upply independent of lighting

or other works circuits. All outputs s hould include suitable means for
indication of the selected voltage, whether ac or de, fixed or variable.
Phase rotation should be clearly marked at all three phase outlets and
s hould be red, yellow , blue from left to ri ght or top to bottom, or
according to the req uirements of BS4343 (see appendix 2). Residual
C urrent D evices (R C D's) shou ld be installed as a means of
supplementary protection where practicable.

OUTPUT The following methods may be used in order to achieve variable voltage
SUPPLIES outputs from t he test switchboard:

Cal A three phase transformer with the output tappings connected to

socket outlets. The voltage is selected by plugging into the
appropriate sockets of three phase groups or by t he usc of three
rotary selector switches (hand or power operated) connected to
three socket oullets;

(b) A variable output transformer (hand or molor driven ) connected lo

a three phase ou tlet;

(c) A single phase and neutral s upply from the test transformer Lo
socket outlets via a variable induct ion regulator:

6
 LOCKABLE
SWITCH OR VOLTAGE RCO s
FUSESWITCH CONTACTOR REGULATOR !IF T"ITTEOI
SOOA V'RIABLE
-X VOLTAGE AC

IOOA FI XED
,.< VOLTAGE AC
IOOA VARIA.BLE
EMERGENCY X VOLTAGE AC
TRIP

25A FIXED
VOLTAGE AC
?5A VARIABLE
VOLTAGE AC

If SfPAAATE CONTAC TORS 100..

ARE riT TEO TO OU TPUT
CIRCUI TS THE (MERGENCY VARIABLE
TRIP SIIOULO I RIP All VOLTAGE DC
OUTPUT CIRCUITS lOA

--0><0-- OVERLOAD DEVICES TO PROVIDE SHORT CIRCUIT PROTEC TION FOR BS88 FUSES

Ftg ure 1: Single line diagram of a typical LV ac and d e teslsw1tchboard

Ftgurt> 2· Outli ne drawing of a low voltage ac and de test SWitchboard

DC I 25A AC I TEST P ANEl] IOOA A C

8 000 0881
8 ffi (j)
I

9 h
d @d liDnJ IWmm 9

0
OJ!
0
0
k
0
00
b
0
00

0
b
0
0
k
0
.
0

0 0 [J
0
s
a bo
[J [J
0
I<
0
0
' [J
co
0
b ..
0 0
c: ' 0
• • • • • •
[J

@
M
00
:::'0
0 0 0
E E E

,I 'ON/OFF' conl:lclclr R<'D test/fa ult.

b duphcnt(' pow!•r "nrmng lights J - current OJ)('n.ttcd CBs t mmnsl
c ·pow<>r no' IOirlcntlon !ihowing phaw rnt:.n•on k range s rlection
d vollng<> r<>g ulULM" I vonable voltag('
vnllng<' 11Hhcat1on M fixed outl<!ts wtlh warnmg lights
phllSl' $l'lccwr A nmmetl'rs
cu rn.• 11t llpt•rnt(•d CB:> E t•nrth tcnmnal s
lvHnahlt• ' 'llll;tgl' uul INs I S - l'nwrgl•ncy slllp button
h currt•nt <I JWI'al(•d Clh lfixNI voltllgc oull<.'l;;l V voltm!'ters

7
 (d) A transformer with a tapped secondary winding whose output is
rectified and connected to two socket outlets, positive (red) and
negative (black);

(e) A variable output transformer whose output is rectifi ed and

connected to two single pole socket outlets;

(f) A mains fed, thyristor controlled, de output to two single pole

socket outlets.

Figl (page 7) s hows the basic diagram for a typical test switchboard

Fig 2 (page 7) s hows the general arrangement of a low voltage ac and

de test switchboard.

ALTERNATORS Motor/alternator and motor/generator sets may a lso be used to provide

AND variable voltage ac and de supplies. The star point of an alternator
GENERATORS winding should normally be connected to frame and earth. Means s hould
be provided at the test area to control and indicate the ac and de output
voltages and currents and in an emergency, to trip all outputs from
generator sets used to provide supplies.

SUPPLY FOR The test facilities should include provision for an unearthed s upply at a
CONTINUITY voltage not exceeding 25V ac or 60V de (see lEE Regulation 411-13). This
TESTING may be derived from either a safety isolating transformer, a
motor/generator set or batteries and s hould be u sed for continuity
tes ting if proprietary continuity meters are not available or s uitable.

1.4.3 FUSING, BONDING AND EARTHING

Fuses s hould comply with the requirements of BS 88 (see appendix 2).

The use of rewirable fuses is not recommended because they do not
provide tl:e safety and reliability afforded by cartridge fu ses. On no
account s hould cartridge fuse carriers be fitted with fusewire. Adequate
stocks of replacement fuse links should be kept under the control of an
authorised person.

All m eta lwork in a test a rea, in cl uding e lectrical and in strument

enclosures, and machine test beds, s houl d be bonded together and
earthe d . Bonding and earthing connections s hould be adeq u ate to
wit h stand the foreseeable fault current in magnitude and duration ,
subject Lo t.he rating of the circuit. protective devices fitted.

1.4.4 CONTROL CIRCUITS

Figure 3 s hows t.he correct disposition of components in a s imple control

ci rcuit.. Basic requirements are that one pole shou ld be fused, the other
pole s hould be earthed and one s ide of lhe coi l connected to the earthed
conductor. Other arrangements are likely to result. in incorrect. operation
if insulation or wiring faults occur.

1.5 TEST SWITCHBOARD FITTI NGS

METERS Voltmeters, ammeters and any other instruments required shou ld be

SWITCHES incorporated in the switchboard circuits. The function of all meters,
AND OUTLETS switches and outlets s hould be slated. All switches s hould be clead y
marked 'ON/OFF' and be readily accessible. The main isolating sw itch
for the test switchboa1·d should be of a type that can be locked in the
'OFF' position.

8
 ONE POLE FUSED

I ONE POLE EARTHED

I
I
I OPERATING CONTACTS IN
IIIII
•--------- ---- THE FUSED LIVE LINE

ONE TERMINAL OF OPERATING

COIL EARTHED

Figure 3: Schemuttc d1ngram showing correcl connection of basic conlrol ctrcuit components

EXTENSION BOX WITH

COVER ATTACHED TO
SWITCHBOARD DOOR

BS 88 FUSES
INCOMING
liVE TERMINALS
WELL SHROUDED

0
TEST SUPPLY ANU
EARTH TERMINALS

l HE DOOR CANNOl B£
OPENED UNTIL THC SWifCH
IS IN THE OFF POSIT ION
ACCESS TO TESI TERMINALS
C ANNOT BE OB TAINlD UNTIL
THE DOOR IS OPE N

TEST CABLES

,..IJ:III't' ·1. A ,;wilchfuse "1lh mterlockcd term mol rovc1·

9
JNDTCATIONS Duplicated red indication lights placed in a prominent position should be
used to indicate that the main isolating switch of the tes t switchboard is
'ON.

All powe r outlets on t h e test s witchboar d s hould have means of

indication to show when they are ·Jive. Lights should show red for
and green for 'OFF' to e nsure indication in the event of a single lamp
failure.

POWER All outlets should include a means for screening terminals, to pre vent
OUTLETS accidental contact with live parts.

All leads from a test panel to equipment under Lest should have a means
of disconnection at the panel but unprotected bolted connections should
not be used.

Safe means of disconnection may include:

(a) a recessed socket for use with an insulated rubber moulded plug.
The sockets should be protected by covers which, on removing the
plug, screen any exposed conductm·s automatically.

(b) 3 phase or single phase plugs and sockets complying with BS 4343
(see appendix 2).

(c) a switchfuse with an interlocked terminal cover. (see fi gw·e 4 page 9)

RESIDUAL R CD's with a rated t ripping current of 30mA sh ould be included in the
CURRENT Lest. switchboard for low voltage ac outpu t circuits. It is important to
DEVICES remember that R CD 's are designed to trip a circuit only when earth
(EARTH LEAKAGE fault currents flow. They do not prevent, el ectric shock but. can provide
CIRCUIT supplementary protection by limiting the duration of eart.h fault current
BREAKERS) capable of causing electric shock.

The choice of rated tripping currents depends on Lhe purpose for which
an R CD is fitted. For example, a tripping current of 300mA is likely to
protect. against fire 1·isks but a lower va lu e (see t he note to lEE
Regulation 471-14 of lhe 15th Edition ) would be t·equired to minimise
shock risk fTom earth fault currents. It is important Lo note that the
performance of some R CD's may be adversely affected by the presence of
a de component in the protected ac circuit. The R CD manufacturer's
technical department s hould be consulted for advice on this subject 01· on
nuisance tripping or discrimination problems.

CONTROL A clearly marked means of switching on and off the equipment under
SWITCHING test. should be provided on the test switchboard. [f the switching device
on the switchboard is not immediately accessible because Lhe Lesl
engineer may be some distance from it, a remote control should be
provided. A suitable number of fixed emergency trip buttons should also
be provided and connected so U1at operation of any one trip button will
make ALL test cir cuits dead . These should be easily accessible for
operation from inside and out.side the test area. Recommended positions
are al the entrance to t.he test area and in front of test suppl y
s witchboards. Trip but.tons should be of the type requiring a positive
action to reset.

ISOLATION Means of isolation, wh ich can be secured when necessary by padlocking

or other means, should be provided so Lhat. test supply terminals and all
con nected equipment can be made dead before work is carried oul on
lhe circuit and kepl dead during Lhe course of lhe work.

10
 1.6 TEST AREAS, DUTIES, TRAINING, SUPERVISION,
ACCESS AND RECORDS

EMPLOYER AND Sections 2, 3 and 7 of the H SW Act (sec appendix 2) set down the general
EMPLOYEE duties of employers and employees, which are summarised in appendix
DUTIES 4 , together with other sections of the HSW Act relevan t to this Code of
Practice.

Regulation 3 of the EAW Regulations defi n es the persons (duly holders),

namely employers, self-employed persons and employees on whom duties
are imposed by t he Regulations for matters within their control.

TRAINING Among the various res ponsibilities of an employer is t he duly to provide

his employees with information, instruction, training and supervision
that will enable them to carry out their duties safely. In particular the
necessa ry detail s of s upply systems, lest procedures and emergency
procedures should be known to all authori sed and compete nt
pe r s ons. The employer should give consideration to the need for w1·itten
test procedures or lest schedules for iss ue to his authoris ed and
competent p e r s ons in the interests of safety. It is also recommended
that safety training s hould include the treatment of electric shock and
basic first aid. Consideration should also be given to the need for an
appropriate level of training and inslrucLion for other em ployees who
m ay e nter a lest area, under lhe immediate supervision of an
authoris ed pers on, for example to check mechanical plant.

