Health & Safety > Testing & Tagging Electrical Equipment Policy
Authorised by Chief Executive Officer
Issue Date: 8 June 2010
Policy
All electrical equipment must be maintained and operated safely; the risk controlled by way of regular inspection, testing and tagging and faulty equipment removed from service for repair, reconditioning or disposal.
Purpose
To provide the systematic management of the in-service inspection, testing and tagging of electrical equipment for all Kyeema Sites.
Procedure
General principles for safe equipment use
To ensure that electrical equipment is not damaged due to inappropriate use, storage or handling between tests, the following guidelines should be followed:
•Ensure persons who are operating the equipment are competent to do so.
•Follow all electrical equipment manufacturers’ instructions regarding operation and safety.
•Do not store electrical equipment next to water taps or sinks unless it is designed to be stored there.
•Regularly inspect equipment (leads, castings and plugs) for damage and wear and tear.
•Do not locate equipment in potentially explosive atmospheres.
•Do not store or use flammable liquids or solids near equipment where a spark may occur.
Inspection:
•Inspection may be carried out by any person who is competent in using the Inspection Checklist found in Appendix 1.
•Appropriate tags must be fixed to equipment that has been inspected.
•Information outlining the details of the inspection must be entered in an Electrical Equipment database
The following equipment checks shall be made by visual and physical inspection of all electrical equipment:
(a) Check for obvious damage or defects in the accessories, connectors, plugs or extension outlet sockets; and for discoloration that may indicate exposure to heat, chemicals or moisture.
(b) Check that flexible cords are effectively anchored to equipment, plugs and cord extension sockets.
(c) Check for damage to flexible cords that:
(i) The inner cores of flexible supply cords are not exposed or twisted; and
(ii) The external sheaths are not cut, abraded, twisted, or damaged to such an extent that the insulation of the inner cores is visible; and
(ii) Unprotected conductors or the use of banding insulation tape are not in evidence.
NOTE 1: Carefully running the supply cord through the hand will often detect internal damage such as twisted conductors or broken core filling.
NOTE 2: Connecting the plugs/sockets of extension leads together helps to confirm that the terminals have not spread.
(d) For portable outlet devices (power boards), check that the warning indicating the maximum load to be connected to the device is intact and legible.
(e) Check that any operating controls are in good working order i.e. that they are secure, aligned and appropriately identified.
(f) Check that covers, guards, and the like are secured in the manner intended by the manufacturer or supplier.
(g) Check that ventilation inlets and exhausts are unobstructed.
(h) The pins of insulated pin plugs should be inspected for damage to the insulation of the pins, and, if fitted, the shroud on cord extension sockets.
Testing:
•Testing must be undertaken for low voltage single phase and poly-phase (e.g. nominal 240V and 415V) electrical equipment, connected to the electrical supply by a flexible cord and/or connecting device, which is already in-service, has been serviced or repaired, is returning to service from a second-hand purchase, or is available for hire or loan.
•Testing, tagging, maintenance and repair of equipment can only be completed by trained, competent or licensed personnel.
New Equipment (purchased or hired):
•Where the equipment is new or hired, the supplier shall be deemed responsible for the initial electrical safety of the equipment.
•New equipment does not have to be tested, however the primary user must ensure the equipment is inspected and tagged - indicating the date it was brought into service – and entered into the Electrical Equipment Database.
•Hired equipment must have a current testing tag fitted when supplied by the hirer or used/supplied by the contractor.
Power Boards and Adaptors:
Electrical power boards can be used only if they have overload protection and all unused inlets be covered with plastic covers. Fabricated electrical portable outlet devices cannot be used within the Kyeema sites unless they have been assessed and a certificate of electrical safety has been obtained.
Double adaptors are not to be used within the Kyeema sites and should be removed and replaced with electrical power boards with overload protection devices fitted and all unused inlets be covered with plastic covers.
6.3 Hired or loaned equipment
This process should be conducted prior to each issue and upon return and include:
•A check for signs of wear.
