Safety Operating Procedures for the Machinery Industry 8......Electrical Work

Substation Operator 1. Must strictly abide by the general safety rules for electrical work. 2. Be familiar with the performance and structure of the equipment, the items and procedures to be followed before power is supplied and during operation, as well as the usage methods of safety equipment and fire-fighting devices. And it has the ability to take appropriate actions in abnormal situations. 3. Perform switching operations in accordance with the dispatch instructions; under normal circumstances, power can be restored once after a switch trips, but power restoration is not allowed after another trip. 4. When performing switching operations, the following must be ensured: (1) Operations must be carried out strictly in accordance with the work instructions; if anything is unclear, it must be reported to the dispatcher. It is strictly prohibited to modify the work order without permission. (2) Switching operations are strictly prohibited during scheduled maintenance times; power shall not be restored after a power outage due to maintenance until the work is completed and inspected. (3) Switching operations must be carried out by two persons, one of whom acts as a supervisor ； Single-person duty stations allow operation by one person. (4) During power outage operations, the sequence must be oil switch, load-side isolator, and busbar-side isolator. The order is reversed when powering on. (5) When powering on the transformer, first close the oil switch and isolating switch on the high-voltage side, then close the main switch and branch switches on the low-voltage side. (6) When connecting lines in parallel or in series, they must be operated using oil switches; it is strictly prohibited to use isolating switches for this purpose. (7) When performing power-off operations on a single-pole isolating switch or a drop-out fuse, it is necessary to follow the sequence of the middle phase, one phase on the downwind side, and one phase on the upwind side. The order is reversed when powering on. (8) Isolating switches must not be operated under load; the permitted operating range is opening and closing voltage transformers and arresters ； Capacitive current of the busbars and the equipment connected to them ； Neutral grounding wire of split-transformer ； Open-circuit power transformers with an open-circuit current not exceeding 2 amps ； Open-circuit power lines with a switching capacitor current not exceeding 5 amps ； The bypass isolating switch, which is connected in parallel with other switches, can be opened and closed only after the main switch is closed. (9) When installing or removing the fuse element of a high-voltage fuse, it is necessary to first disconnect the circuit breaker located in front of the fuse. (10) When operating high-voltage switches, an insulating rod must be used, along with insulating boots and gloves. Operating outdoor high-voltage switches also requires standing on an insulating mat, and switching operations are prohibited during thunderstorms. (11) After a power outage or an accident-induced outage, before the relevant circuit breaker is opened and safety measures are taken. Entry to the barriers or contact with the equipment is prohibited, as well as any maintenance work. (12) The interval between the opening and closing of switches in the electrostatic capacitor bank must be no less than 5 minutes. (13) When the bus is de-energized, the voltage transformer must be turned off last; the order is reversed when energizing. (14) When maintaining the voltage transformer and its circuit, in addition to shutting down the high-voltage side, the fuse element on the low-voltage side must also be removed. (15) It is strictly prohibited to open the isolating switch under load, to accidentally open or close the power switch, or to close it with the grounding wire still in place. 　4. The duty officer should inspect the equipment once a day; the frequency of inspections should be increased in case of overload or abnormal operation. Both parties involved in the shift handover should conduct a thorough inspection together. Inspections should be carried out during heavy loads at night, and for power stations without on-site staff, inspections should be conducted at least three times a week. 5. The duty officer may conduct inspections alone, but is not allowed to move away from or cross barriers, nor to touch equipment that is in operation. 6. The operating transformer is experiencing severe oil leakage. If the oil level is too high or too low, there are abnormal noises, or discharge occurs in the porcelain bushing, it is necessary to find the cause and report it to the electrical dispatcher. 7. If a high-voltage distribution device in operation exhibits discharge, overheating, abnormal noises, oil leakage, incorrect opening/closing indications, or swelling of the electrostatic capacitor housing, it is necessary to identify the cause and report it to the electrical control department. 