HSEQ CORPORATE STANDARD
ELECTRICAL SAFETY MANAGEMENT
SYSTEM
Reviewed:
Document Ref:
Approved by:
July 2012
70120/HS4/Electrical Safety
Management system/4
Darren Broadhead H&S Dept
Contents
1. Purpose
2. Scope
3. Responsibilities
4. Requirements
4.1 Management structure
4.2 Recruitment
4.3 Key skills, knowledge, experience tasks and objectives
4.4 Working rules
4.5 Design and installation
4.6 Inspection and testing
4.7 Reporting and defect rectification
4.8 Monitoring, inspection and audit
5. Records
6. Appendix
7. References
8. Definitions
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1. Purpose
1.1 The purpose of this standard is to minimise the risk of injury to persons
from electricity.
1.2 To specify Aggregate Industries requirements for compliance with Holcim Fatality
Prevention Element 4.
2. Scope
2.1 The standard applies to all Aggregate Industries owned, leased or managed sites
and to all Aggregate Industries managed operations.
2.2 This standard applies to activities being undertaken by the following personnel:
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Employees,
Sub Contractors,
Third Party Workers, and
Members of the public.
2.3 This standard supersedes CPR 529 Electrical Safety Management System
Revision 3.
2.4 Where this standard is to be complied with in EU and non EU countries, all
references to UK legislation shall be ignored and the legislation of that country shall
be used.
2.5 Where reference is made to Standards (BS, EN and ISO), these shall be used in
EU and non EU countries where they have been adopted.
2.6 Where for any reason it is not possible to comply with any aspect or requirement
of the Standard the site manager must raise the matter through their line manager
and propose to their Director, an alternative means of compliance. Any such
alternative would be authorised by that Director, having satisfied themselves that the
alternative offers an equivalent level of protection under those particular
circumstances.
2.7 This Standard does not detail all of the requirements for rail and shipping
businesses. Relevant legislation and guidance shall be used for those businesses in
conjunction with this standard.
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H&S Team/Senior Electrical
Engineer
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Site/Office/ Contracts
Manager
Foreman
Ensuring that the electrical supply details
to the site are documented.
Ensuring all inspections and tests as
outlined in the standard are carried out.
Ensuring that the defects highlighted by
inspections and tests are rectified and
closed out as outlined in the standard.
Ensuring electrical installations are
carried out in line with this standard.
Where applicable ensure that electrical
support receives adequate training to
enable them to carry out their duties.
Ensuring electrical line diagrams are
produced and kept up to date.
Communicating the relevant sections of
this standard to all persons required take
part in activities requiring the isolation or
locking off of equipment.
Provide clear instructions to all personnel
relevant to this standard in a form
appropriate for their needs and
Supervisor
Ensuring a list of appointed staff is kept
at the site.
Area/ General Manager
Embedding this standard within each
individual business.
Ensure adequate and competent
resource is available to meet the
requirements of this standard.
Ensure all sites are designed, organised
and managed so that personnel can work
safely with electricity.
Ensuring all persons working on
electrical equipment and installations are
competent and authorised.
Director/ Functional head
Key
R – Responsible
A – Accountable
C – Consult
I - Inform
Employee/ Sub Contractor
Third party
3. Responsibilities
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purposes.
Monitoring those procedures to ensure
they are working effectively.
Follow all safe system of work and use
equipment and control measures
provided.
Report any equipment defects or safety
concerns.
Review and Audit.
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4. Requirements
4.1 Management structure
4.1.1 To comply with the requirements of Health and Safety Legislation, the
management structure must identify the persons or organisations responsible for
ensuring that electrical systems are safe. At each site, the site manager shall have
access to nominated competent persons (recorded using Appendix 1), the purpose
of which is to ensure that electrical systems are properly designed, installed,
operated, maintained (including inspection and test). These persons include:
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Senior Electrical Engineer,
Site Manager,
Site Electrical Support,
Additional Electrical Support (where applicable),
Competent person for thorough inspection and test of fixed low voltage
equipment,
Competent person(s) for 6 monthly visual inspection of fixed low voltage
equipment,
Competent person(s) for inspection and test of portable appliances,
Competent person(s) for inspection and test of safety equipment including
Isolators, e-stops, safety interlocks and RCD’s,
Site high voltage senior authorised person (where applicable),
Competent person(s) for operation of high voltage equipment (where
applicable), and
Competent person(s) for maintenance of high voltage equipment (where
applicable).