•An inspection to identify cracked or frayed cords to ensure replacement.
•An assessment to ensure replacement of any equipment if there are reports of, or it causes even small electrical shocks, overheats, shorts out or gives off smoke or sparks.
•Inspection and/or testing documentation.
Testing frequency
The frequency of testing should relate to the risk of damage to the electrical equipment due to type and amount of use, the environment, the portability of the equipment, age, etc.; Electrical equipment shall be tested:
•Before return to service, after repair or servicing which could have affected its electrical safety,
•Before return to service from a second-hand sale, to ensure the equipment is safe,
•At intervals specified in Table 4 of AS/NZS 3760:2003: (In-service safety inspection and testing of electrical equipment) which also allows a tolerance of two (2) weeks either side of the test date.
All audiovisual equipment hired or loaned to internal/external users must have a current test tag affixed and be assessed and visually and physically inspected prior to each hire according to the procedures outlined Inspection of Equipment and Hired or loaned equipment. The hirer must also document this appropriately.
Tagging and Documentation
•Equipment that has been tested and found compliant must be fitted with an appropriate tag, which must be supplied by the tester
•New equipment must be tagged into service prior to being used, and documented.
•The following information is required for documentation:
− Name of the person who conducted the inspection, test or maintenance.
− Date(s) on/over which the inspection, test or maintenance was carried out.
− Result or outcome of the inspection, test or maintenance (if the equipment was found to be faulty, this must be clearly indicated and the action taken recorded appropriately).
− Action taken after results/outcome obtained.
− Due date for next inspection, test or maintenance procedure.
5.9 “Hazard! Do Not Use” Tags
For any unsafe/broken electrical equipment, staff must affix “Hazard! Do Not Use” tags to the item(s) and inform the appropriate person to ensure their removal for repairs or disposal.
•“Hazard! Do Not Use” tags are available from your Program Manager. Each “Hazard! Do Not Use” tag must be completed and all information written clearly in the spaces provided.
•The person affixing the tag must ensure that the item is immediately removed from service.
•Equipment must NOT be used or operated if a “Hazard! Do Not Use” tag is attached.
•The person taking equipment out of service should ensure that the appropriate supervisor is notified when equipment is out of service for maintenance or repairs.
•The fixing of a tag would normally be the responsibility of the equipment operator; however, any person may affix a tag to indicate a piece of equipment should not be used.
•Isolate faulty or hazardous equipment where possible (i.e. unplug the equipment if safe to do so or have an authorised/competent person remove the power source).
OH&S Representative
Ensure that all electrical equipment within their control is inspected, tested and/or tagged according to the requirements of this policy.
Ensure that all testing and tagging of electrical equipment in their areas is performed by:
− Competent and licensed contractors
− Maintain inspection and testing records/documentation
Staff
− Ensure that electrical appliances are set up correctly and used safely, in accordance with the manufacturer’s operating and safety instructions.
− Visually inspect electrical equipment / appliances prior to each use.
− Check for signs of wear.
− If the cords are frayed or cracked, replace them.
− Replace any tool if it causes even small electrical shocks, overheats, shorts out or gives off smoke or sparks.
− Not interfere with the marker label or tag on electrical appliances or with the tagging procedure utilised.
− Not use or permit the use of electrical equipment when the due for inspection/retest date shown on the marker label of an electrical appliance has passed.
− If they become aware that an appliance or associated wiring may be in a dangerous condition or is considered unsuitable for use for any other reason, must switch off and unplug (if possible) the appliance. They should immediately notify the proper supervisor so the appliance can be tagged and removed from service.
− Not repair, modify, or interfere with electrical appliances in any way.
Appendix 1. Electrical Inspection Checklist
Disconnect all equipment and connections from power source!