8. In the event of the following conditions, the high and low voltage switches of the transformer must be disconnected immediately, and the situation must be reported to the power dispatch center. (1) The noise inside the fuel tank increases significantly, accompanied by uneven cracking sounds ； (2) Oil leaking out from the oil pillow or explosion-proof cylinder ； (3) Severe oil leakage resulting in the oil level being invisible ； (4) Sudden change in oil color accompanied by carbonaceous material ； (5) Severe discharge or cracking of the porcelain sleeve. 9. In the event of tripping due to excessive gas, the transformer must not be reconnected to the power supply until the cause is identified. 10. The transformer must be taken out of service in case of a fire. If a fire breaks out on the lid, after taking safety measures, the bottom valve can be opened to drain oil so that the oil level drops below the ignition point, allowing the fire to be extinguished. 11. Special inspections are required in the following situations: ① During sudden climate changes such as lightning discharges, heavy rain, ice and snow, thick fog, high temperatures, or extreme cold ； ②When it trips on its own due to the grounding circuit ； ③New equipment or equipment after major repair can only be put into operation thereafter ； ④When adopting new technologies or new operating methods ； ⑤Power supply must be ensured during the holidays. 12. Based on the seasonal characteristics, the key inspection items are as follows: ① During the foggy season, special attention is paid to checking the discharge conditions of the porcelain insulators or sleeves of outdoor equipment. ②During the thunderstorm season, special attention should be paid to checking for signs of flashover discharge on porcelain insulators and covers, the condition of lightning protection and grounding systems, as well as any leaks in the buildings and water accumulation in the areas. Insulated boots must be worn during inspections, and it is forbidden to approach lightning protection devices. ③During the windy season, it is important to thoroughly inspect outdoor equipment and structures, as well as to ensure that the foundations of buildings are solid. ④During the rainy season, it is important to check for water accumulation in outdoor areas and to ensure that there is no risk of water seeping into indoor spaces. ⑤In summer, focus on checking the operation of ventilation and cooling equipment ； ⑥In winter, pay special attention to checking whether the circulation water pipes in the cooling system are frozen and blocked, and take measures to prevent the batteries from freezing. Outdoor electrician 1. Safety precautions when digging pits: ① Before digging, determine whether there are any underground pipelines, cables, or other underground facilities at the construction site; contact the relevant parties and take safety measures to address these issues properly. ②When digging pits in residential areas, near traffic roads, and close to buildings, barriers should be installed, and fluorescent signs should be set up at night. ③When the digging depth exceeds 1.5m, it is necessary to prevent the soil from falling back into the pit. ④When digging holes in soft soil, barriers and braces should be used to prevent collapse. 2. Matters regarding the installation and removal of poles: ① A dedicated person must be assigned to provide unified command, with strict adherence to electrical installation standards. ②During the process of setting up or removing poles, no one is allowed to work inside the pole hole; except for the commanders and designated personnel, everyone else must stay at a distance of 1.5 to 2 times the length of the pole. ③When digging holes for the upright poles and adjustment poles, measures should be taken to prevent the poles from rolling or tilting. ④When raising the pole, when it is 0.5 m above the ground, a thorough inspection of all stress points should be carried out before continuing with the lifting process. After the pole has been raised by about 60°, the lifting speed should be reduced, and the tension in the lifting ropes on all sides should be checked again. Once the pole is properly erected and meets the specified requirements, the hole where the pole stood should be filled back in promptly, compacted in layers, and then the protective devices can be removed. ⑤When removing the pole, first check the base of the pole and take measures to prevent it from falling over. Before digging the hole, tie the pull rope first. When removing the wires from the pole, use a rope to secure them and lower them slowly; it is strictly prohibited to cut the wires directly. 3. A dedicated person should be assigned to give unified instructions during wire laying, removal, and tensioning. Staff are not allowed to straddle the conductors or stand inside the corners of the conductors. Before tightening or removing the wires, it is necessary to check whether the tension wires, tie rods, and rod bases are secure; temporary tension wires should be installed for reinforcement if needed. 4. When laying or removing cables at locations where they cross various lines and roads, it is necessary to obtain permission from the relevant authorities first and to take reliable safety measures, such as setting up sturdy crossing structures and assigning dedicated personnel to monitor the intersections.