4.1.2 In addition to the nominated persons in section 4.1.1. Other competent
persons may be authorised to work on electrical systems. These include but are not
limited to:
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Electrical installation sub contractors / third party workers,
Competent Person to carryout testing of portable appliances,
Competent Person to reset overloads and protective devices,
Competent Person to work on high voltage equipment (under the direct
supervision of a Senior Authorised or Authorised Person),
 Competent Person to install low voltage equipment, and
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 Competent person to enter switchrooms /substations.
4.1.3 All persons working on electrical systems shall be authorised in writing by the
site manager using Appendix 2.
4.2 Recruitment
4.2.1 The recruitment of employees and sub contractors / third party workers
required to perform electrical work must ensure:
 Suitable criteria for medical fitness and health of personnel. For employees
this will be the Aggregate Industries occupational health programme. For
sub contractors / third party workers a suitable programme shall be used.
 Personnel, who design, inspect, maintain and repair electrical installations
and equipment hold appropriate qualifications,
 Competency assessments shall be carried out to ensure electrical support
personnel are competent to design, install, inspect, maintain and repair
electrical installations and equipment. The system shall also include an
appointment letter for authorised persons and training requirements,
 Competence reports and appointment letters shall be retained within this
standard,
 Re-assessment of competencies within a period not exceeding 3 years. This
may include a requirement for recertification if issues are highlighted in the
competence report,
 All Electrical Support personnel shall receive training on electrical safety as
part of their induction, and
 All records on training provided and the results of competency assessments
performed will be retained for a minimum of 12 months after the
completion of the employee’s term of employment.
4.2.2 Some specialist companies, third party workers / subcontractors that carry out
work on electrical systems may be exempt from the competency assessment
programme due the nature of the work or high level of skill required to carry out the
work. These companies must still be authorised to work on site as required in this
standard. This includes:
 High voltage third party workers / sub contractors who carry out
maintenance, inspection and repair,
 National low voltage inspection and test third party worker / sub
contractor,
 Original equipment manufacturers electrical personnel,
 Control system designers and installers, and
 Equipment service engineers.
4.2.3 These competency assessments are conducted under the approval of
Aggregate Senior Electrical Engineer, using Appendix 17.
4.3 Key skills, knowledge, experience, tasks and objectives.
4.3.1 All persons working with or on electrical systems must have core skills,
knowledge and experience. These include but not limited to:
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 Health and Safety training relevant to the site,
 Risk assessment and method statements,
 Qualified to BTEC, C&G or higher. Lower qualifications may be accepted if
demonstrated through experience and the assessment process,
 For low voltage systems knowledge of the IEE Wiring Regulations BS7671
17th Edition in relation to design, protection, installation practices,
verification, inspection, testing, reporting and certification,
 Planned preventive maintenance,
 Motor control including soft starting, isolation, interlocking, emergency
stopping, safety relays, PLC controls,
 Live working concepts,
 Isolation procedures,
 Testing and inspecting of portable appliances (where applicable),
 For high voltage systems attended a recognised training course on
operation and maintenance of high voltage equipment in the previous 5
years,
 For high voltage systems be a senior authorised or authorised person,
 For high voltage systems be experienced in high voltage engineering and
have experience of the equipment and systems used at the site, and
 For the Senior Electrical Engineer and where applicable the Regional
Electrical Engineer. Be an experienced Chartered/ Incorporated Electrical
Engineer or an Electrical Engineer having the necessary skills and expertise
and operating at a level equivalent to that of a Chartered Electrical
Engineer/Incorporated Engineer.
4.3.2 All persons working with electrical systems shall have key tasks and objectives
established. These include but are not limited to.
