ONLINE INDUSTRIAL SAFETY

CERTIFICATION PROGRAM

Faculty : Ravi Prakash, Manager Safety

Road and Rail, Tata Steel
 Session Schedule
# Course Topics Faculty Date
0 Orientation Sukesh Jha 05-07-2025
1 Safety Management System (Part -1) Sukesh Jha 11-07-2025
2 Factories Act 1948 Sunil Kumar 19-07-2025
1.1 Safety Management System (Part -2) Sukesh Jha 25-07-2025
3 Electrical Safety Ravi Prakash 01-08-2025
4 Construction Safety Bijay 08-08-2025
5 Hazard Identification and Risk Assessment Vishal Srivastav 15-08-2025
6 Gas Cutting and Welding Safety Abhishek Kumar 22-08-2025
7 ISO 45001 Rishi 29-08-2025
8 Fire Safety in Industries Abhay Ranjan 05-09-2025
9 Safety in Working at Height Ved Prakash 12-09-2025
10 Positive Isolation and Work Permit Pratik 19-09-2025
11 Chemical Safety and Confined Space K P Sarkhel / Sudip Saha 26-09-2025
12 Rail and Road Safety Binesh Shaw 03-10-2025
Module 3
Electrical Safety
2 Agenda

5
 Hazard and Electrical Hazard

•Hazard : any potential or actual threat to the wellbeing of people, machinery or environment.

•Electrical Hazard : taking precautions to identify and control electrical hazards.

The electrical installations for medium, high
and extra high voltage should have a danger
notice
 Electrical Hazards

Hazards:
• Electric shock and burns from contact with live parts
• Injury from exposure to arcing
• Fire from faulty electrical equipment or installations
• Explosion caused by unsuitable electrical apparatus

Mitigation Steps:
• Regular electrical safety audits
• Proper electrical design and zone classification
• Ensure a safe environment
• Following NFPA 70 standards or Indian electrical rules
 Cause of Electrocution Fatalities

Electrical hazards exist in almost every workplace. Common causes of electrocution are:
- Contact with Overhead Power lines

- Contact with Live Circuits

- Undertaking maintenance on live equipment

- Not following Lock/Tagout procedures

- Poorly Maintained Extension Cords

- Working with damaged electrical equipment, such as extension

leads, plugs and sockets

- Defective Power Tools

- using equipment affected by rain or water ingress

 Electrical Injuries

There are three direct and two indirect types of electrical injuries:
Direct:
➢Electrocution or death due to electrical shock
➢Electrical shock
➢Burns
Indirect:
➢Falls
➢Fire
 Shock Severity

Severity of the shock depends on:

- Path of current through the body
- Amount of current flowing through the
body (amps)
- Duration of the shocking current through
the body

LOW VOLTAGE DOES NOT MEAN LOW

HAZARD
 Overhead Power Lines Hazard

• Usually not insulated

• Examples of equipment that can

contact power lines:
✓ Crane
✓ Ladder
✓ Scaffold
✓ Backhoe
✓ Scissors lift
✓ Raised dump truck bed
✓ Aluminum paint roller
 Tools and Devices to be made available in
Electrical Room
1 2
5 6

3 4 1. Kool Koat
2. Safety Gloves
3. Electrical Overshoes
4. Safety Belt
5. Power Tester
6. Earthing Device
One point Lesson : Electrical Safety Communication
on Hand Gloves
 What should not be done?
- Do Not wear loose clothing, metal watch straps, bangles or finger rings while working on Electrical
Appliances

- The Electrical installations for high and extra high voltage shall have a
running tap water and in case of electric burns , the burnt portion should be
cooled down using water.
Service water should not be used only drinking water
- No high and extra high voltage system/switchgear which has been
disconnected , for 6 months of more for any maintenance job should be
energized without testing and written clearance by testing department
 What should not be done?

- Records of all tests, repairs, maintenance work of all electrical

Equipments should be kept in registers.

- Precautions against auxiliary's circuits : Precautions to be taken to ensure

that control circuits to equipment are disconnected from the
supply before work

- Don’t attempt to disengage a person in contact with live apparatus

without standing on rubber mat or dry board.
- Don’t touch his body, use dry wood/ insulated rod
 What should not be done?

- Power testing not to be carried out on moving Equipments such as EOT cranes, oven machines in
coke oven, loco etc as there are chances of flash over due to sudden jerk in the testing leads. Proper
clearance to be taken to ensure that Equipments stand still while working.

- No work to be carried out in panel exposed to 415-volt supply

 What should be done?

- Make sure that voltage transformer is dead and isolated before it is examined. Care to be taken to
ensure that transformer is not liable to be live due to feed back via the secondary side

- Earthing of equipment to be done as per standard eg; Every earthing system

shall be tested for its resistance to earth on a dry day not less than once a year

Lead Acid Battery Rooms

- The battery rooms should have the explosion proof lighting,
exhaust fan and acid-resistant floors
- Lead acid battery rooms should have one packet of lime (1/5 kg)
permanently to neutralize leaked acid
 What should be done?