SUPE RVISION A test area should at all limes be in lhe c harge of an a uthoris ed and
compe t e nt e mployee, appointed by the e mployer because it is a place
set apart where electrical danger may be present.

COMPETENCE Only an autho ri sed p e r son or a co mpe tent p e r s on under his

immediate s uper vision s hall be in charge of carrying out tests. Only
persons who are competent to avoid danger by reason of their training,
knowledge, ski ll and experience shal l work in a test area where
equipment is energised or conduct tests from a position outside the test
area.

ACCESS BY Any other person, for e xample a visitor representing a cuslomer or an

OTHER employee who is not a competent p e r s on, who may he required to
PERSONS e nter a test area in the cou rse of hi s duties, s ha l l be under the
immediate supervision of an authorised p e rs on. This requi rement also
applies to pet·sons under training, who ghould be closely s upervi sed
when permitted lo carry out any work where technical knowledge or
experience is required lo prevent injury.

ACCESS AFTER No person, whether or not electrically skj JJed , should be permitted Lo
SUPP LY work alone in a test area to clean or pain l , to handle materials, to rig
ISOLATION equipment, to curry out assembly or filling work, or for any si mil ar
purpose, until all sources of supply have been secw·ely isolated and the
area made safe by the tesl engineer.

SUB DMSION If necessary, a large Lest area may be temporarily subdivided into a parl
OF TEST AREAS where testing is being performed and where electrica l danger may be
pr·cscnl and a parl where other persons, for· example e rectors and filters,
may have access to dead equipment only. Temporary internal barriers
and notices should be used for this purpose and an authorised p e r son
!>hould keep arrangements under his direct control.

RECORDS Up-to-date drawings of the circuit arrangements of lhc test switchboard

should be avai lable to the lest engineer.

11
 1.7 AUXILIARY EQUIPMENT

TEST Electrical test instruments (preferably of proprietary manufacture)

INSTRUMENTS should be of sound construction, provided with protected terminals and
adequately insulated test leads. Test probes should have only the
minimum length of exposed metal which is required to make the test
contact.

The use of makeshift devices which are likely to be unsafe should not be
permitted.

On numerous occasions electricians have s uffered accidents because

multimeters have been set on current or res is tance ranges and the
instrument probes then applied to Lerminals at a substantial potential
difference e.g. at mains or higher voltages. As well as the risk of injury
from the damaged meter, severe arcing can develop from the fault.
applied at the equipment under test, leading to burns. In cases where it
is not necessary to measure a voltage precisely, but intended simply Lo
detect Lhe presence (or absence) of voltage the usc of a proprietary
voltage detector, rather than a multi meter, is strongly recommended.

Electrical test instruments should be used only by persons who are

electrically skiJled. The usc of handheld instrume nts on live equipment
s hould be limited to conditions where they may be used safely; otherwise
test connections should be made before the circu it is energised. The jaws
of 'clip on' type instruments should be well insulated, undamaged and
suitable for the circuit voltage.

TEST CABLES To encourage a tidy test area a rack with hooks should be provided on
which to hang unused test cables. All lest cables s hould be nexible,
durably insulated, oversheathed and adequate for the intended use. It is
good practice for cables to have their maximum voltage and current
s hown by attached labels so that they may be identified easily.

Cable insulation and terminations s hould be examined frequently for

damage or wear and renewed as soon as damage or deterioration is
observed. Trailing cables are vulnerable and require regular inspection
and maintenance.

Cables which are too long or too s horl may constit.ute a hazard and the
cable length should be s uitabl e fo1· the sa fe route chosen for test
connections.

PORTABLE Portable elect.ric.tools s hould not be used in an area where testing is in

TOOLS progress. Where it is impracticable lo remove a machine from the test
(REDUCED area to carr-y out. work, such as drilling, soldering, welding or grinding,
VOLTAGE aJI connected test circuits should be madC' dead before work commences.
OPERATION> Tools s hould be operated at reduced voltage supplied from a 240/llOV
transformer with a secondary winding centre tap earth. This ensures
lhal not more than 55V exists belween any live conductor and earth. As
a n alternative to the use of earth ed Cclass I) portable tools, all insulated
or double insulated CCiass IIA or llB > tools are recomme nded. BS 2769
(see appendix 2) refers Lo the \'arious classes of this type of equipment.

O'l'HER It is important. t o remem ber that the safely of ea rth e d (Class I)

PORTABLE equipment de pends ultimately on, internal insulation, on the integrity of
ELECTRICAL t he ear t h continuity conductor in the ncxible cable, in plug and socket
EQUIPMENT connections and in lhe fixed installation. In su lation and earth
continuity tes ts shou ld thl.'reforc he regu larly co nducted and the
resu lts recorded. No portable clt'clrica l eq uipm ent. s hould be used if

12
 there a r e signs of damage to cables, connectors, plugs or cord grips.
DefecLive mains voltage portable and transportable electrical equipment.
has been the cause of many accidents.

FIRE A portable extinguisher suitable for electrical fires should be placed in

EXTINGUISHERS the vicinity of a test area. Dry powder or C0 2 ex tinguisher s a r e
generally used for this purpose. Further advice is obtainable from the
local Fire Prevention Officer.

1.8 INSPECTION AND MAINTENANCE

BEFORE A visual check s hould be made by t.he test. engineer before testing
TESTING commences, to include the following:

(a) the condit.ion of insulation , the joints at connect.ors, plugs and

terminals, and in particular the leads on instruments which are
likely to be handled;

(b) the condition of the switchboard and its fittings;

(c) rubber mats, for wear or impregnation by conductive material;

(d) all main circuit connections together with any necessary control,
protection, indication and aiMm circuits; and

(e) any associated equipment that is prone to wear and damage.

Any it.e ms found to be defective s hould be repaired or replaced before

use.

PERIODIC The complete test facilities shoul d be regu larly exam ined by a
EXAMINATION competent p e r son at intervals that will ensu re the maintenance of all
AND RECORDS equipment. in a safe condi tion, a nd at least. once in ever·y period of 12
months. Records s hould be ke pt of ins pection dates. faults found and
remedial action taken. The following list gives examples of items to be
checked which should include:

( ll operation and re-calibration (when necessary ) of meters and

e lectrica1 protection devices;

(2) measurement of output voltages;

l31 bonding and eat·thing of mt•lallic enclosures;

(4) measurement of ins ulation resis tances ttnd earth loop impedances;

t51 fuse ratings and relay settings:

!61 correct operation of all switc h es;

(71 repair or replacement of any items found to be defect.ive during

maintenance:

181 cleanliness of lhe inside and outside of the t.esl swttchboard and
connection panels;

191 correct fitt.mg of a ll protective co,·er·s;

t 101 condition of all portable and tran::;ponable e lectrica l

pnrticulal'ly cables. plugs nnd terminalions. whrch should bl'

13
 renewed as soon as damage or deterioration is observed; and

(11) the condition of rubber mats, insulating screens and insulated

tools.

BS 921 refers to requirements for insulating rubber mats and BS 6423 to

the maintenance of LV control gear and switchgear (see appendix 2).

1.9 SAFE WORKING PRACTI CE

1.9.1 GENERAL RECOMMENDATIONS

STORAGE Equipment awaiting test should norma lly be kept outside the designated
area.

PRE- A mechanical inspection and preliminary electrica l test should be carried

ENERGISING out to ensure safety before energising equipment either before or after
CHECKS repair. Unused shaft keys s hould be removed and temporary s h a ft
guards put in place. The fixing of fans, pulleys, couplings, etc., should be
checked and s hafts s hould be free to rotate. Brushes shou ld be
undamaged and circuit resistances should be measured. Units that have
been repaired or rewound should be checked to ensure that winding and
terminal block connections a re correct. In sulation r esistance s hould
a lways be checked before energis ing repaired elecLrical equipment.

CHARGED All static charges shou ld be discharged after pr·essure or insulation

COMPONENTS testing. Care should be taken t o discharge capacitors before handling
and testing as they may have been received in a charged slate.

CONNECTIONS In ordet· that live conductors shall not present a shock or burn hazard,
TO UNIT terminal covers s hould be replaced or temporary insulation or screens
UNDER TEST fitted after connecting the test. supply leads at the terminal box. The
types of termination at equipment under test may include:

(a ) sleeved temporary connections;

CbJ boiLed cable lugs:

(c) screw terminals;

(d) s hell clamps;

(e) boiLs, washers and nuLs.

J OINTS AN D All joints and co nn ections sho uld hav e adequate conductivity.
CONNECTI ONS mechanical strength, electrical insulation and protection.

WORKING There s hould be adequate space around equipment under lest for tes ts Lo
SPACE AND be carded out safely wilh unobstructed access Lo swit.ches and conLrols
ACCESS and a clear way Lo enler or leave the Lest a rea at all limes.

EARTHING The metal enclosure of any equipment nur·mally intended to be earthed

s hould be adequately ea t·thed when under Lest.

MECHANICAL Reference s hould be made to appendi x 5 for advice on precautions whit:h

DANGERS a re recommended to preve nt mechanical danger.

PREVENTION All practicable efforts s hould be made Lo work on ly on eq uipme nt which

OF INJURY has been madE' safe. Connecto rs, t.erminals or other bare conductors
should be protect.ed by temporary screenmg before electrical equipment

14
 is e nergised. After testi ng has been completed the a uthorised p e r son
in charge should securely isolate all sources of s upply.

WORKING ON If during the course of electrical testing an a uthorised p e r son, or a

ORNEARUVE competent pers on under his s upervision, is working on or near bare
CONDUCTORS live conductors at voltage in excess of 125V ac or 250V de or where the
fauiL energy is capable of discharging high currents then he s hould take
a ll reasonable steps and excr·cise all due diligence to prevent injury. I t is
a lso wise to treat voltages up to 125V ac or 250V de with caution as
voltages in excess of 50V ac or 120V ripple free de can be a source of
shock risk.

ACCOMPANIED If a second person can s igni fi cantly contribute to safe working practice
WORKING then he should accompany t he per·son carrying out the test. He should be
t ra ined to recognise danger and, if necessary, to render assistance in the
event of an emergency {sec appendix 3).

ADJUSTMENTS 8quipment under test s hould be isolated whenever possible before any
AND adjustments or modificat.ions are made . If it is necessary to remove
MODIFICATIONS inspection covers or make internal adjustments whils t equipment is live,
for· example to set brushgear, then s uitable precautions s hould be taken
lo prevent injury. I nsulated tools and tempora ry insulated screens
s hould be used where necessary for· this purpose. The advant ages of
accompanied working s hould be taken into account.