Inside-line electrician: 1. When installing any wiring or equipment, it is necessary to first connect the equipment and wiring before turning on the power supply. It is strictly prohibited to connect the circuits and devices below the power supply after the power supply has already been turned on. 2. After the wiring and equipment have been installed, an insulation test should be carried out using a megohmmeter before powering on to conduct tests. 3. After removing electrical appliances or wiring, any exposed wire ends that might still be energized must be wrapped with electrical insulating tape. 4. After removing high-voltage motors or electrical appliances, the remaining wire ends must be short-circuited and grounded. 5. When working on high-voltage equipment and important low-voltage panels and main circuits, a work order must be issued by a dedicated power dispatcher or the responsible supervisor. The person on duty is responsible for shutting off the power, testing for electricity, installing grounding wires, hanging warning signs, and setting up temporary barriers. Only after checking together with the person in charge of the work and completing the approval procedures can the work proceed. At least two people must work together while performing the task. 6. When high-voltage equipment is de-energized for maintenance work, equipment that is within a distance from the workers’ normal working area that is less than the value specified in Table 1 must be de-energized. For equipment whose distance is greater than that specified in Table 1 but less than that specified in Table 2, a sturdy temporary barrier must be installed at a distance from the live parts that is not less than the distance specified in Table 1. Otherwise, the power must be cut off. The live parts must be on the front or one side of the worker. If the live parts are behind or to the sides of the workers and there are no reliable safeguards, the power must be shut off. Table 1: Normal operating range for staff and safe distances from live equipment. Voltage level (kV): Safe distance (m): 10 and below – 20–35; 44. 60–110 – 0.35, 0.6, 0.9, 1.5. Table 2: Safe distances when the equipment is not shut down. Voltage level (kV): Safe distance (m): 10 and below – 20–35; 44. 60–110 – 0.7, 1.0, 1.2, 1.5. 2. During duty, it is necessary to regularly check various operational instruments to determine if there are any changes. 3. When powering on, carefully check the equipment instruments according to the work order for any damage, short circuits, or looseness, and confirm that everything is in good condition. Wear appropriate insulating protective gear; one person should act as a supervisor while another performs the operations. After the work is completed, place a clear sign in place. 4. In the event of a power outage, check the switches according to the operation sheet as well; wear insulating protective gear, have one person supervise while another performs the operations, and place a visible sign after the work is completed. 5. During the handover, the person handing over the shift must provide a detailed account of all operational conditions during that shift, as well as relevant documents and oral instructions. 6. The successor should arrive at the work post 15 minutes in advance, check all equipment and protective gear, and inquire about the status of operations; once both parties are satisfied, they shall sign in the handover book to take over the shift. 7. If a malfunction occurs during the handover, the person handing over the duty is responsible; the person taking over can proceed with the handover only after assisting in resolving the issue. 8. If, at the time of handing over, the person who is to take over has not arrived, is sick, drunk, or in a similar condition, the person handing over must not leave their post; they must inform the relevant personnel (department, workshop, team leader) to conduct an inspection and handle the situation before leaving. 9. All safety insulation equipment at this site must be regularly inspected and tested for dielectric strength.

Maintenance Electrician: 1. Electrical equipment must not be disassembled or repaired while it is in operation. It is necessary to shut down the equipment, disconnect its power supply, remove the fuses, place a sign that reads “Work in progress – do not close switch,” and only after confirming that there is no electricity present can work be carried out in accordance with the requirements outlined in the work order. 2. During maintenance, replace the plug-in busbar distribution box and fuses; do not operate them under load. 3. When maintaining the power distribution box or replacing fuses, the power must be turned off; it is not allowed to operate the power switches under load. 4. During maintenance, the lighting should use a safe voltage of 36V, and the light bulbs should be equipped with safety guards. 5. Before working on the circuit of the electrostatic capacitor bank, wait at least 5 minutes before grounding it and starting work. 6. Attention should be paid to the selection and replacement of the melt. 7. Appropriate or specialized tools must be used for assembling and disassembling electrical equipment. 8. At the end of each maintenance task, tools, parts, materials, etc. must be counted to prevent them from being lost or left inside the equipment.

