Working with industrial automation equipment means working with electricity, often at voltages that can cause serious injury or death. Every automation engineer must understand electrical safety regulations, standards, and best practices applicable in the UK.
Key UK Regulations
The Electricity at Work Regulations 1989 is the primary legislation governing electrical safety in the workplace. It places duties on employers, employees, and self-employed persons to prevent danger from electricity.
Key requirements include:
- All electrical systems must be constructed and maintained to prevent danger
- Work on or near live equipment is only permitted when it is unreasonable to work dead
- Adequate precautions must be taken when working on live equipment
- Competent persons must carry out electrical work
The Health and Safety at Work Act 1974 provides the overarching legal framework requiring employers to ensure the health, safety, and welfare of employees and others affected by their work.
Safe Isolation Procedures
Before working on any electrical equipment, a safe isolation procedure must be followed:
- Identify the circuit or equipment to be isolated
- Isolate using a suitable isolator, circuit breaker, or fuse
- Lock off using a personal padlock and danger tag (Lock Out Tag Out - LOTO)
- Prove dead using a voltage indicator that has been tested on a known live source
- Secure the work area and inform all affected personnel
Control Panel Safety Standards
Automation engineers who design and build control panels must comply with BS EN 61439 (low-voltage switchgear and control gear assemblies). Key considerations include:
- IP ratings appropriate for the installation environment
- Thermal management with adequate ventilation or cooling
- Cable sizing according to BS 7671 (IET Wiring Regulations)
- Emergency stop circuits compliant with BS EN ISO 13850
- Arc flash protection for panels with high fault current levels
Machine Safety
Automation engineers must also understand functional safety standards:
- BS EN ISO 13849 (Safety of machinery - Safety-related parts of control systems) defines Performance Levels (PL) from PL a to PL e
- IEC 62061 defines Safety Integrity Levels (SIL) for machine safety systems
- BS EN 60204-1 covers the electrical equipment of machines including stop categories, EMC, and wiring practices
Risk Assessment
Every automation project should include a thorough risk assessment:
- Identify hazards associated with the machinery and automation system
- Assess the risk considering severity, frequency, and probability of occurrence
- Implement controls following the hierarchy: elimination, substitution, engineering controls, administrative controls, and PPE
- Document and review the assessment regularly and after any incident
Safety Training at EDWartens UK
Electrical safety is integrated into every course at EDWartens UK. Our students learn safe working practices from day one, including safe isolation procedures, LOTO, and risk assessment methodologies that comply with current UK regulations.