Work on or near live hig h voltage systems with bare conductors is not
permitted. ·

EXTENDED Somct.i mes il is necessary to leave equipmen t e ne rgi sed or a machine

RUN running for a long period of Lime unattended. In Lhis case it s hould be
tested in a stale which is, so far as reasonably practicable, si milar to
that in which it will be installed . The a uthori sed person should ensure
that all enclosures and inspection covers arc in place, terminals are
adequately protected , moving parts guarded and information signs
digplayed.

RUNNING Additional precautions should be taken if it is impracticable to carry oul

TESTS IN a test in a perma nenlly designated a rea a nd it is necessary to perform
TEMPORARILY the test elsewhere while th e eq uipme n t unde r test is suppli ed with
DESIGNATED power from t he test swi t chboard in t he permanenlly designated test
AREAS area. Care should be given to the selection of the supply cable, its rou te
<ADDITIONAL to the tempo rarily dcsignntccl lest area and the provision of cable
PRECAUTIONS) proteclion to prevent damage. If necessary. remote controls. indication
and emergency lrip!:i shou ld be provided close lo the equipment under
lesl. A competent p e t·son should be in control of the supply and in
communication with and p1·eferably within sight of the a uthori sed
p c t·so n ca rrying out the lest. Before an Ol'casional operational
n•quirement becomes <1 regular occurrence, consideration should be
lo equipping a lot·al test a rea to meet the needs.

BENCH When testing motors nfler repa ir on a work bench with integral s upplies
TESTING OF unci contro ls the herH'h and working area lwcome a tempo r arily
SMALL MOTORS d«?signated Lest area for the duration of the lest. Permanent or
temporary barriers are needed and unauthorised persons should nol
approach whilst testing is in progress. Suitably placed e mergency trip
butlons should be pro,•idccl at. each work bench used for this purpose. It
is preferable to treat such combined repair and test areas as
pernu1ncntly designat('d lest ar·eas staffed by c ompetent p erson s
undt•r the supervision of an authorised person .

lfi
CONTINUITY Subject to the exception noted below the practice of using mains leads in
TESTING series with a test lamp for testing commutators and winding continuity,
or for a ny other forms of continuity testing, s hould not be permitted.
Proprietary instruments or extra low voltage testers s hould be used
unless customers test specifications demand otherwise.

240VPROOF When these tests a re required, e.g. by contract s pecification , the test
TEST equipment should be constructed so that:

the s upply is derived from an isolating transformer

the 240V lamp is securely mounted and enclosed.

the test leads are adequately insulated and over s heathed and t he test
probes are fitted with s pring mounted retractable s heaths.

1.9.2 DC TESTS

ARMATURE The purpose of the Lest is Lo compare voltage drops across a rm atu re
DROP TEST coils. This may mean passing substant ial curren t, which may approach
load current val ues, t hrough a winding circuit so that voltage drops
between commuLators bars can be measured. The voltage measured will
depend on the cu rren t and on t he winding resistance. Care s hould be
taken to avoid contact wit h exposed commulaLor segments when drop
testing armatures. Variable voltages used for the Lest should be derived
from an unearthed somce and should be as low a magn itude as possible
consistent with the Lest current.

Where substantial inductance exists, for examples in la rge a rmature

windings, it is recommended that the de Lest supply s hould be switched
off before repositioni11g the test leads on the com mu tator , in order to
prevent arcing. The means of switching s hould be s uitable for this duty.

;}. de dmp t csltn g

16
WINDING The foregoing advice also applies to the use of de s uppl ies for testing the
POLARITY polarity of field and stator windings and wound rotors. When shunt
TESTS windings are iest.ed it may be necessary io carry out drop tests at the
rated voltage of the machine in order lo si mulate service conditions.
Steps should be taken to discharge stored energy safely, for example by
gradually reducing the applied voltage.

1.9.3 INDUCED VOLTAGE TESTS

GROWLER The growler induces a voltage into stator, armature or rotor windings in
order to enable s hort circuited turns to be identified by transformer
action. The magnitude of the induced voltage depends upon the winding
design of both the growler and the equipment under iesi. Contact with
bare cable ends and other exposed conductors, for example sLator lead
connections, commutator s and rotor slip rings, s hould be avoided.
Similar conditions occur if one winding of a dual wound machine is
supplied from an ac source. Adequate precautions are necessary lo
prevent. inadvertent contact with the connections to the other windings
as dangerous voltages may be induced.

CORE TESTS As low an ac voltage as reasonably practicable should be used for this
test, consistent with the factors which innuence the desired magnetic
nux, for example core size, number of turns of t.esl cable and the
available current. output. Any joints in the test circui t. should be suitably
insu lated and the cable size shou ld be adequate to avoid overheating.
The core under test shou ld be e at"thed. Test. currents shou ld be
gradually lo a level below magnetic saturation while the core
is examined for areas of local overheating.

1.10 INSULATION TESTING OF LOW VOLTAGE EQU£PMENT

1.10.1 PURPOSE

I.R.ANDHV To determine the integt;ly of the insulat.ion of electrical equipment it is

PRESSURE important that it. is suitably tested. A lest using a de instrument.
TESTS measures a value of insulation resistance. subject to the lime necessary
t.o cha1·ge the effective capacitance of an insulated conductor. An HV
pt·ess ure tes t applies a short. duration over- voltage proof t.est to
insulation. LR. t.esls should always precede and follow over-voltage tests
and should precede the initial connection of equipment lo a source of
supply. Results oblaim'cl should be reco,·dccl.

1.10.2 l.R. TESTS

INSTRUMENTS Portable 250V. SOOV or lOOOV instruments may be used to determine

absol ute values of insu lation resistance or the polarisation index of
insulalion by comparalivc values at intervals of lime. J\n important
safeLy characteristic of the range nf instruments available is the
inlwrent limitation of de output current to about 5mA oJ·)('ss.

PROCEDURE Test111g should be carried out by a competent p e r so n who should

ensure lhat instruments, terminals, lest leads and clips arc in good
condition before usc and Lhal no bare conductors under lest are within
reach of other persons. The Lesl circuit should be dischargC'd before tlw
Lest. leads are disconnected. Some instruments include a switch for
discharging stored en('rgy after a lest and the use of this method is
recommended.

17
 1.10.3 HV PRESSURE TESTS ON LV EQUIPMENT

PRESSURE HV pressure test sets with maximum voltages of the order of SkV may
TEST SETS be portable or transportable. Other functions are often included in
sma ller equipment with lower output vollages. For example portable
appliance testers with a means for insulation resistance testing,
protective conductor continuity testing and pressure t esting have
output currents usually limited to 5mA or less. Larger equipment
intended only for pressure t esting may not be cWTent.limiLed to a safe
value. Such equipment is often available with substantially insulated
and screened test probes which designed to be hand held.

TEST SET HV pressure test sets should be provided with the following controls,
FITTINGS indication and protection:

(a) a local on/ofT s witc h ;

(b) a 'mains on' indicating light;

(c) a control for selling applied voltage;

(d) a voltmeter to indicate output voltage;

(c) a circuit breaker which will operate at the lowest practicable HV

output current, which should not normally exceed 30mA;

( f) a lockable switch to control HV outpul cw-renls in excess of 30mA,

if this facility is provided;

(gJ The metallic enclosures should be ear t h ed ;

(h) Zero voll inte rlocks should be fit.t.ed.

HV TEST LEADS HV test probes should have insulated handles, finger guards and spring
AND PROBES loaded retractable screening sleeves covering the electrode tips as shown
in the adjoining illustration. The cable should enter on the side of the
gua rd which is remote from the operator's hand. Only insulat.ed and
sheathed flexible test leads suitable for the maximum operating voltage
of the test set shou ld be used. The leads should be t.erminated at the tesl
sel so that no bare conductors are exposed.

HANDLE

INSULATING DISC

PROBE F ITTED WITH

SPRING LOADED
INSULATED SLEEVE

l'tlftll'l' (): probe for use wtlh lt'st set output \'oil ages nut cxcl'f'dtng 1)()()1)\ ' ;tt

18
EARTH Pressure test set output voltage may or may not be referenced to eat·th
REFERENCE but a Lest probe which is normally connected to earth s hould be clearly
ident.ificd . IL is preferable that the HV s upply to hand held probes is not
referenced to earth.

PROCEDURE Pressure testing should be carried out only in a des ignated test area
unless HV outpu t curren ts are limited to 5mA or less. All pressure
tes ting s hould be car ried out by an authorised pers on or a
c ompe tent p e r son acting under hi s immediate s upervis ion. As an
additional safeguard, pressure test sets with an output current not
exceeding 5mA are recom mended for use in a ny Lest. where it is
reasonably practicable to perform the t.cst within this limitation.

The person carrying out a n HV pressure test s hould first check that.
the les t equipment is undamaged and safe for use, the insulation of test
leads and probes is intact and that the probe screening s leeves operate
correcUy. Any defects s hould be repa ired before the equipment is used.

On compl etion of an HV pressure tes t , the conductors under test

s hould be safely discharged to earth by the person carrying out the test,
using an insulated and s ubstantia lly constructed earthing conductor.

FIXED Fixed pressure tes t sets generally do not incorporate hand held probes
PRESSURE but require HV test connections to t he equipment undet· test to be made
TESTS at the back of the test seL.

In s uch cases it is essential that means arc pro,·ided lo require t he

operator to stay at lhe control console for the duration of the test. for
example by:-

1) A spri ng loaded "on" button which must be operated in conjunction

with the voltage setting control or a spring loaded control device

2> The use of an operator's spring loaded foot swi t ch located at the
control console

31 A barrier used lo denote a temporari ly designated test a rea

4) An inte rloc ked barrier between t.he control position and Lh e

equipment under lest.

Training a nd particular circumstanCl'S may be taken into account when

deciding which comb1nations of the abo,·c or s imil ar methods are
approp1;ate. The objectives a re that lht! operator carrying out the tests
has to s tand at the control console whil<> the test is ca rried out and LhaL
lh e equipm ent under test is se pa rated by a safe distance from th e
operator's working position.

If tlw l<•,;;t Pquipmenl does not include means lo the equipment

und<>r test to ear th , means for safe manual earthing need to be provided
and used.

19
NOTES

20
PART2
TESTING OF E LECTRICAL E QUIPMENT WHOSE RATED
VOLTAGE EXCEEDS LOW VOLTAGE

2.1 INTRODUCTION

Many repair wor kshops have no provis ion for high voltage supplies and
are limited to proving machines by static tests, HV pressure tes t s and
by LV t·unning tests, these tests being carried out in a per manently or
temporarily designated test a rea.

Some companies have provis ion for high voltage running test supplies.
In addition to the recommendations in Part 1, the advice which follows is
directed to HV tests carried out on equipment with rated volLages in
excess of low vol tage.

2.2 LEGAL RE QUIREMENTS

The duties placed on e mploye rs and employees by the Ele ctricity at

Work Regulations 1989 require vigorous safety procedures to counter
dange r as the voltages and fau lt levels on electrical systems incr ease.
The safety meas ures adopted have to be commensurate with the r isks of
injury.