Artificial Respiration
- In every high and extra high voltage sub section, an artificial respirator to be provided. Do
not discontinue artificial respiration until recovery or death declared by doctor. It may take
even more than 2-3 hours for recovery

Fuse

- When removing the fuse, pull out the supply end first and during replacing , the supply end
should
be put last.
- No attempts to be made to rewire a non-wire able fuse
- Switch Fuse Unit (SFU) to be discarded if phase barrier are found damaged
- Fuse should be replaced with original make and should not be interchanged
 What should be done?
MCCB ( Molded Case Circuit Breaker )used in Motor feeder shall have auxiliary contact for
tripping of contractor in case of MCCB tripping

1. After switching off the isolator no live parts shall be exposed in the MCC (Motor Control
Centre ) module . If it is so it shall be replaced.
2. Under trickle charging conditions stratification of the electrolyte can occur and it is
recommended that at intervals of approximately 2 years the batteries should be charge and
discharge cycle, alternatively a boost charge to ensure its reliable operation

Circuit Breaker

1. Racking -in and Racking -out of breakers having isolating

contacts in vertical plane are very risky and these breakers shall
be racked –in or out under protection plasma shield & Kool coat
or through Tele –breaker racking device
 Checklist for Electrical Accident

1. Do not touch a person who is in a live circuit.

2. Disconnect the power supply as soon as possible.
3. Outside, you can use a wooden stick to push the accident victim off a wire only if you
are sure, it is a low voltage network. If you are not sure what type of network it is, call
112 and wait for help.
4. There is a danger of electric shock in a radius of eight metres from the place where a
medium voltage network wire touches the ground; in damp conditions, for example if it
is raining or if the grass is wet, the dangerous area is larger and can be up to 20 metres.
5. If there is an accident indoors you can use long dry wooden objects like a broomstick or
a stool leg as insulators.
6. If people get hurt in an electrical accident, call the 112-emergency number immediately.
7. When you have called for an ambulance and removed the person from the live circuit,
give as much first aid as you can.
 Electrical Shock can be avoided

Follow the recommended practices listed below. Faulty installation, improper grounding, and incorrect operation and maintenance of
electrical equipment are always sources of danger.

1. Ground all electrical equipment and the work piece. Prevent accidental electrical shocks. Connect power source, control
cabinets, and work piece to an approved electrical ground. The work lead is not aground lead. It is used to complete the welding
circuit. A separate connection is required to ground the work(illustrated on p. 5); or the work lead terminal on the power source
may be connected to ground. Do not mistake the work lead for a ground connection.
2. Use the correct cable size. Sustained overloading will cause cable failure and result in possible electrical shock or fire hazard.
Work cable should be the same rating as the torch cable.
3. Make sure all electrical connections are tight, clean, and dry. Poor electrical connections can heat up and even melt. They can
also cause bad welds and produce dangerous arcs and sparks. Do not allow water, grease, or dirt to accumulate on plugs,
sockets, or electrical units.
4. Keep dry. Moisture and water can conduct electricity. To prevent shock, it is advisable to keep work areas, equipment, and
clothing dry always. Fix water leaks immediately. Make sure that you are well insulated. Wear dry gloves, rubber-soled shoes, or
stand on a dry board or platform.
5. Keep cables and connectors in good condition. Improper or worn electrical connections can cause short circuits and can
increase the chance of an electrical shock. Do not use worn, damaged, or barecables.
6. Avoid open-circuit voltage. Open-circuit voltage can cause electric shock. When several welders are working with arcs of
different polarities, or when using multiple alternating-current machines, the open-circuit voltages can be additive. The added
voltages increase the severity of the shock hazard.
 Elements and Atoms
Every known substance –solid, liquid or gas is composed of elements
•An atom is the smallest particle of an element that retains all the properties of that element
•Each element has it’s own kind of atom
ATOMS
Inner part composed of protons & neutrons
Outer part composed of electrons
Protons = positive charge
Neutrons = no charge
Electrons = negative charge

• Each element has a definite number of

electrons and the same number of protons
• They are oppositely charged and therefore
attract each other. This tends to hold the
Electrically Balanced Atom electrons in orbit around the atom.
 Elements and Atoms
Every known substance –solid, liquid or gas is composed of elements
•An atom is the smallest particle of an element that retains all the properties of that element
•Each element has it’s own kind of atom
ATOMS
Inner part composed of protons & neutrons
Outer part composed of electrons
Protons = positive charge
Neutrons = no charge
Electrons = negative charge

• Each element has a definite number of

electrons and the same number of protons
• They are oppositely charged and therefore
attract each other. This tends to hold the
Electrically Balanced Atom electrons in orbit around the atom.
FREE ELECTRONS
• Some atoms are easily moved out of orbit
• The ability to move or flow is the basis of current electricity
• If channeled in each direction, a flow of electrons occurs ---when flowed through a
conductor it is dynamic electricity

ELECTICAL MATERIALS
• CONDUCTOR –contains many free electrons ---gold, copper, silver, aluminum
• INSULATOR –contains few free electrons-Usually non-metallic such as wood,
rubber, glass, etc
Thank You