Safety Alert 134 | Electric Shocks

Over a short period, two electrical incidents have occurred involving apprentices working on or around switchboards. Both incidents could have been avoided if the correct isolation and testing procedures had been followed. 

These incidents highlight the importance of always following the Test Before You Touch process and correct isolation procedures, regardless of how a circuit appears or what it was previously connected to. 

First Incident  

A 1st year apprentice was working on a switchboard upgrade where the previous fuse board had been removed to install a new board to current standards. The apprentice and tradesperson were preparing the circuits for installation into the new board. 

The cables had been removed from the old switchboard and were assumed to be deenergised when the apprentice was tasked with extending a feed cable. 

While stripping the cable to extend its length, the apprentice received a shock to their thumb when it came into contact with their pliers during the stripping process. 

It was later discovered that the cable was also connected to another distribution board and remained energised. The apprentice had not followed the Test Before You Touch procedure before handling the conductor. 

The apprentice was immediately taken for an ECG and received a clear result. 

Second incident  

A 2nd year apprentice was working with a tradesperson on a site that was still in the decommissioning phase. The tradesperson instructed the apprentice to remove decommissioned circuits from a switchboard that both the tradesperson and apprentice were aware contained a live busbar and three live circuits. 

There had been instructions that the security and UPS circuits were not to be turned off until the client was ready. 

While carrying out the task, the apprentice began removing some of the old circuits and was then asked to assist with resetting a temporary board that had tripped while being used by other trades on site. 

While stopping one task to start the other, an earth conductor moved and came into contact with the live busbar, resulting in an arc flash incident within the switchboard. 

The apprentice suffered flash burns to both eyes (sometimes called ‘welder’s flash’ or ‘arc eye’) that he is expected to make a full recovery from, but the incident had the potential for more severe consequences. 

Remember your ABC – Assume nothing, Believe no-one, Check everything 

Root Causes 

1. Job/System Factors:
   • Inadequate work practice – Circuits were assumed to be de-energised without proper testing. 
   • Inadequate supervision. 
   • Failure to comply with Code of Practice requirements for working on or near live parts and Section 55 of the licensing regulations. 
     
     
2. Inadequate work procedures: 
   • Improper procedure – Test Before You Touch process was not followed. 
   • Improper isolation – Circuits were not proven de-energised prior to work. 

Contributing Factors  

• Test Before you Touch – All EGT apprentices must ensure they always test before they touch. 
• Incorrect isolation – EGT apprentice must NEVER work LIVE  
• Incorrect supervision  
  • “Safe working guidelines for electrical workers and apprentice” section 6.6.1 
  • Apprentices are only permitted to isolate or carry out live testing under DIRECT supervision in their FINAL year of their apprenticeship, and must not work live in any other circumstances. 
    
    
• The instructions that the security and UPS circuits were not to be turned off until the client was ready. 
  
  Working live is the leading cause of burns, shocks, serious accidents and fatalities for electricians. To help keep workers safe, the law was changed in 2017 to ban live work on or near an exposed, energised part of an installation that can be deenergised. 
  
  Building and Energy prepared a letter signed by the Director of Energy Safety to inform electricity customers about the new laws, which strictly limit work on or near energised electrical equipment to exceptional circumstances. Electrical contractors and electricians are encouraged to provide a copy of this letter to their customers when quoting and performing electrical work.  
  
  The letter is available here 
  
  

Recommendations 

• EGT apprentices are to ensure the “test before you touch” principles are followed prior to commencement and re-commencement of all work activities.  
• EGT apprentices must ensure that they DO NOT work in the vicinity of live parts.
• EGT apprentices should ensure circuits have been isolated by the tradesperson and participate in the process including attaching a personal danger tag and lock when possible (i.e. follow steps of isolation in the IITT). 
• EGT apprentices have the right to say NO to any unsafe situation, your safety ALWAYS comes first. 
• Bookmark the link to the letter above so you can find it later if you need it. 

For further information regarding this Safety Alert, please contact EGT on (08) 6241 6100 or talk to your Field Officer.