4.3.2.1 Senior Electrical Engineer:
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Provide an oversight of electrical matters and provide guidance on health
and safety, changes to legislation and technical matters to Company
Directors, Regional, Area and Site Managers, the Head of Health and
Safety and Senior Health and Safety Advisors,
Monitor and review arrangements for electrical safety,
Design, amend and implement company standards, policies and
procedures relating to electrical safety and engineering,
Assess and review the competence of employees, sub contractors / third
party workers dealing with electrical systems and give advice on
authorisations of persons,
Act as the Authorising Engineer for Senior Authorised Persons,
Advise the Site Manager on the authorisation of relevant company
employees, sub contractors / third party workers,
Together with Management, represent the company when contacting the
HSE, DTI and other relevant agencies,
As required assist with incident investigations,
Advise on the management of high voltage systems,
Carry out audits of the condition of the electrical systems, and
Audit the results of the written scheme of examination, inspection and
testing and of actions necessary to remedy any reported deficiencies and
defects.
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4.3.2.2 Regional Electrical Engineer (where applicable):
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Assist the Senior Electrical Engineer with designing, amending and
implementing company standards, policies and procedures relating to
electrical safety and engineering,
Advise regional and site management on compliance with current
legislation and provide advice and guidance on electrical matters,
Assess and review the competence of employees, sub contractors / third
party workers dealing with electrical systems and give advice on
authorisations of persons within his region,
As required assist with incident investigations,
Where requested by a site manager, manage high voltage systems,
Carry out audits of the condition of the electrical systems, and
Audit the results of the written scheme of examination, inspection and
testing and of actions necessary to remedy any reported deficiencies and
defects.
4.3.3.3 Site Electrical support (employee, sub contractor / third party worker):
 Undertake electrical work in accordance with UK legislation and Aggregate
Industries standards using the safe working procedures set out in
Aggregate Industries policies, procedures and instructions,
 Ensure that all persons under his control are competent and authorised by
the site manager for work at the site,
 Ensure that adequate assessment of risks are made before work under
his control is undertaken,
 To receive and action in a priority agreed with the site manager, the
defects and deficiencies set out in the results of the portable appliance
tests and inspection and tests of the fixed low voltage installation,
 Maintain all diagrams, circuit schedules and other information,
 Carry out all portable appliance testing (where required) in accordance
with the Aggregate Industries specification,
 Carry out inspections and tests of fixed electrical equipment and
installations in accordance with UK legislation and Aggregate Industries
specification,
 Immediately report, in writing to the site manager, all defects which could
result in either a serious risk of personal injury, fire or a breach of
statutory requirements, and
 Ensure all documentation specified in this standard is kept up to date.
4.3.3.4 High voltage engineer and or installation engineer (employee, sub contractor
/ third party worker):
 Undertake electrical work in accordance with legislation and Aggregate
Industries standards using the safe working procedures set out in
Aggregate Industries policies, procedures and instructions,
 Carry out all operational switching of high voltage switchgear, including
isolation, earthing and releasing for work,
 Ensure that adequate assessment of risks are made before work under
his control is undertaken,
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 Ensure that all persons under his control are competent and authorised by
the Site Manager for work at the site,
 Issue and receipt safety documents Permits to Work, Sanctions for Test
and Limitation of Access,
 Carry out high voltage planned preventive and post fault maintenance,
and
 Ensure all work undertaken is inspected and tested and all documentation
is handed over the site manager before the installation is handed over.
4.3.3.5 Electrical installation sub contractors / third party workers:
 Undertake electrical installations in accordance with legislation and
Aggregate Industries standards using the safe working procedures set out
in Aggregate Industries policies, procedures and instructions,
 Ensure that all persons under his control are competent and authorised by
the site manager for work at the site, ensure that adequate assessment
of risks are made before work under his control is undertaken, and
 Ensure all work undertaken is inspected and tested and all documentation
is handed over the site manager before the installation is handed over.
4.3.5 Low voltage inspection and test sub contractor / third party worker:
 Report within specified time limits,
 Carry out inspections and tests in accordance with legislation and
Aggregate Industries inspection and test specification,
 Immediately report, in writing to the Site Manager, all defects which could
result in either a serious risk of personal injury, fire or a breach of
statutory requirements,
 Issue a report of the completion of the tests, the report form to be in a
format agreed with the Aggregate Industries, and
 Agree with the Site Manager or senior person on site any limitations of
the inspection and test.
