Europe Materials , September 2011

Electrical Safety
Guidance Note

This guidance note is intended to act as a template for each country / company to draw up their
own internal guidance in consultation with their in house or external electrical specialist . This
will allow country specific issues such as national legislation and national supply voltages
(which differ across the division ) to be assimilated into specific company guidance .

A suggested checklist is included at the back of this guidance . These may be of use for each
company when drawing up their own checklist as a means of formal follow up to the 2 recent
fatal accidents involving electricity

This guidance relates to portable and transportable electrical equipment . This covers
equipment that is not part of a fixed installation but is intended to be connected to a fixed
installation by means of a flexible cable and either a plug and socket or a spur box or similar
means . This guidance also applies to equipment likely to be moved when connected to a
supply
Fixed plant should have permanent and efficient earthing in accordance with national
legislation.

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 Contents

Section 1: Deals with portable and transportable heavy duty plant

Section 2: Deals with portable equipment including cables and extension leads

Section 3 : Deals with a number of issues

Use of voltage testers including multimeters to confirm that a circuit is no longer

live
Control of access to electrical switchrooms

Points to Note :
1. An RCD or similar device is only part of a collective solution which
includes , regular inspections by competent persons , armoured
cabling (for heavy duty plant , see section 1 ) , regular inspections
by competent person , Insulation for portable electrical equipment
(see section 2) and protection of damage/exposure to cables in the
first instance

3. The use of Isolation procedures , effective earthing and risk

assessment remain the principal risk control measures in the use
and maintenance of any electrical equipment

Photo 1: A digital multimeter

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1. Portable , transportable heavy duty plant (400V , 3 phase )

Key Requirements
1. The use of Isolation procedures , inspection and risk assessment remain the principal risk
control measures in the use and maintenance of any electrical equipment.

2. Installation , disconnection and Inspection of such equipment must be carried out by

competent persons

3. An RCD system should be fitted

Nuisance tripping must be resolved through technical investigation or the fitting of an RCD
to individual circuits :

Possible causes of nuisance tripping (which should be investigated )

- Currents from items with poor or lowered insulation resistance

- where a number of circults are connected to the same RCD
- a large number of small burden currents
- earth leakage from the device in question

4. Armoured cables or equivalent must be used where cables can be damaged by impact or
moving vehicles- where required , cables can be ducted underway areas where mobile plant
may be moving (see photo 3 )

5. All distribution cables which carry 400V should be of a type which has a metal sheath and/or
armour which is continuous and effectively earthed .

6. Where extension leads are used , they must be of the 3 core construction having a separate
protective (earth) conductor .

7. A regime of regular inspection must be in place , including each time the plant is moved

Photo 2: MCCB system installed on pre-

homgenisation hall stacker cable

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 Photo 3 : Supply cables running under an
access road to a mobile crushing operation

2. Portable Tools

Key Requirements
.

8. Battery powered should be used where possible ( see photo 9 ) . Pneumatic tools can be
used for certain activities e.g tightening of bolts on crusher housing etc.

9. For portable electric tools , the 110 V centre-tapped (CTE) system is recommended . The
following particular situations should have mandatory requirements :

Portable hand-held lamps for use in confined or damp situation , should not exceed
25V single phase
Other Hand held lamps : 50V

Often portable equipment is available that is powered from a 110 volt supply through a
simple transformer and these are often centre tapped to earth so that the maximum voltage
between a live conductor and earth (the most common cause of electric shocks from
equipment) is limited to 55V.

10. As a minimum all 220 Volt equipment must be double insulated and have RCD protection
(fitted at the point of supply) . For 220V systems only the appropriate blue industrial plugs
should be used

11. RCDs must be fitted for all portable tools connection points (greater than 110V)

12. An Inspection regime for the inspection of cables/extension leads must be in place at each
operation .

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 Photo 4 : A selection of site and
power tool transformers : 240V
(step down ) to 110 Volt site
electrical transformers with
integrated power breakers to
protect against electric shock

Photo 5: An example of
damaged cabling

Photo 6 : 13 amp, 30 mA RCD

for use with 16a type plugs.

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 Photo 7 : Inverter arc welder
uses 400 volt 16 amp 30 mA
RCD.

Photo 8 : Heavy duty

110V extension lead

Photo 9 : Battery powered

portable tools

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3. Other Issues

The use of Isolation procedures , inspection and risk assessment remain the principal risk
control measures in the use and maintenance of any electrical equipment.

Key Requirements
13. All maintenance work on electrical systems must be based on electrical isolation
procedures and risk assessment .

14. As a secondary risk control measure , confirmation that a circuit is isolated can be
verified through the use of voltage testers . see photos below.

15. Live working : In practice there are very few occasions when work cannot be carried
out with the equipment dead . If live work such as diagnostic testing is required to be
carried , safe working procedures incorporating :

Use of competent people

Prevention of accidental contact
Checks on the suitability of test equipment and tools
Use of temporary barriers , insulating screens
Use of insulating mats and protective clothing

16. Access to electrical switchrooms must be controlled and restricted (locked) to authorised
personnel . Tasks such as the resetting of thermal relays must be carried out by a
competent person .

Photo 11: A digital

multimeter

Photo 10: a digital electrical

tester

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 (Suggested ) Location Checklist
1. Electrical Isolation procedures reviewed with electrical staff in light
of fatal accidents at Dycore and CRH US. ? ____

2. Consultation with electrical contractors (working at your location) on recent

fatal accidents (electrical ) completed (including portable electrical tools) ? ____

See also points 15 to 17 below

Heavy Duty Portable/Transportable electrical equipment

3. Systems in place to ensure that a competent electrical person plans and

supervises the installation , disconnection and inspection of heavy duty
portable and transportable electrical machinery? ____

4. RCDs fitted ?

5. System in place for testing of RCDs ? ____

6. Armoured cables or equivalent in place where damage is likely ? ____

7. System in place for inspecting same ? ____

8. Last inspection date ? ____

Portable equipment

9. 110V supply in use for portable electric tools ? ____

10. RCDs fitted to all supply outlets for portable tools (greater than 110V)? ____

11. System in place for testing of RCDs ? ____

12. If electric hand held lamps are used for confined space work are they 25V ? ____

13. All other hand held lamps 50V ? ____

____
14. System in place for inspecting portable electrical equipment , leads and extension leads
(including contractors) ? ____

Other Issues

15. All electricians issued with a multimeter or equivalent ? ____

16. All contract electricians mandated to carry and use a multimeter (or equivalent )
where appropriate ? ____

17. Access to electrical switchrooms controlled and restricted (locked) ? ____