− Visually check the cords, plugs, outlet sockets and other accessories for obvious damage. Look for:
− Discolouration (may indicate heat, chemical or moisture exposure)
− Cuts, abrasions, twists in the outer sheath of the cord (these can be something small or they could be deep cuts such that the inner cores are visible)
− Electrical tape or other foreign objects attached to cord (may indicate a break or cut underneath)
− Damage to the insulation on the pin plugs (if applicable)
Physically check
− Flexible cords by running the cord through the hand to detect any twisting of the inner cores or damage to the outer sheath
− Pin plugs and other connections to ensure they are not loose by lightly wiggling them
− Check that flexible cords are effectively anchored to equipment, plugs and cord extension sockets
NOTE: Connecting the plugs/sockets of extension leads together helps to confirm that the terminals have not spread.
− For power boards, check that the maximum load warning is intact and easy to identify and read.
− Check that any operating controls are in good working order i.e. that they are secure, aligned and appropriately identified
− Check that covers, guards, and the like are secured in the manner intended by the manufacturer or supplier. If you are unsure, refer to the appropriate manual or contact the manufacturer/supplier.
− Check that ventilation inlets and exhausts on electrical equipment are Unobstructed If the equipment passed the inspection, complete an inspection tag, enter the information into your Department’s Electrical Equipment Database/Inspection
− Record and affix the tag to the equipment.
Definitions
Basic insulated, protectively earthed or Class 1 equipment is equipment in which there is basic insulation between metal parts and live parts and displays a clearly marked, protective earth terminal. (I.e. computers, microwaves, toasters – in general, any appliance with a metal case.) Documentation is a written record identifying all electrical equipment in a specified area – the maintenance, inspection and testing required and the details of the work carried out.
Inspection means a visual and physical check of electrical equipment and connectors that follows a specific procedure to identify damage or defects before they create a significant risk.
Fixed or Stationary equipment is equipment that cannot be carried or moved easily by hand. Examples of fixed or stationary equipment include: freezers, refrigerators, large photocopiers, hand-dryers, fixed air conditioning units, centrifuges, fixed workshop equipment etc.
Portable equipment is electrical equipment that is carried or moved while the electricity supply is connected, that is either designed to be portable, (i.e. laptop computers, hair dryers, curling wands, power tools, vacuum cleaners, industrial polishers, etc) or can be made portable (i.e. overhead projectors and other learning and teaching equipment, urns, heaters, etc). Kitchen appliances, such as toasters, kettles, jugs, fry pans, urns, etc are also defined as portable equipment.
Safety Switch - Residual Current Device (RCD) is a mechanical switching device designed to make, carry and break currents under normal service conditions, and to cause the opening of the contacts when the residual current attains a given value under fault conditions.
Tagging involves fitting a durable, non-reusable, non-metallic tag or other indicator to equipment that has been tested or inspected and found compliant. The tag identifies the equipment, who performed the test, date of the test/inspection and possibly a retest date
Testing includes the following procedures, which must be undertaken in accordance with AS/NZS, 3760:2003: (In-service safety inspection and testing of electrical equipment) and performed by a trained person:
− External inspection of equipment and connecting facilities;
− Protective earth continuity tests for Class I equipment, power boards and cord sets;
− Insulation testing measuring resistance or leakage current;
− Confirmation of correct polarity of live connections in cord sets with re-wireable plugs and cord extension sockets.
Testing includes the following procedures, which must be undertaken in accordance with AS/NZS, 3760:2003: (In-service safety inspection and testing of electrical equipment) and performed by a trained person:
− External inspection of equipment and connecting facilities;
− Protective earth continuity tests for Class I equipment, power boards and cord sets;
− Insulation testing measuring resistance or leakage current;
− Confirmation of correct polarity of live connections in cord sets with re-wireable plugs and cord extension sockets.
Testing equipment is the equipment required to carry out the tests detailed in AS/NZS 3760:2003: (Inservice safety inspection and testing of electrical equipment).
Related Policies, Procedures and Documents:
Routine Service (Non-ESM) Test & Tag SF-79