Thi s means t hat all high voltage conductors which are within reach of a
person a t work s hall be p•·otected to prevent. danger.

1\lloreover , no one s ha l l u ndertake work on or n ea r hi g h vo ltage

conductors unless t he conductors a re:

( 1) proved Lo he d ead;

(2 } isolated a nd all practicable steps taken to sepa rate and lock-off

from live conductors;

(3) efficiently con nected to earth at all points of disconnection of lhe

supply or between such points and the place of work;

(4 ) scr eened where necessary to prevent. danger; and

(5) released for work by:

(aJ the issue of a p e t·mi t t o work (see Appendix 2 BS

662ti: 1985 J:

or lbl by lh e oper ation of a sequenlial inte rlocking system which

wi ll rPsulL in conditions which arc as safe as those intended
under lhe permit to work system;

or ICl by following procedures lo achieve an equa lly eflective safe

system of work.

The pe1·son who then undertakes the wor k shall be fully conversant with
the safely measu res adopted and with the extent and limitations of lhc
work l.o be done.

21
 2.3 COMPLIANCE

Practical means of compliance in premises to which the Code of Practice

applies, where HV testing is carried out, require that the design of test
eq uipment and appropriate safely procedut·es will e ns ure that:

ACCESS (a) no live HV conductors are exposed where they may be touched;

AUTHORISED (b) all HV test equipment a nd the conduct of HV tes ts is under the
PERSON immediate s upervi s ion of an authoris ed p e r s on who has
technical knowledge a nd experience in this class of wor k. This will
include the preparati'on, carrying ou t the tests and making all
equipment sa fe at the end of the test;

ISOLATION (c) HV test s witchboard terminals are isolated a nd earthe d before

connect ing or di sconnecting test connecti ons n t eithe r the test
switchboard terminals or equipme nt under test;

PRESSURE (d) s uitable precautions are take n to achieve pe rsonal safely during
TESTING AND the use of both fixed a nd lrans portable high voltage pressure
SPECIAL t est sets by equipment and methods of work which ensure that t he
PURPOSEHV ope rator is s afely sepa rated at. all times from bare conductors
TESTS and/or dangerous voltages.

2.4 DERIVATION OF HV SUPPLIES (see Fig.7)

LOW VOLTAGE Variable high voltage Lest supplies a re required lo enable equipme nt to
STARTING be run up to speed without. drawing excessive sta rting currents and to
facil ita te the testing of equipment of various rated voltage.

A typical a rrangeme nt would be to energise the primary winding of a

regulating tJ·ansformer at LV and step up the output using an LV/HV
lest su pply t ra nsform e r with tap changing facili ties. Output voltage is
controlled to the desired value by the on-load operation of the regulating
lt·ansformer after off-load selection of appropriate links or tappings on
the test supply t ra n sforme r.

1 CSr SUPPL IES SUBSTATION

MV CB FS
OA M CCB
0>;<0

---o
, REGUlATING
__/. - -- I BOX
!I SUPPLIES
IRANSFORMER
f'j - - -
0 HV TEST
SUPPLY
TERMINALS
0
: J

1 r
Cl

1 ! j
...
AND INOICAIION
-
t:NC LOSUR(
•

: KEY INTERLOCKEr VARIABLE

.
' KEY INT(RlOCKf 0

.---------------.
• WITH ACCESS D<lOI1 • MV SUPPLY • WITH 1l RMINAL
' EN1..LOSUIU ,
'------·--·-----
HV CIRCUI I BAt AK( R MAY BE CUBICLE rYPE Wllt1 THf TEST SUPPLY EARTHING &WI ICII AS SHOWN
OR WIIHDRAWA!!U IYP( Wlf>i TRAN SFER (ARTHING rACILITY THE EARTHING fACiliTY SttOULD
B£ INTrRNAll' INTff<L{)(;KfO SO THAT Itt( If .>T SUPPLY C IRCUIT CAN NOT 13( [ ARTHEO
UNLESS IH[ URC.UII OR£ AKER IS OPEN

Ft)l/111' I lllu<'k chugrnm showml{ Jill" a I clt•t"l\.'.lliOII ur II\' lt'St s uppli• •s

 In the basic arrangement described, there are several safety aspects to be
consider ed, namely:

SUPPLY (a) Means should be provided to isolate secu rely the source of LV
ISOLATION supply, for example by padlocking.

SUBSTATION (b) The transformer arrangement desc,·ibed constitutes a test supply

ACCESS substation , entry to w h ich is permitted only to a u t h o rised
persons.

REMOTE (c) Means should be provided to switch the LV supply and to control
CONTROL the regulating tt·ansformer from a safe position.

INTERLOCKING (d) The door to the test supply substation should be key interlocked
with the incoming supply isolator so that access for the purpose of
changing off load vollage selection links is only possible after lhe
supply has been made dead.

TEST SUPPLIES (e) The use of a standard delta-star distribution transforme r used as a
TRANSFORMER Lest s upply transfo rme r by energising the lower vollage (star)
winding from the regulating transformer output is not
r ecommended because the HV delta winding sup plyi n g the
equipment under test cannot be readily earth r eferenced. Thus an
earth fault occurring either in the unit, under test or on associated
HV test connections would not be detected.

UNREFERENCED (f) A single earth fault on an unre ferenced de lta system is unlikely to
SECONDARY cause immediate danger to person nel , but the occurrence of a
second earth fault on a different phase v.riU cause a short circuil.
Al though insulation should be proved before a running test is
started and although testing may be of relatively short duration
a nd continuously monitored it. is better practice not to consider this
method as other than an expedient.

EARTH (gJ It is preferable that the test supply transformer should be a

REFERENCED star/delta transformer, (vecto r group Ydl or YdliJ, with the delta
SECONDARY winding supplied at variable low v oltage and t he star point of the
HV winding earthed.

HVCIRCUIT (h ) The test supply circuits described so far do not provide for voltage
and em-rent indication, for HV "circuit e lectrical protection 01· for
application of HV safety earthing when work is Lobe carried out on
lhe e lectri cal conn ecti o ns to the equipme nt unde r test. It is
recommended that all these functions should be provid ed by
including in the insta llation an HV circuit breaker rather than
making unco-ordinated arrangements lor measurement, protection
and safety ea1·thin g functi o n s. An adequately rated circ ui t
breaker with voltage tra nsformers, current transformers and a
circuit earth ing fa c ility is advised. In new installation;;
consideration should be given to airbr·eak or vacuum switchgear lo
minjmise !ire risks.

DIAGRAM OF (il 7 shows the com ponents a nd principal features of a typical

RECOMMENDED HV Lest s upply as recommended. The regulating transformer may
INSTALLATION also be used to pr·ovide a variable low voltage supply to a
separate LV Lest s witchboard via interlocked selector swiLches or
contact,ors.

CONTROL (j J Remote cont,rol at the HV test st,ation should he provided al a safE>

location which is manne d for the duration of the lest and wh1ch
should include control of the Lest supply circuit breaker and of

23
 the applied t.est voltage. Additional emergency trips s hould be
provided, if the layout of the test area and its enclosure require
them.

INDICATION (k) Remote indicating instruments and indicating lamps s hould be

provided at the control position. These should include means for
indicating the a pplied test voltage a nd t he line currents. The
circuit breaker position should be indicated by a red lamp for
'closed' and green for 'open'.

PROTECTION (I) The HV circuit breaker should be fitted with a p1·otective relay
comprising instantaneous overcurrent and earth fau lt elements.
The secondary circuits of Voltage Transformers and Current
Tranforme rs should be earthed. Care should be taken to ensure
that current transformer secondary circuits are not. open circuited
whenever primary cur rent is flowing.

The setting of protective relays s hould be as low as practicable for

the tests being undertaken, particularly in respect of short circuit.
and earth fa ult protection.

2.5 EQUIPMENT AND SAFETY PROCEDURES

TEST No HV conductors, equipment or test. terminals s hou ld form part of a

SWITCHBOARDS low voltage test switchboard but s hould be accommodated separately
and clearly identified.

No liue HV conductors should be exposed where lhey may be touched.

CIRCUIT The c ircuit breaker controll ing HV supplies, whether directly or by

BREAKER energising the primary winding of a step up transformer , should be
LOCKING capable of being locked in the isolat.ed position and should be at. all times
in the charge of a person who is authorised to conduct. HV testing.

RATING AND All HV equipment should be suitably rated for the maximum system
PROTECTION voltage and prospective faul t current. HV test terminals should be
located in an enclosure with a hinged cover and slots in the bottom
through which the test cable Jugs wiU pass. The cover should be capable
of being secured in the closed position by a padlock, the key of which is at
all times in the charge of the authorised p e rs on.

INTERLOCKING Preferably, the cover should be mechanically key inte rloc ke d with the
LV c ircuit breaker controlling the HV test supply as shown in figure 4
(page 9) so the cover may be opened only when the circuit breaker is
open and so that the circuit breake1· cannot be closed unless the cover is
clo:>ed.

CffiCUlT If an HV circuit breaker controls the test supply <lirecUy, then the
EARTHING ci rcuit breaker 5hould include a lest circuit earth ing facility. This
feature should be included in the safety interlockin g scheme to ensu re
that the HV test terminals cover can be opened only when the HV
c irc uit breaker is in the ci1·cuit earth position.

EARTHI NG Ir t he circuit breaker controlling the lest supply is a low voltage

SWITCH circuit breaker a means should nevertheless be provided for earthing the
HV Lest terminals when working on Lhe HV lest circuit., for example
connect.ing or disconnect.ing test circuit connections. This may take the
form of a separate earthing switch or an earthing assembly which can be
safely applied to the Lest terminals and should be in position whi le work
is being carried out. If a separate ea1·Lhing switch is provided it should be
key interlocked with the tesl terminal cover.

24
FLEXIBLE Fl exible HV conductors for connection between test terminals and t he
CABLES termina ls of equip me n t under test s hould be s ingl e co re cables to
min i mise the risk of sh ort circuits. T h ey s hould be insulated for the
working voltage and furthe r· efficiently protected by an abrasion resistant
oversheath. If cables wilh a metallic braid a re used the braiding should
be earthed at one point. Terminal box covers or equivalent temporary
protection s hould be securely fixed before equipment under test is
energised.

PERMIT TO When s afety procedure is determined by an effective interlock system

WORK no p e rmit to work is necessary when making up or di s mantling
connections at t he tes t term i nal s. If, on the other band, safety is
dependent on t he operation of locks, c it·c uit breakers and manual
earthing by the authoris ed pers on i.e. on personal control of the means
of safety, then it is recommended that work s hould only proceed after the
issue by the auth ori sed p e r s on of a p e rmit to work or equa lly
effective safe system uf work. For example lhe use of a signed switching
procedure log book stating that the system has been isolated, made d ead
and earthed would be acceptable.