4.3.6 Competent Persons include but not limited to.
4.3.6.1 Competent Person to carryout testing of portable appliances:
 Carry out all portable appliances testing (where required) in accordance
with the Aggregate Industries portable appliance testing specification.
4.3.6.2 Competent Person to reset overloads and protective devices:
 Reset overloads and other protective devices in line with risk assessment
RIS12 and on equipment identified in the limitation of access part of the
authorisation.
4.3.6.3 Competent Person to work on high voltage equipment (under the direct
supervision of a Senior Authorised or Authorised Person):
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 Carry out work on high voltage equipment which may include cable repair
and/or cable jointing, taking oil samples and installation and maintenance
work under the direct supervision of a Senior Authorised or Authorised
Person.
4.3.6.4 Competent Person to install low voltage equipment:
 Carry out installation work on low voltage equipment which may include
cable tray and or cable handling systems, cables and motor control panels
under the supervision of an authorised electrician.
4.3.6.5 Competent persons to enter switchrooms:
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A competent person to enter switchrooms and substations to take
readings from meters and instruments and other duties that are none
electrical as set out in the limitations of the authorisation.
4.4 Working rules
4.4.1 All work will be carried out in accordance with Aggregate Industries electrical
safety rules (Appendix 13). The safety rules must be made available to all
employees, sub contractors and third party workers who must be familiar with the
requirements set out in the rules.
4.5 Design and installation
4.5.1 All work will be carried in accordance with UK legislation and Aggregate
Industries Standards for New Electrical Equipment and Installations (Appendix 15).
4.5.2 All sites must have details of the electricity supply to the site and record this
using Appendix 3.
4.6 Inspection and testing
4.6.1 The inspection and test specifications describe the frequencies and
requirements for the inspection and tests of fixed low voltage equipment, portable
appliances, functional tests of electrical equipment and high voltage equipment
(where applicable) for the site (See Appendix 9, 10, 11 and 14).
4.6.2 All inspections and tests shall be undertaken by competent persons as outlined
in this standard. Appendix 5, 6, 7 and 8 provide inspection templates.
4.7 Reporting and defect rectification
4.7.1 Following the completion of a new, additional or modified electrical installation,
the installation shall be inspected and tested before use and an electrical installation
completion certificate or a minor electrical installation works certificate shall be
completed by the person responsible for the installation. Also, where required all
schematic diagrams, equipment registers and test schedules must be amended.
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4.7.2 Electrical installation certificates and minor work certificates for low voltage
installations must be set out in accordance with IEE Wiring Regulations BS7671 17th
Edition. They shall be supplied to Aggregate Industries on completion of the works
and the certificates shall be retained.
4.7.3 Inspection and testing reports of low voltage fixed electrical equipment and
installations shall be in the same or similar format as those contained within the IEE
Wiring Regulations BS7671 17th Edition. 4.7.4 An emergency report of code 1 and
code 2 defects shall be issued to the site on the day they are identified and before
the engineer surveyor leaves site.
4.7.5 Reports on the inspection and testing of low and high voltage equipment and
portable appliances shall be supplied to Aggregate Industries within 10 days of the
inspection being completed.
4.7.6 Where required in this standard defects shall be recorded and defect action
reports (Appendix 4) shall be used to record the following:
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Defect code,
Defect description,
Remedial action taken,
Completion date,
Date completed, and
Name and signature person completing the remedial action.
4.8 Monitoring, inspection and audit
4.8.1 A review of this standard, risk assessments, SSOW and procedures, to include
the effectiveness of corrective actions must be carried out, especially following any
changes in tasks, operation or legislation and as a minimum there must be an annual
review carried out. Appendix 16 should be used to conduct this annual review.
4.8.2 Routine safety tours and audits must be performed to verify the quality and
effectiveness of the requirements set out in this standard, including but not limited
to:
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Ensuring all inspections and tests set out in this standard are being
carried out including defect rectification,
Verification of the quality of the risk assessments,
Ensuring all authorisations and lists of nominated staff are up to date,
Compliance to training and competency requirements, and
Feedback and reporting requirements.
