QC SAFETY SYSTEM

• Significance• Origin of the Idea• Technical Concept• Use• Records• Dos, don’ts• Appreciation

SIGNIFICANCE• In the company where HS & E is

paramount, the QC (Testing) area was easily accessible to all the personnel even especially when the testing was in progress.

• This could have posed a measure threat to the safety of visitors or other unauthorized personnel due to chances of exposure to the 3 phase electric supply.

• In light of this a safety system was proposed and applied which resulted in creating and nourishing a safe working environment.

ORIGIN OF THE IDEA• As an MNC, we frequently hosted for various

clientele as well as other counterpart Dept. heads. One of these personnel did express a concern about the unsafe feeling while witnessing the testing of a switchboard.

• This resulted in a drive to have a system in place which encouraged a safe working environment. A deadline was issued during which the testing was kept on hold

• After consulting various sister facilities of the MNC, it was decided upon the general outline of the system to be in place.

TECHNICAL CONCEPTEquipments used and their

uses1. Testing Console2. LCPs3. JB4. Emergency stops and Door

limit switch5. Warning flash light6. Tower light7. Warning hooter8. Visual Indication set

OPERATION• Preconditions- 1. A perimeter of fencing is to be

formed around the panel to be tested.

2. All the emergency stops must be in released conditions

3. The main entry door is to be closed.

4. All the interconnections between JB, test console and Switchboard are done and secured.

5. The test generator sets are checked to be healthy.

OPERATION• Operation1. Inform all the personnel about the

testing being commenced.2. Switch on the safety system supply.

And turn on the key switch of any LCP. A siren will sound for the set time (10 sec.) after this delay the LCPs can be switched on.

3. Switch on the LCPs of respective Generators and switch the o/p on.

4. Now the Test console is fully operational. Generators can be controlled from the console.

5. The generator running and supply output can be observed from the visual indication provided.

OPERATION• Safety’s1. All the emergency stops will disrupt

the safety system supply thus switching off the LCPs which in turn will disconnect all the supplies from generators as well as transformers.

2. The main entry door when pushed open without the authorization will also work as a an emergency stop actuation and will sound a siren indicating forced entry.

3. All the test generators are provided with inbuilt overload and reverse power protection.

4. The supply from each generator is provided with overload protection in form of MPCB at Test console.

PROJECTS

• More than 20 projects were tested using the safety system.

• These Projects comprised of LV Switchboards and starter panels.

DOs and DON’Ts• All the shop floor employees

and visitors are to be introduced to the working of safety system.

• Only the authorized personnel are to be in charge of testing.

• The entry authorization is to be monitored.

• The safety system is always to be manned by two authorized personnel.

• All the repair and updating work are to be carried out on dead circuits.

APPRECIATION• The safety system was a

much appreciated endeavor (by visitors as well as our counterpart Dept. heads).

• Yellow belt certificate was awarded for the safety system SOP prepared.

• It created a safe working environment for live testing of the switchboards and other products.