Any work to be undertaken on other pat·Ls of a fixed HV installation, for

example on switchgear. cables or transformers. s hould be the subject of a
p ermi t to work.

TESTING Typical vol.tage ratios of di stribution transformers are 11, 6 .6 , or

DISTRIBUTION 3.3/0.433 kV. For t he purpose of s hort circuit and open circuit tests these
TRANSFORMERS transformers wiii normally be ene rgised at the lower voltage (secondary)
terminals in which case da ngerous voltages will be produced at the HV
terminals. These term inals, with leads and a uxiliary apparatus which
may be connected to e nable voltage measw·e ments to be observed, s hould
be protected or placed so Lhal lhey ca nnot be touched. For advice on
voltage measurements, reference s hould be made to Section 2.6.5.

2.6 INSULATION TESTING OF HIGH VOLTAGE EQUIPMENT

Ins ulation testing plays an increasingly important role as the working

voltage of electrical equipment increas es. For high voltage equipment
a n ins ulation test. is one of Lhe factors indicating the electrical condition
of equipment before decisions are taken on any reconditioning measures.
When machines are re wound insulation tests are carried out at various
stages of coil manufactu re and fittin g.

The advice which follow s is in addition to the recommendations

expressed in Seclion l. 10 on the insulation testing of LV equipment, to
which prior reference s hould be made.

2.6.1 INSULATION TESTS AND SAFETY PRECAUTIONS

I.R. TESTS de I.R. tests at lOOOV, 2500V and occasionally 5000V may be used to
determine absolute va lues of ins ulation resistance. The instruments may
be motor dri ven and s hould have inherentli mitation of de output current
lo safe values, as described in Section 1.10.2.

POLARISATION de polari sation index tests us ing either an J.R. tester or an ionisation
INDEX TEST meter (an electronic instrument calibrated to read leakage current)
determine ins ulation integrity by comparative values of resis tance or
leakage current al interva ls of time.

PROCEDURES The safety measures a nd procedures applyi ng lo I.R. tests a re those

already described in Section 1.10.2. When ionisation meters a re used for
polarisation index tests, their output voltage s hould be reduced and

25
TESTING OF allowed to de cay through the voltmeter b e fore t est leads are
INSULATING disconnected.
OILS
The dielectric stre ngth of insulation oil is an important indication of its
condition. Only equipment designed and manufactured for determining
the electric s tre ngth of ins ulating oils should be used and the tes t s hould
be carried out in accordance with BS 148: 1972 (198 1) (see appendix 2).

The test equipment used is usua lly tra nsportable and includes a double
wound trans forme1· with a high voltage seconda ry outpuL. This winding
s hould be centre tapped to earth. The ac input to the test set is normally
either llOV or 240V si ngle phase and output voltage adjustment is
obtained by a variable a u to-tran sform er. The test is ca rried out by
a pplying the test voltage between two metal s pheres immersed in the oil
sample contained in a covered glass test cell. In modern eq uipment the
cell is positioned under a transparent hinged cover which is inte rlocked
with the incoming ac s upply thus making it impossible to oper·at.e Lhe
equipment. unless the safety cover is in place.

The s phe re gap should be set us ing the gauge provided and there should
be s ufficient oil in the tes ting vessel to cover the s phe res. The voltage
s hould be raised slowly and evenly to 30kV for used oil and to 40kV for
new oi l.

Oil s pillage should be cleaned up immedia tely and oil which may collect
on the insulators, cables and the inner s urface of the hinged cover s hould
be removed after each test.

The equipment should be maintained in a :;afe condition and switc h es,

safety interlocks a nd means of indication s hou ld be checked to ensure
thal they function correctly.

Efficienl earthing of the equipment by means of t he protective conductor

in the supply lead s hould be regularly checked. Any items found to be
defective s hould be repai r·ed before testing commences.

2.6.2 HV PRESSURE TESTS AND SPECIAL TESTS ON HV COILS

PRESSURE Pressure tests on HV equipment, us ing fi xed or t ra ns porta ble test sets,
TES'l'S prove ins ulation integriLy by Lhc application of a s pecified Lest voltage in
excess of Lhe working vo!Lagc. The rn ajoriLy CJ f HV distribution and
indusLrial equipme nt operates ut voltages between 3 a nd 36 kV ,
demanding test voltages ranging from about 5 to over 70kV.

HV COIL TESTS HV dielectric loss angle or tan della test:; a rc a ppl ied during HV coil
manufacture according Lo a specification agreed with the customer. HV
tmpulse t ests are a lso used duri ng HV cor! manufactu re to prove the
rnlegrily of inter-turn insulation a nd aflcr coils have hecn placed in
a stator core, braced and wedged bl•forc tntt•rc·onncctton.

2.6.:3 SAFETY PRECAUTIONS

PRESSURE Pressure test sets for teslmg HV equipmC'nl are therefon· lar·gpr and
TEST SETS more powerful than the test equipment dt'st•ribcd rn Pa rt I. Oulpul leads
from thts equipment a re not. designed or intended to be hand-held but
need to be connected before the lest set is c•rwrgist•d.

TEST AREAS Large equipment under test e.g. rl'WOltrHl machrnes or repaired
switchboards wrll require a permarwnt l:v or lt•rnporarily dt'signated lest
.u·ea. A pcrmancnlly destgnalcd ll'sl arPa ts rccomnwtHI<'ll for HV coil
tests after manufacture. Suhscqu<'nl lPsls on installed coils cilhC'r in
works or on site will r<'qum• lcmpora.nly dc•stgn:tl<'d Lest ar('aS.

26
AUTHORISED All high voltage insulation testing should be under the direct control of a
PERSON trained and experienced person who is authorised to perform the test.

EQUIPMENT IN Equipment under test and conductors at hjgh voltage should be located
TEST AREAS inside a designated test area from which all persons should be excluded
AND CONTROL during the test. The press ure test set controls should be located outside
OF TEST the test area and should be arranged so that, when released, the test
VOLTAGE voltage is instantaneously cut off.

The test connections should be as short as practicable and the safety

clearance distances should be such that no conductor which is live, or
may become live, can be touched from outside the designaled test. area.

DISCHARGING After HV testing, conductors of equipment under test should be safely

TO EARTH discharged to earth, preferably by an effective means provided for this
purpose on the test, equipment,. Before conductors which have been
subject to high voltage a re handled by persons discharge s hould be
ensured by a suitable earthing rod fitted with an insulated handle.

PERMANENTLY The establishment of a permanently test area with fixed

DESIGNATED barriers and key interlock ed access is recommended in any works test
HV TEST AREAS area used solely for testing. Access to such dedicated areas should only be
possible after supplies to the HV test equipment have been isolated and
conditional on the correct closure of a manually operated earthing switch.

Cit·c u it break e r control circuit interlocking should be employed only

if a visible automatic earthing switch forms part of the installed safety
system. Additionally, separate auxiliary control circuits from the c h·cuit
b r·eak e r and the earthing switch should govern lhe position of magnetic
bolts fitted to the frame of the access door so that the door can only be
opened when the circuit breaker has tripped and the automatic earthing
switch has closed.

TEMPORARILY Equipment and systems of work adopted in temporarily designated HV

DESIGNATED test a reas need to be as effective to prevent. risk of injury as the
HV TEST AREAS precautions a lready described for permanenLly designated test a reas.
This places particular responsibilities on companies and persons in
OOOR CLOSED
AND SECURED

OPERATIONAL AREA REPAIRERS WORKING AREA

TEMPORARY BARRIER WITH MAC HIN E

WARNING NOTICES

TEMPORARY TEST
SAFETY BARRIER '
I

SPRING LOADED
ANO VOLTAGE CONTACTS - -1--_ - -f----.L.._......_---11-

TEST ENGINEER REPAIRER"$

ACCES S WITH
ACCOMPANYING PERSON
WARNING
NO TIC (

F iJ!III"I' 8 Basic prC'caut1 ons dunng HV p.-essure l t:>sung of HV m a clu n<> on ><lle

27
 charge for safe systems of work and on employees who work in
s urroundings wher·e they are not protected by the safety featu res which
are recommended lfor permanent HV test areas.

WRITI'EN Companies s hould draw up and monitor the effectiveness of written

PROCEDURES procedures appropriate to high voltage testing which has to be carried
out in assembly areas or on site, namely in locations were the test area is
necessarily temporarily designated for the duration of the test.

2.6.4 EARTHING AND OVERLOAD PROTECTION OF PRESSURE

TEST SETS

EARTHING AND Pressure test sets for test voltages in excess of 5kV s hould normally
P ROTECTION have one pole permanently earth e d. The live and earth poles should be
OF PRESSURE clearly distinguished and the HV output overload protection should be
TEST SETS set to the lowest practicable value in all cases. It should be noted that
test set overload protection is provided Lo safeguard the test equipment
and does not provide protection from electric shock. A zero-volt
interlock on a spring-loaded voltage control is recommended. Release of
the control switch s hould cause the output voltage to fall to zero. The
addition of a s pring-loaded on-ofT button is recommended , thus requiring
the operator's two-hand control of the HV test set in order lo energise it
and regulate t.he applied voltage.

All metallic enclosures of pressure test equipment s hould be earth e d.

2.6.5 VOLTMETERS FOR HV MEASUREMENTS

SCALED Indicating voltmelers on p ressu re test sets nre normally connected to

READINGS AND the lower voltage primary winding of the HV transformer and scaled lo
DIRECT indicate the HV output. Laboratory type instru ments may be necessary
READING when accur ate direct. indication of hig h vol tage is requi red. These
VOLTMETERS consist of a resistor column, the lower end of which should be bonded to
earth and to which the voltmete1· tappings a re connect.ed between lhe
earth referenced end of the colum n and an intermediate point oo the
column. The HV conductor under test is connected lo the top of the
column. The meter may be mounted on lhe same base as lhe resistor
column or may be connected via a voltmeter lead so that it can be used
remotely from both the resistor column and the conductors under Lest
which are charged nt. high voltage.

The necessary safety precautions for the use of direct-reading voltmeten;

should ensure that:

EARTHING fa) 'l'he base plate of the resistance column and therefor<' one terminal
of the indicating meter is normally connected to earth;

INTEGRAL Cb l Equipment which comprises an integrul assembly of resislanrc

ASSEMBLIES column and indicating meter is never used in locations where lhP
assembly and its HV connrclions can bC? touched. Il is pr<'ferablc lo
locale a separate resistance column within the HV equipment lest
area, for example lo mount this unit on the HV t ransformer and
then connect a remote voltmeter placed at the lest control position;

REMOTE ( C) ff a separate vollmeler has a metallic enclosure it. should bl'

VOLTMETER earthed wilh one of' the meter termina ls;
EARTHING
td l Voltmeter lcrmmals should be shrouded w1lh insulation.
INTERPHASE If a single phase resistance column voltmete r is used for making
VOLTAGE interphase voltage m easu rements no earth reference is possible. The
MEASUREMENTS whole assembly, including the integral or remote indicating meter, 'floats
at a potentially dangerous voltage to earth. It must therefore be placed so
that no part of the assembly or other conductors at high voltage can be
touched while the voltmeter is observed from the working area, using
binoculars if necessary.