5. Records
5.1
5.2
5.3
5.4
5.5
List of appointed electrical staff
Authorisations of persons
Competence reports and appointment letters
Details of the electricity supply
Current inspection and test results for fixed low voltage electrical equipment
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5.6 Defect action reports
5.7 Emergency reports from Inspection and Test Contractor
5.8 Twelve monthly low voltage routine visual inspection form
5.9 Completion certificates for new installations
5.10 Six monthly inspection and test of isolators form
5.11 Three monthly functional tests of RCD’s form
5.12 Functional tests of plant safety devices
5.13 Portable appliance register
5.14 Portable appliance inspection and test reports
5.15 High voltage switchgear maintenance report
5.16 High voltage transformer maintenance report
5.17 Transformer oil sample test reports
5.18 Twelve monthly high voltage routine visual inspection form
5.18 Diagram of high voltage systems (where applicable)
5.19 Diagrams of low voltage systems
5.10 Annual Review
6. Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
Appendix
1 List of appointed staff
2 Authorisation of persons,
3 Details of the electricity supply
4 Defect action report form
5 Six monthly low voltage routine visual inspection form
6 Six monthly inspection and test of isolators form
7 Three monthly functional tests of RCD’s form
8 Twelve monthly high voltage routine visual inspection form
9 Specification for inspection and test of fixed low voltage systems
10 Specification for inspection and testing of portable appliances
11 Specification for inspection and test of safety equipment
12 Generic risk assessments
13 Electrical safety rules
14 Specification for inspection and test of high voltage systems
15 Standards for New Electrical Equipment and Installation
16 Compliance audit
17 Competence report and appointment letter
7. References
The Electricity at Work Regulations 1989 and memorandum of guidance
Supply of Machinery (Safety) Regulations (amendment) 2011
Electrical Equipment (Safety) Regulations 1994
The Electricity Safety, Quality and Continuity Regulations 2002
IEE Wiring Regulations BS7671 17th Edition and associated guidance notes
HSE Guidance - Electrical Safety in Quarries
Electricity at Work: Safe working practices - HS (G) 85
Electrical Test Equipment for Use by Electricians - GS 38
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8. Definitions
Quarry site - All quarry process and loading plants or other process plants, such as
asphalt and concrete plants that are physically connected by process to the quarry
plant and/or the aggregates used in the process are directly fed by conveyor or
feeder from the quarry plant.
Non quarry site - All other process plants, sites, laboratories, workshops, welfare
facilities and offices whether they are standalone or standalone on a quarry site.
Supply Voltage - The supply voltage to the Aggregate Industries site from the
electricity supply company or from another electricity supply or supplier.
High Voltage - Any voltages in excess of 1000V, voltages commonly used are
3,300V, 6,600V and 11,000V.
Low Voltage - Any voltages between 50V – 1000V, voltages commonly used are
110V, 230V and 400V.
Extra Low Voltage - Any voltage less than 50V including supplies derived from
batteries.
Control Voltage - The supply voltage to the control circuit actuators of machinery.
Electrical Installation - An electrical installation means the total connected system
at any site and includes all fixed and portable equipment at all voltages.
Fixed Equipment - Fixed equipment means all electrical equipment permanently
installed with a fixed connection to a source of supply and includes all switchgear,
cables, motors, lighting and sockets. Fixed equipment also includes mobile crushing
and screen plants, electrically powered paving equipment and other electrically
powered mobile equipment used within Bardon Contracting.
Portable and Transportable Equipment - Portable and transportable equipment
(appliances) means all electrical equipment which is or can be connected to a source
of supply by a cable connected to the appliance and terminated by a plug. Portable
equipment or appliances include but not limited to drills, angle grinders, welding
machinery, pressure washers, catering equipment, domestic type equipment and IT
equipment.
Live - Live means electrically charged or capable of becoming charged and a
potential source of danger.
Dead - Dead means equipment at or about zero voltage, disconnected from all live
systems and not charged.
Isolated - Isolated means the disconnection and separation of electrical equipment
from every source of electrical energy in such a way that the separation and
disconnection is secure. Isolation includes locking off at all sources of supply and
testing to prove the conductors are not charged.
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Earthed (High Voltage isolation) - Electrical equipment is earthed when all phase
conductors of the source of electricity supply to the equipment being worked on are
connected together and to earth by conductors of sufficient capacity to safely pass
fault current. Earthing may be carried out using earth switches on circuit breakers or
by using substantial cables applied separately.