(II) Safety Technical Operating Procedures for the Manufacturing and Maintenance of Electrical Equipment – Electric Motor and Electrical Appliance Repair Workers 1. When repairing electric motors and electrical devices, it is necessary to first disconnect the power supply, remove the fuses, and hang a sign at the power switch that reads “Work in progress; do not close the switch.” 2. If work must be carried out with power on, it must be done under the supervision of an experienced electrician. At the same time, it is necessary to wear insulating shoes and gloves, use tools with insulated handles, and stand on a dry insulating mat. 3. After the motor and electrical appliances are removed for repair, any wires that might still be energized should be wrapped with insulating tape, and high-voltage wire ends must be short-circuited and grounded. 4. Before testing the motor under power, check first whether the insulation is in good condition and whether the machine casing is grounded. During the trial run, attention should be paid to aspects such as steering, noise, and temperature. Staff should stay away from the rotation direction of the coupling. After the work is completed, the area must be cleaned up, the power supply disconnected, and any sources of fire extinguished before leaving. 5. The plugs, switches, and wire insulation used for debugging must be in good condition. It is prohibited to supply power or cut off power under load using a knife switch. 6. When lifting a transformer, do not put coins or other items that may fall out in your pockets. 7. Safety precautions when using an electric oven: ① Do not store flammable or explosive items on or around the oven, and do not use flammable solvents to clean parts or apply paint near the oven. ②Electric ovens must meet explosion-proof requirements; their enclosures must be grounded, and explosion-proof types must be used for interior lighting, wiring, switches, etc. ③Before using the oven, it is necessary to check whether the oven cabinet is deformed, whether the temperature control device, grounding wire, power cable, etc. are in good condition, whether the exhaust vents are unobstructed, whether the thermometer is within its calibration period and in good working order, and whether it is properly secured at the bottom. ④It shall be carried out in accordance with the process specifications at the time of scheduling, transfer, and drying after coil impregnation. After the paint has dried completely, it must be placed on the iron mesh rack inside the oven; direct contact with the resistance wires is strictly prohibited, as is overloading the device. A dedicated person should be on duty during baking to monitor temperature changes at all times and keep records. ⑤It is strictly prohibited to bake food and clothes in the oven. 8. Before filtering transformer oil, the oil filter must be checked first and its ground wire connected; smoking and open flames are strictly prohibited at the oil filtration site. 9. When using lifting equipment, it is necessary to comply with the \"Safety Technical Operating Procedures for Lifting Machinery,\" and there must be a dedicated person to give instructions. Pulling or lifting at an angle is prohibited, and no one is allowed to stand under the hook.

Automobile repair electrician: 1. Appropriate tools must be used for installation and maintenance; it is not allowed to strike electrical equipment with hammers or similar objects. 2. When servicing the battery, protective goggles and acid-resistant gloves must be worn to prevent acid from splashing, and flammable materials are not allowed to be stored at the service site. 3. At the end of work, count the tools to prevent them from being left inside the engine. 4. When cleaning parts with gasoline, the use of open flames is strictly prohibited.

Machine Tool Electrical Repair Technician: 1. Electrical repairs on machine tools must be carried out with the power turned off; working on the equipment while it is powered on is strictly prohibited. 2. The lighting used for maintenance should operate at a safe voltage of 36V, and the lamp holders must be equipped with guards. 3. When using lifting equipment, first check whether the equipment is in good condition; do not lift beyond its capacity, and avoid lifting at an angle. No one should stand under the load being lifted. 4. When removing or installing the motor end cover, pulley, shaft, and bearings, special tools such as copper rods, wooden hammers, and pull hooks should be used; it is not allowed to use hammers or flat shovels for striking directly. 5. Equipment and electrical appliances with amplification circuits should be tested after adjustment. Safety measures should be taken before testing, and it is necessary to carefully check whether all the limiters in the mechanical components, as well as the zero-voltage, zero-magnetism, over-voltage, and over-current relays, are safe and reliable. 6. During testing, it is necessary to closely observe whether the motor’s rotation direction, sound, and other parameters are normal. Staff should avoid the rotation direction of the coupling. After the work is completed, the site must be inspected and cleaned up; the power supply should be turned off and any sources of fire eliminated before leaving. 7. When cleaning electrical components with gasoline, the use of open flames is strictly prohibited.