An alternative method is to u se a voltage transformer whereby the

proportional secondary voltage is of a relatively safe magnitude and the
remote indicating voltmeter can be convenien tly located and safely
handled. One pole of a voltage transformer secondary circuit s hould
always be earthed. Primary connections from the source of voltage to
the voltage transformer primary terminals need to be placed or protected
so that, no live HV conductors can be touched.

2.6.6 TAN DELTA, DIELECTRIC LOSS ANGLE AND IMPULSE

TESTS

SAFETY The safeLy measures required for these tests do not vary from the safety
MEASURES FOR precautions already described above for testing HV eq uipment in
SPECIALHV general, the only difference being the type of test equipment used.
TESTS
For dielectric loss tests Lhis will include within the designated test area
Lhe equipment under test, a resistance column (with local or remote
voltmeter), a standard capacitor and a high voltage transformer. The
measuring bridges and LV variac for control of HV output voltage should
be located outside t h e designated test area at the test control position.

Impulse testing requires the use of a proprietary self-contained test set

located outside the test area with insulated Lest leads connected to the
equipment under test. When a second person is present to change over
coil connections for repetitive tests he should stand clear of equipment
whilst it is under test and use an earthing rod to ensu re that tested
conductors are discharged before handling the impulse test set leads.

The terminals of t h e test seL leads should be covered with effective

insulation so far as reasonably practicable e.g. well insulated crocodile
clips.

2.6.7 ACCOMPANIED WORKING

IL is strongly recommended that any pe rson car rying out HV pressure

tests or s pecia l tests on HV equipme nt should be accompanied wherever
temporarily designated test areas, as opposed to permanent dedicated
facilities, are in use. This recommendation particularly applies to work in
assembly areas or on s ite where the customer can provide the necessary
servi ce by prior arrangement.

29
NOTES
 PART3
WORK ON SI TE

3.1 INTRODUCTION

AEMT member compa nies are frequently called upon as contractors to

examine and repair all classes of installations and plant in domestic,
commercial, industrial and marine settings. This type of work may range
from dealing with electrical and mechanical fau lts in swimming pool
installations to maintaining switchgear or re pai r ing hig h v o ltage
machines on site or electrical plant on board ships.

TECHNICAL Supporting technical information and drawings may sometimes be

INFORMATION available but at other times repairers may have to take things as they
find them, using skill and experience to determine the cause of faults, to
carry out appropriate repai rs and to re-com mission the plant, all in
accordance with a safe system of work.

OTHER ln keeping with the purpose of the Code of Pt·actice, Par t 3 deals
HAZARDS principally with the minimising of electl'ical danget·. The nature of site
work also introduces other factors which m ay not be directly under the
control of a contractor working on site but may influence health and
safety generally. Examples of these other aspects, which may require
consideration and agreement. between the repairer and the customer on
any necessary precautionary measures, arc discussed in 3.3.1 and listed
in Appendix 6. Further advice on some of these subjects is obtainable
from area offices of the H ealth and Safety Executive.

3.2 LEGAL REQUffiEMENTS

HSWACT The provisions of the Health and Safety at Work etc Act (the H.S.W. Act,
see Appendix 4 ) apply lo all activities where persons a re at work.

RELEVANT Important requirements of the HSW Act are expressed in sections of the
SECTIONS OF Act which are described in appendix 4. These sections of the HSW Act
THEHSWACT are relevant to AEMT member com panies, both in companies' own works
and on site. The requirements of Section 3 have an obvious relevance to
site work and app ly mutually to the repaire r an d customer. The
requirements of Section 6 (3), dealing with erection and installation are
of direct concern to contractors working on s ite.

EAW l n addition to the duties imposed by lhe HSW Act, lhe E lectrici ty at
REGULATIONS Wor·k Regulations 1989 CEA W Regulations) place duties on the duty
holders in respect of electrical systems, equipment, conductors and in
respect of work on or neat· electrical equipment. in so far as they relate lo
matters within persons' control.

3.3 SAFE WORKI NG PRACT IC E ON ITE

3.3.1 GENERAL RECOMMENDATIONS

L'nfamiliar surroundings, a customer's own procedures for safe systems

of work. or in some cases a lack of relevant safely procedures, sen·e to
illustrate how safety problems may arise when a repairer carries out
work on site. This section of lhe Code gives general advice concerning
procedures, awareness and prevention of possible risks when a repairer's
staff undertake such work and section 3.3.2 advises specifically on
ell.'ctrical safety. ll is important to note thal prior plannjng of safety is
required, as opposed to hasty decisions taken by either the customer or
 the r e pair e r after work has star ted, pe rhaps without r efe r·e nce to the
other party.

ELECTRICAL Measures wruch are taken for the protection of persons from contact with
TESTING live conductors, whether by barriers or systems of work or combinations
PROCEDURES of t hese methods need to be rigorous ly a pplied and maintained. Mis takes
made on site are likely to have more serious consequences than in the
established working environment of the r epair s hop.

WORKING Th e person represe ntin g the rep a irer s hould obt.ain all po ss ibl e
INFORMATION information about t.he job during initial discussions with the customer.
Th e fuller the inform ation the bet ter is t he repa ire r able to select
s uitable staff and equipment to complete t he job safely and efficiently.

PERSONS ON Repair personnel who work on s ite mus t be competent and r esponsible
SITE WORK persons who are capa ble of dea ling with problems outside their normal
place of work. The person in charge must. be capable of representing the
r e pairer on matter·s of safety and technique, must be conve rs ant with
s afe working practices and have su ffi cie nt technical knowledge a nd
expe rie nce to avoid dange r to himself or· others.

PERSON IN This t.it.le refe rs to the senior person on site work who is in charge of
CHARGE ca rry ing out the work in ha nd. The person in cha rge may not have a
s uperv isory title but. h as the r espon s ibility e.g. a s kill ed e ngineer
accompanied by an apprentice. On occasion a person may have to work
on s ite alone and therefore would be deftncd as the person in charge.

SITE On arri val at site t he re pair s taff should report to a designated member
PROCEDURES of the customer's staff who should continue to be res pons ible for the
organisation of a ll n eces!"ary cust omer/ repa ire r l iaison while th e
rcpa ir·er's staff are on s ite. At this time the repaire r s hould obtai n from
the customer , and unde rstand s ufficienlly !'or the purpose of his work ,
the s ite procedures for:

(a) ftre precautions and alarms;

(b) t he s ummon ing of immediate ftrsl aid equipment and assist a nce. A
very worthwhile precaution is Lhe ins tallation of a ftrst aid outfit in
all service vehicles for possible usc on isolated or ill-equipped sites;

{c) security, including checking me n and materials in and out;

CdJ the applicat ion of site safely rui<'s, includi ng an) procedu r e!'
s pecific to.thc customer's industry; and

Ce) communication inte rna lly and externally .

SEGREGATION Whe n necessa ry because of the proximity of other persons or plan t, lhe
OF WORKING working area shou ld be separated by barnl•rs filLed with notices warn111g
AREAS unauthorised perso ns lo keep out.

Secu rity staff s hould be wa rn ed by lh<· customer of llu· repai r er's

presence so that doors a nd gates arP not locked or lights switched off
without prior refere nce. Truck and cra rw drivers s hou ld bl• warned by the
customer of the nel•cl for particular care in lhc vicinity of the worki ng
area.

Th(• re paire r should make s ure that il rs rwnnissibh• Ln usc an) naked
namP or welding Pquipment which may IH' rwct•ssary .
 ll is the cu stomer's res ponsibility to maintain guards fi tted to protect
moving parts of machinery which remain in service but the repairer is
advised to keep clear of any pla nt not involved with his own work.

LIFTING AND An early decision should be made by the customer and the repairer as to
OTHER who will provide any required lifting tackle. If temporarily erected lifting
FACILITIES tackle is to be used the repai rer s hould consult the cus tomer and satisfy
himself regarding the adequacy of proposed anchorage or suspension
points.

Agreement should also be sought on the use of any other plant, tools or
workshop facilities thai may be made available by the cus tomer.

NOISE High noise levels can disturb concentration, maki ng communication

difficult, a nd this has obvious safety implications for persons working
together. lt. s hould also be noted that long term exposure to excessive
noise can cause permanent da mage to hea1;ng.

OTHER There a rc other non-electrical safety aspects which s hould be taken into
HAZARDS account when planning a safe system of work on a customer's site.
Further examples of these which may require joint consideration and
decisions a re listed in a ppendix 6.

A recommendation which may be helpful to repai rers who frequently

carry out site work is t he use of a standard enquiry sheet to identify and
allocate safety related responsibilities when a repa irer seeks information
on the matters noted above and in appendix 6.

LEAVING SITE Before leaving a work siLe, for example for meal breaks or at night, the
repai rer s hould ensure that barriers an d warni ng notices a re in place
and that there is no source of danger which might a ffect others in t he
vicinity of lhe working a rea fo r which he is responsible.

Afle1· more prolonged absences from t he site, for example over a weekend
or due lo an unforeseen delay, safety meas ures s uch as electrical
isolation should be checked before recommen cing work.

Before finally leaving site the repairer s hould ens ure t hat the working
area is left in a safe condi tion , s ubject to any particu la r agreements made
with the customer.

3.3.2 ELECTRICAL SAFETY PROCEDURES

PO\VER The \'Oltage, f1·equency and power of electrical s upplies on site are fixed
SUPPLIES b) the design of the customer·s installation and the ty pes of plant which
the insta llation serves. The method of stas·ting ac or de motors will be
already det.ermined by t he type and size of machine, the conditions of
operation and the need to limit s tarting currents to acceptable values.
With the exception of s mall power supplies which may be controlled by a
va riable transformer Lhe repairer is unable to utilize t.he variable voltage
s upplies which a re norma lly avai lable in the works hop for Lesl purposes.
This consideration reinforc<.-s Lhe need for equipment under tesl with iLc;
control gear. electrical protection and connections to be restored to a safe
operational stale before energisation a fter repair.