Circuit Main Earth - A circuit main earth is an earth connection applied to the
source of supply to isolated electrical equipment for the purpose of making it safe to
work on before a safety document is issued.
Additional Earth - An additional earth is an earth connection, connecting all phases
of the supply together and to earth by conductors of sufficient capacity to safely pass
fault current and applied at or near the point of work. An additional earth is applied
in addition to the circuit main earth.
Key Safe - A key safe is a lockable box or container used to secure keys from
switches, circuit breakers, earthing switches or other safety devices which are used
as points of isolation.
Caution Notice - A notice of prescribed format applied to points of isolation and to
circuit main earths warning DO NOT TOUCH – POINT OF ISOLATION.
Danger Notice - A notice of prescribed format applied to live equipment in the
vicinity of isolated equipment warning DANGER – LIVE EQUIPMENT.
Approved Voltage Proving Device - An Approved Voltage Proving Device is a
voltage indicating device supplied for the purpose of proving equipment to be worked
on is dead. The voltage proving devices must be of a type listed in appendix 13
Electrical safety rules.
High Voltage Electrical Permit to Work - A safety document issued by the site
Senior Authorised Person who may be either a high voltage contractor or company
employee authorised to issue such permits to an Authorised Person stating that
equipment to be worked on is dead, isolated, caution and danger notices attached,
earthed, proved to be dead and released for work.
Low Voltage Electrical Permit to Work - A safety document issued by an
Authorised Person or Site Electrical Support to an authorised competent person
stating that equipment to be worked on is dead, isolated, proved to be dead and
released for work. Where the point of isolation is at high voltage, the equipment to
be worked on must be dead, isolated, earthed, proved dead and released for work by
the issue of an Electrical Permit to Work – High Voltage.
High Voltage Sanction for Test - A safety document issued by the site Senior
Authorised Person who may be either a high voltage contractor or company
employee to the Authorised Person in charge of the test, stating which electrical
equipment is to be tested and the conditions necessary for the tests to be carried out
safely.
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Limitation of Access - A safety document issued by an Authorised Person to a
person carrying out work in areas such as high voltage switchrooms or substations
near or adjacent to enclosed live electrical equipment but not on live electrical
equipment, for example, painting internal walls of switchrooms, building repair etc.
Senior Electrical Engineer - A competent Electrical Engineer with expertise in the
use of electricity at quarries and/or allied processing plants, appointed to advise the
UK Health & Safety Advisor, Directors and Managers on electrical matters.
Regional Electrical Engineers - A competent Electrical Engineer with expertise in
the use of electricity at quarries and/or allied processing plants, appointed to advise
regional management on electrical matters and assist the Senior Electrical Engineer
to develop and implement electrical standards and rules.
Site Electrical Support - A competent electrical contractor or competent employed
electrician with expertise in the use of electricity at quarries and/or allied processing
plants and who provides day to day electrical support to the Site Manager on design
and installation, safe use and maintenance, inspection and test of electrical
equipment and issue Permits to Work – Low Voltage and if a Senior Authorised
Person issue a Permit to Work – High Voltage.
Electrical Installation Subcontractor/Third Party Worker - A competent
electrical contractor with expertise in the use of electricity at quarries and/or allied
processing plants who is used to install electrical equipment and carry out project
work for Aggregate Industries inline with current legislation and Aggregate Industries
standards.
Inspection and Testing Contractor Subcontractor/Third Party Worker - The
competent contracting company, organisation or person appointed by the business to
carry out thorough inspections and tests of fixed electrical equipment in line with the
specification issued for such inspections and tests.
Competent Person - A nominated trained person authorised in writing by the Site
Manager to carryout duties as set in appendix 5.
Senior Authorised Person - A competent person authorised to issue Permits to
Work and Sanctions for Test to Authorised Persons to work on high voltage
equipment which has been isolated and made safe to work on and issue Limitation of
Access Permits to competent persons.
Authorised Person - A competent person authorised to receive and clear Permits to
Work, Sanctions for Test and carryout work on high voltage equipment. An
authorised person can also issue Limitation of Access Permits to competent persons.
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