Telephone station operator duties: 1. The machine room must be kept clean; it is strictly prohibited to store flammable, explosive, or corrosive items, and smoking is also strictly forbidden inside the room. 2. No items unrelated to work are allowed on the phone desk. 3. Stay at your post and constantly monitor the mechanical, electrical, and signaling conditions of the switchboard. 4. Be familiar with the power supply status of the equipment, so as to be able to cut off the power to the faulty section promptly and accurately in emergency situations. 5. If a keyboard key with a high temperature is detected, the machine must be stopped for repair. When a bakelite odor is detected, the faulty area should be located and repaired promptly. 6. Be familiar with the usage of fire-fighting equipment.

(III) Safety Technical Operating Procedures for Instrument Workers – General Safety Rules for Instrument Workers: 1. Under normal circumstances, work on live circuits is not permitted; if it is necessary to do so, insulating shoes and gloves must be worn, and the operation must be carried out by at least two people. 2. When working on instrument pipelines involving toxic gases, it is necessary to turn on the ventilation system, stand upwind, wear the required protective equipment and gear, and at least two people must be involved in the operation. 3. All instruments must be calibrated regularly and may only be used after passing the inspection. During use, regularly check whether the gauge readings are accurate and whether the operation is smooth. Operation beyond the specified range is strictly prohibited, as is any unauthorized handling by unqualified personnel. 4. When adjusting instruments filled with mercury, it should be done in a place away from crowded areas. Blowing on the mercury or touching it directly with hands is prohibited. A layer of water must cover the surface of mercury. 5. When operating in high-altitude pipelines or areas with flammable and explosive materials, the pressure tapping points or gates, valves, etc. should be closed first. Strictly adhere to the safety operating procedures for \"work at heights\" and \"work in hot and explosive environments\". 6. Equipment, wires, pipes, etc., that may affect the sensitivity of the instruments shall not be placed around the instrument room (panel), nor shall chemical substances that produce corrosive gases be stored there.

Instrument repairman: 1. When calibrating instruments, special tools and dedicated calibration benches must be used. 2. When using a soldering iron, it should be placed on a heat-insulating stand. Unplug the power cord when not in use; before leaving work, turn off the power to all testing devices before departing. 3. Before verification, prepare the work order properly; after shutting down the power supply and checking for electricity, hang a sign that reads “Work in progress – do not close the switch.” It can be disassembled and assembled only; operation while powered on is strictly prohibited. 4. When installing or removing ammeters and wattmeters, the current circuit must not be open-circuited, and the voltage circuit must not be short-circuited. 5. Two persons must be present for on-site disassembly, assembly, and maintenance, one of whom shall act as the safety supervisor. Otherwise, entry to the site is prohibited. 6. Once the on-site repair work is completed, the original wiring should be restored. Only after obtaining the signature of the person in charge on duty and returning the work order can one leave.

Instrument calibrator: 1. When cleaning parts with oils or other solvents, ventilation equipment must be turned on, and open-flame operations are strictly prohibited. The remaining solvent after use must be properly packaged and stored and managed in accordance with the regulations for flammable and explosive materials. 2. It is prohibited to use electric stoves, ovens, or similar devices to heat flammable substances such as oils. A designated person must be responsible for electric heating equipment. 3. For equipment in kitchens used to test the voltage resistance or vacuum performance of instruments, close attention should be paid to prevent mercury from being drawn out. The voltage withstand test area must have protective partitions or barriers to prevent accidents. 4. When the power supply supplied to the instrument exceeds the safe voltage level, strict insulation measures must be in place. It is strictly prohibited to insert wires directly into sockets without plugs.