CONTROL OF In cons ultation on site with the customer the repairer should note the
ELECTRICAL poi nts a t which all electrical s upplies to the plant on which he will be
SUPPLIES working can be made d ead, for exampl e al sockets, fuseboards,
switch es and circuit ba·eaker·s. If the repairer JH given sole control of
one or more sources of suppl.v he s hould a ppoint an authorised p e r·son
 who unde rtakes respon sibility for t he control of d a nger from those
sources. If, on the other hand, the customer remains in control of the
danger , for example by the issue to the repairer of a pe rmit to work,
then h e s hould appoint an a uthorised p e r s on who unde r takes
responsibility for the con t rol of danger from sources under the customers
cont rol. A t hird possibility is that t he customer does not employ any
person s competent for more t han the routine work of opera ting the
plant, in which case the repaire r whom the cu stomer calls s hou ld
appoin t the authorised p er son.

ISOLATION Work on or nea r bare conductors should be performed only a fter the
PROCEDURES conductors have been first made d ead and appropriate measures taken
to prevent them being made inadvertently live. Measures will include
visible disconnection by withdrawing a plug, removal of fuses together
with the posting of caution notices, and locking ofT switches. Unless it is
self-evident that the isolation procedure will make the selected circuit.
dead, it is recommended that a verification test is carried out using a
safely constructed voltage indicator (preferably not a multimeler ), before
any assumptions a re made abou t safety. T he duty of carrying out safe
isolation procedures prior to work on or near conductors falls to the
authorised p e rs on.

CONTROL Repair personnel should pay attention to the possible presence of other
AUXILIARY AND circuits which may be a source of danger. These may incl ude control and
STANDBY interlocking circui ts, cubicle lighting, anti- condensation heate rs and
SUPPLIES emergency or stand-by s upplies. When referen ce to drawings or other
records is not poss ible, extra care s hould be taken by authori sed
p erso n s to ensure t h al s uch ci rcuits are initially made d ead and
securely isolated if they a re otherwise likely lobe a source of dangel'.

PERMITS TO P et·mits to w ork may be issued by some customers for work on the
WORK principal parts of LV supply systems, for example switchboard infeeds
and int.e rconnectors but, for LV work gene rally. implementing the
principles of safe and secure isolation meets the safety objective.

Before work is carried out.. on parts of HV systems, the issue by the

auth orised p e r son of a p e rmit to work is s trongly recommended
after he has performed the required iso13tion and earthing. The permit
to work is a wri tten declaration, by the person who is in control of the
danger· to be prevented, that he has Laken a ll necessary measures for
safely and that these will be maintained until t.he completion of the work
and the cancellation of the permit.

WORKING So far as in the of site wo r k, t..hc

PROCEDURES recommendations in Parts 1 and 2 of the Code should be followed on site
ON SITE and nol discar·ded unless equally £'11cctive sa fe of work a re put
inlo <'fT'cct. References lo previous advice arc summn ri sed below:

1.3 T emporarily test art>al'

1.6 Test a reas· duties, supervision and access
1.7 Auxiliary equipment
1.8 lnspection and maintenance Cbcforc testing)
1.9 Safe working practice
J 10 Ins ulation of LV equipment
2.2 Legal requirements
2.:l Compliance
2.;) Equipment and :;afl'lY pr-ocedures
2.6 I nsulation testrng of HV equipment.
 APPENDIX 1
DEFINITIONS

The following definition s relate to some of the terms used in this

document. For other electro- technical definitions, see BS 4727, P art 2
Group 06.

authorised a person employed, appointed or selected by his employer to carry out

person d efined duties concerned with the ge n e ration , trans formati on,
distribution or use of electrical energy, such person being a competent
person.

bonded connected together eleclrically, not normally for the purpose of carrying
current but so as to ensure a common potential.

circuit a mecha nical device for making and breaking an electrical ci rcuit u nder
breaker load, overload and short ci rcuit conditions.

competent a person with sufficient training, knowledge or experience to prevent

person danger, having regard to the degree of supervision which is appropriate
to the nature of his work.

continuity a test to check th!lt a ci rcuit is complete.

test

d ead al or about zero potential and disconnected from any live system.

earthe d connected to the general mass of earth in s uch a manner as \vill en sure
at all times an immed iate discharge of electrical energy danger.

em ergen cy a device for making a ll test circuits dead.

trip

interlock a device which makes the operation of a switching device dependent upon
the position or operation of one or more other pieces of equipment..

isolation sec BS 6423 : 1983 Appendix A.

procedure(LV)

isolator or a device capable of opening or closing a circuit u nder s pecified load

disconnector conditions

live electrically charged.

permit to sec HS 6626: 1985 Appendix D

work (HV)

pressure test a test for msulation strength.

RCDor residua I current device: an electro-mechanical

ELCB device for breaking a ci rcui t when a s pecified earth current nows.

s witch a mechanical device capable of making, carrying and breaking current

under normal circuit conditions, which may include specified operating
overload conditions, a nd also of carrying for a specified time currents
under specified abnormal circuit condit.ions such as those of a short
circuit.

NOTE A switch may br capable of mak1ng, but not breaking, short circu1t currents

35
extral.ow a voltage in a system not normally exceeding 50V ac or 120V de.
voltage

low voltage a voltage in a system not normally exceeding 1000V ac or 1500V de

between conductors or 600V ac or 900V de between conductors and
earth.

high voltage a voltage in a system normally exceeding low voltage.

reduced a supply for UOV portable Loots etc., not exceeding 55V to earth in single
voltage supply phase systems (or 64V to earth in three phase systems).

HSWACT The provisions of the Health and Safety at Work etc. Act 1974 (the HSW
Acl, see appendix 2) apply to all activities where persons a re at work.

relevant Important requirements of the HSW Act are expressed in sections of the
sections of Act which are described in a ppendix 4. These sections of th e Act are
tbeHSWAct relevant to AEMT member companies, both in com panies' own works
and on site.

The requirements of Section 3 have an obvious relevance to site work

and apply mut ually to the repairer and customer. The requirements of
Section 6(3), dealing with erection and installation are of d irect concern
to contractors working on site.

Electricity The Electricity at Work Regulations 1989 (the EAW Regulations, sec
at Work appendix 2) took effect from 1 April 1990, when the Electt-icit.y (Factories
Regulations Act) Special Regulations 1908 and 1944 were revoked.

The EA W Regul ations a pply wherever the HSW Act a pplies and are
directed to prevention of electr ic danger from s hock , burn , arci ng,
explosion or fire. Duties arc placed on employers, lhe self-employed and
employees to comply with the Regulations in relation to matters within
their control.

36
 APPENDIX2
REFERENCES

INTERIOR CIBS Code for interior ligh ting:

LIGHTING copies obtainable from:

Chartered Institute of B uilding Services

Delta House
22 Balham High Road
London SW12 9BS

Telephone: 081-675 5211

lEE The current issue of regulations for Electrical Ins tallations published by
REGULATIONS the Institution of Electrical Engineers, obtainable from:

The Institution of Electrical Engineers

P 0 Box No.8
Hitchin
HertsSG51RS

HSWACT The Health and Safety at Work etc. Act. 1974, obtainable from HMSO
bookshops.

MEMOR.A:NDUM Health and Safety Executive B-ooklet HS(R) 25, obtainable from HMSO
OF GUIDANCE bookshops (gives guidance on the relevant regulations, based on legal
ON THE requirements)
ELE CTRICITY
AT WORK
REGULATIONS
1989

ELE CTRICAL The H ea lth an d Safety Executive booklet HS (G) 13 (revision in

TESTING preparation ) obtai nable from HMSO bookshops.

BRITISH BS 88: Cartridge fuses for voltages up to and including 1000V a.c. and
STANDARDS 1500V d.c. (in several parts; see BSI Year Book or BSI Sectional List 26.
for further reference).

BS 148:1984 Specification for unused mineral in s ula t ing oils for

transforme1·s and switchgear. (fEC 196)

BS 921:1976 (1987) Specification. Rubber mats for e lectrical purposes.

BS 2769: Hand-held electric motor-operated tools (in two parts and in

several sections, a lll984 ; see as above).

BS 4343:1968 Specification for industrial plugs, socket-outlets and

couplers for a.c. and d.c. s upplies.

BS 4999: General requirements for rotatin g electrical machines (in

several parls; see BSI Year Book or BSI Sectional List 26. for further
reference).

BS 5000:Rotating electrical machines of particular types or for particular

applications (in several parts, 1981-88 see as above).

BS 6423:1983 Code of Practice for maintenance of electrical switchgear

and conlrol gea r up to and including 650V.

37
 BS 6626:1985 Code of P ractice for maintenance of electrical switchgear
and control gear for voltages above 650V and up to and including 36KV.

NOTE: These British Standards include important. appendices referring

respectively to safe isolation procedures (lower voltage systems) and
Safety Rules and Documents (higher voltage systems}.

BS 5730:1979 Code of practice for maintenance of insulating oil.

The sectional list of British Standards (SL26) under the heading

Electrical Engineer ing ( power, e lectronics, telecommunications,
acoustics, illumination, domestic appliances) is a useful document for
electr·icaJ references.

The above BS publications, are obt.ainable from:

Sales Department.
British Standards I nstitution
Linford Wood
Milton Keynes
MK14 6LE

Telephone: 0908 220022

The current British Standard catalogue and com plete sets of British
Standards are kept for reference in the UK in the principal public
libraries.

FIRST AID Britis h Red Cross Society

ORGANISATIONS 9 Grosvenor Crescent
London SWlX 7ES

Telephone: 071-235 5454

St.. John's Ambulance Association

1 Grosvenor Crescent
London SWlX 7ES

Telephone: 071-235 5231

.... St. Andrew's Ambulance Association

Milt,on Street
Glasgow G4

Telephone: 041332 4031

HEALTH AND The regularly updated library listing of all Heallh and Safety Executive
SAFETY publications, known as t.he Publications in Series List, is available free of
EXECUTIVE charge from the offices of the Health and Safely Executive.

38
 APPENDIX3
NOTE ON ACCOMPANIED WORKING

The former legal requirement for accompanied working in cer tain defined
circumstances no longer exists. In the Electricity At Work Regulations
1989, this subject is addressed in the guidance to Regulation 14 which
considers the need to take precautions in order to prevent injury.

One of several suitable precautions cited in Section (c), paragraph 14 is

"accompaniment by another person or persons if the presence of s uch
person or persons could contribute significantly to ensuring that injury is
prevented". Paragraph 15, headed "Accompaniment" goes on to refer lo
the exercise of judgement by a duty holder (see Regulation 3), having
regard to the work lo be undertaken and consideration of how injury is lo
be prevented .

An accompanying person shoul d be t rained to recognise danger and to

render assistance in the event of an emergency.

This Code, written t.o guide the staff of AEMT member companies and
others concerned with s afety in testi ng, contains practical advice to
supplement. lhe Memorandum of guidance on the Electricity At Wor·k
Regulations. In circumstances such as any of the following the AEMT
recommend s accom panied working, without prejudice to the legal
requirement expressed in Regulation 14 :

1) Voltage or current m easure m e nts on systems whose voltage

exceeds 200V where space may be unus ually restricted, e.g. in
ceiling voids, on board s hips, on the gantt·ies of electric overhead
travelling cranes, etc.;

2) HV pressure or similar testi ng carried out on site where the only

sepa ration between the s killed person and the equipment unde r
test is a temporary barrier and the s killed person is not using hand
held probes;

3> where a s killed pe rson needs assistance to perform his task safely ,
e.g. with an accompanying perso n to hold in place temporary
ins u lation or screening to enable safe completion of the task;

4) where work r eq uires entry into confined s paces, e.g. vessels,

manholes, tunnels, cabs or control compartments of electrically
powered mobile equipment:

51 where the safe handling of materials, components, tools or other

equipment requires the assistance of a second person ;

61 when a quantity of data has to be assimilated and recorded and

lest co nnections or equipment operating modes are changed
repeatedly;

71 where there are factor s suc h th a t di st raction or mental

preoccupation could cause a normally com pete nt. person to become
liable to mistakes or forgetfulness;

81 where the working envi r onment e.g. fumes or poor lighl could
cause drowsiness or impair judgement. to the detriment of
performance;

39
9) when field activities such as vibration analysis and balancing arc
called for it may be advisable for the person car rying out t he work
to be accompanied in adverse working conditions;

10) in any other circumstances where previou s experien ce and

supervisory judgement indicate a practical need for
accompaniment

NOTE 1 Just as the fitting of residual current devices to circuits is no

excuse for a n inherently dangerous electrical installation so
the provision of an accompanying person is no excuse for
defective systems of work or the failure of an employer or
employee to provide, maintain and use the necessary safe
equipment

NOTE2 Skilled persons who are sent on site have a res ponsibility to
work sa fely and to report back to their su pervisor in
circumstances where they see the need for the latter's safety
or technical advice, or foresee a need for assistance in order
to be able to continue their work safely.

NOTE3 It has been the custom for repairer personnel to work long
hours, so metimes in difficult site conditions, in order to
minimise the time required to repair urge ntly required
equipment..

[tis the res pon sibi lity of the employer or the person in
charge of the work to organise s uch w01·k and to allocate
sufficient labour to preclude excessive fatigue, maintain safe
working practices and minimise the risk of injury.

40
 APPENDIX4
NOTES ON THE HEALTH AND SAFETY AT WORK ETC ACT 1974

Section 2 deals with particular duties of every employer. I l calls for the
provision and maintenance of plant and systems of work that are safe;
arrangemenLs for ensuring safety and absence of ris k to health from the
u se etc. of articles and substances; the provision of information ,
instruction, t raini ng and supervision necessary to ensure hea lth and
safely of employees; the maintenance of any place of work et.c. under the
employers' control in a condition that is safe and without r·is k lo health;
and finally lhe provision and maintenance of a working environment. that
is safe and wilhoul risk to health. Each part. of Section 2 is qualified by
the words 'so far as is reasonably practicable'.

Section 3 calls for every employer to condud his underlal<ing in a way

t.hal ens ures persons not in his employment are not exposed to risks to
their healt.h and safety ; and that self-employed persons conduct their
undertakings similarly. Both these parts are qualified by t.he words 'so
far as is reasonably practicable'. Section 3 concludes by s tating Lhat. it. is
the duly of employers and self- employed persons to give to other persons
information about the ways their undertakings are conducted which
might affect the health and safely of the other persons.

Section 6 refers to articles and substances used at work a nd the legal

duties of designers, manufacturers, imporler·s and suppliers, erectors and
insta llers. This pa rt of the HSW Act was modified in March 1988 and the
full text of Section 6 of the HSW Act 1974 (as amended by the Consumer
Proleclion Act 1987> is reproduced in HSE Booklet INO CG ) l( L l REV,
avai lable free from HSE Area Oflices.

I n brief, t his SecLion of the Act now includes a rt.icles of fai rground
equipment. as well as a rticles for use a t. work and t.he new wording of
Sectio n 6 ( l) (a) replaces "properly used" by "set, used, cleaned or
maintained by a person at work".

Sec/ion 6 (3) is still particularly relevant to contracted services, referring

to the duty of a person who erects or installs a ny article for use at work
in premises where th&t article is to be used by persons at. work. So far as
is reasonably practicable nothing about the way in which the article is
erected or inst.alled s ha ll make it unsafe or a ris k to hea lth .

Sectwn 7 ex presses Lhe duty of eve ry employee at work to la k e

reasonable ca re both for his own health and safely and fo1· that of other
persons who may be affected by his acts or omissions.

This continues by requiring an employe<> to co-operate with his

employer in the fulfilment of any duty or requirements legally imposed
on the employer.

ectwn 8 refers to intentional or reckless imerference with, or misuse of,

anything that 1s legally provided in the interests of health, safety or
welfare.

/I:OTE When neccssar-'. further referenct> be mnde to pnrttcular sccltons of the Act.

41
 APPENDIX5
MECHANICAL HANDLING E Q UIPMENT, MECHANICAL AND
OTHER RISKS ASSOC IATED WITH TESTING

SAFETY RECOMMENDATIONS

TRUCKS Trucks used for loading and unloading in a test area s hould not be
operated during the test. If equipmen t is being tested on a pallet, the
truck sh ould be un loaded so that the pallet rests firmly on the ground.

HOISTS Mechanical hoists with long hand chains a nd slings s hou ld be kept
outside a test area when not in use.

OVERHEAD Overhead cranes should not be permitted to travel or park over a test
CRANES a rea except with the permission of the test engineer. The test engineer
shou ld be responsible for ensuring that. these conditions arc satisfied and
that, when necessary, t he passage of a cra ne over a test area or loading
or unloading within a test area is carried out under his direction.

LOAD Equipment s uch a s res istance banks used for starting or load testing,
RESISTANCES which are known t o get h ot, s h ould be adequately gu a r ded and
ventilated. Such equipment should, if possible, be permanently installed
and s uitably protected. (Arrangements s hould be made, when necessary,
for safe load switching).

UNGUARDE D All dangerous moving parts should be guarded unless safe by position or
MOVING PARTS constru ction. Exposed moving parts s uch as cooling fans s hould be fitted
only if they can be guarded. If unguarded fans must be fitted temporary
ba rrier s s hould be placed so as to prevent access. Unused s haft keys
s hould be removed from s hafts.

SE CURING It is so metimes necessary, and when load testing always necessary, to

secure a machine under lest to a heavy base viz by clamping or bolting.

MOTORISED Fans s h ould be tested in a fenced a rea or barriers erected to prevent

FANS danger from rotating parts. Danger warning signs should be dis played.

APPAREL Ties, loose clothing, rings, necklaces a nd loose bracelets s hould not be
worn in a tes t area. Long ha ir should be restrained.

MAGNETS It. s hould be noted that large electromagnets which a rc energised can
exct"l considerable a nd s udden forces on loose ferrous tools a nd materials
which may be i11 usc, being transported or lying in t he vicinity at the
workplace. Appropriate precautions s hould be taken by an a uthorised
person before high power lifting magnets or similar pl ant arc energised.

42
 APPENDIX6
EXAMPLE S OF OTHER SAFETY, HEALTH AND WELFARE
CONS IDERATIONS APPLYING TO WORK ON SITE

The following list includes other examples of subjects which may require
joint considerations and decisions by the repaire1· a nd the customer when
planning for health safety and welfare:

(1) adequate working space;

(2) maintenance of a safe place of work;
(3) handling and storage areas;
(4 ) safe means of entry and exil for men and materials;
(5) disposal of waste materials;
(6 ) venti lation, for example in respect of fumes from welding or
painting;
(7) fire risks or possible presence of explosive atmospheres;
(8) possible presence of substances which may be harmful to health;
(9) availability of manufacturers' drawings, operating and
maintenance instructions;
( 10) mechanical isolation and venting, draining and purging of
pipework. ducts and vessels;
(11) messing and sanitary facilities;
(12J procedur!'s for testing and •·ecommissioning plant. t.hat. has been
repaired;
Cl3l excessive noise.

APPENDIX 7
ABBREVIATION
ac Alternating cu1Tent HSW Act Health and Safely al
Work etc Act 1974
BS British Standard
HV High voltagt'
BSI British Standards
Tnsli lution lEE lnstituLion of Electrical
Engineers
CIBS Chartcrl.'d Institute of
Building Services k\' IGiovolt

CB Ci rctnt breaker LV Low ,·oltage

de 0 11·ec l tu rre n t mA 1\Jilliamperes

ELCB Earth leakage circui t MCCB Moulded case ci rcuit

breaker breaker

FS FusC' switch RCD Residual current device

HMSO Her l\laJesty's Stationery EAW The Electricity At Work

Offic<• Regulations Regulations 1989

HSE Health and Safety \' Voltage

ExecutJvl.'

43
 APPENDIXS
COMMUTATOR AND SLIPRlNG MAINTENANCE BY THE USE
OF HAND HELD STONES OR GRINDING TOOLS

Although this process cannot be termed testi ng the following advice and
gujdance is included in this Code in the interest of safety.

Resurfacing stones a re often used , chiefly on site, to restore grooved or

scored collector su rfaces by the minimum removal of metaL

AJso brush bedding s tones are often used to bed new carbon brushes to a
commutator surface. Both are referred to below as grinding processes.

Subject to appropriate precautions it may be safe to use grinding stones

on live commutators and sliprings whilst an electrical mach ine is
rotating under its own power. H is s afer, however, to work on dead
collectors if possible by bringing the machine up to speed, switching off
and allowing it to coast to standstill over repeated grinding cycles.

Work on live collectors operating at. voltages in excess of 250V de should

not be attempted.

Some s uggested precautions to minimise the risk of inJury when

u sing hand h eld t ools

* Adequate prio1· training

R unn i ng the m achine at. as low a voltage and speed as is

practicable

Selling overload protection as low as is practicable

Using rubber gloves and safely glasses as hand and eye protection

* Using a rubber mal as temporary Ooor insulation

* Insulating a brush arm t.empo1·arily as a support. for a grinding

st.one

Using a respirator during grinding operations

.... * Using well-made proprietary tools with insulating properties or

with insulated handles

* Selecting stones with C01-rect size, shape and grit to suit the surface
and speed of the colleclor being restored

* Driving the machine from another power source

* Using accompanied working

Switchi ng off machines with sufficient kinetic energy to allow

grinding whilst. coasting down from full speed.

14
 Remember-
Electric shock can be fatal. If safety
is in doubt, switch off and seek advice

AEMTLtd
St Saviours House
Published St Saviours Place
YORK YOI 7PJ
Tel: 01904 674899
Fax: 01904 674896
'!:> A£MT Fobru•ry 1991