Electrical Risk Assessment: Importance and Best Practices

Electrical systems present unique and often invisible hazards that aren't always obvious during routine inspections. I remember this one service electrician at my previous company who had a horrible accident while working on an old fuse panel. Believing he knew exactly what to expect, he completely disregarded critical safety protocols and insisted on working on the electrical panel without conducting a risk assessment. When the panel was energized, a fuse blew, severely damaging his eyes.

Hidden dangers like faulty wiring or degraded insulation can go unnoticed in cases like this, making it crucial to conduct a thorough assessment. A specialized electrical risk assessment helps identify and control these risks, preventing serious injuries, equipment damage, or worse.

Key Takeaways

• Electrical risk assessment is a systematic process used to identify, evaluate, and manage potential hazards associated with electrical systems and equipment.

• Electrical risks include shock, arc flash, fires, and equipment failure, all of which can lead to severe injury, downtime, or fatalities if not properly managed.

• Following the hierarchy of controls ensures electrical hazards are addressed at their source.

• Verifying a zero energy state ensures electrical equipment is completely de-energized before maintenance.

What Is Electrical Maintenance?

Electrical maintenance is the preservation and repair of electrical equipment and systems in a residential or industrial establishment. It may be conducted either by the owner or a contracted maintenance electrician and is usually scheduled based on the age of the structure, complexity of the electrical system, and necessity.

There are three types of electric maintenance, and each differs in purpose and procedure:

• • Corrective: Required to identify, isolate, and repair any equipment that has malfunctioned or is already worn out to bring it back to good working condition.

  • Preventive: Performed at predetermined intervals to prevent unexpected system failure and downtime. This is just like automobile periodic maintenance. It’s not easy to find a system that holistically covers all damage and malfunction possibilities, but there is a preventive maintenance management software that could significantly help.

  • Predictive: Done by closely monitoring the condition and performance of electrical equipment to detect and correct issues before unscheduled downtime or accidents happen.

Electrical maintenance is more than just replacing all electrical parts as needed; it also includes electrical system inspection, testing, and monitoring to keep systems and machines running smoothly. It is critical not only for the safety of equipment but also for industrial facilities, especially the workers involved.

What Are Electrical Risks?

Electrical risks refer to hazards that arise from working with, around, or being exposed to electrical systems, electrical components, or electrical equipment. These risks can lead to serious injury, death, fires, or damage to property and equipment. The most common electrical risks include arc flash and electric shock.

An arc flash is a sudden, intense release of energy, resulting in extreme heat, light, and pressure waves. Electric shock occurs when a person touches an energized electrical source, such as exposed wires or faulty equipment.

Also, several other electrical hazards are often related to improper procedures or overlooked dangers during standard maintenance, like unauthorized energization, degraded insulation, mislabeled panels, or faulty wiring hidden behind walls. Outdated single-line diagrams that no longer accurately reflect the electrical system can also pose a serious hazard.

To manage these risks effectively, the NFPA 70E (National Fire Protection Association) provides guidelines for the installation, maintenance, and operation of electrical systems, emphasizing a comprehensive safety program that includes safe work practices, hazard identification, risk assessments, and emergency procedures.

Similarly, OSHA (Occupational Safety and Health Administration) Standard 1910 Subpart S sets regulations for electrical safety in the workplace, requiring proper procedures, training, and system maintenance to protect employees from electrical hazards. Together, these standards help ensure a safe work environment and minimize electrical risks.

What Is Electrical Risk Assessment?

An electrical risk assessment is a systematic process used to identify, evaluate, and manage potential hazards associated with electrical systems and equipment. It is an essential tool for complying with safety requirements set forth by OSHA 1910 Subpart S, ensuring worker safety before any electrical work is performed. An electrical risk assessment should be conducted:

1. Before any electrical work is performed, ensuring that potential hazards are identified and addressed in advance.

2. When new electrical systems or equipment are installed or modified, to assess any newly introduced risks.

3. During routine maintenance or inspections, to look for any evolving or previously undetected hazards.

4. After incidents or near-misses, to evaluate if the risk management practices in place are adequate or need updating.

Importance and Benefits of Electrical Risk Assessment

By systematically assessing electrical systems and equipment, you can ensure that hazards are properly controlled and mitigated to help protect workers from both visible and hidden electrical dangers. A good risk assessment for electrical work gives you the ability to:

• • Prioritize Maintenance Efforts Based on Actual Risk: Electrical safety risk assessment helps identify which systems pose the highest risk, allowing you to focus resources on the most critical areas. This targeted approach ensures that maintenance efforts are efficient and address the most pressing hazards first.

  • Reduce Unexpected Outages: By identifying potential electrical hazards early, you can perform preventative maintenance, reducing the likelihood of system failures. A well-conducted electrical safety risk assessment helps catch problems before they lead to unplanned downtime.

  • Minimize Liability: A thorough risk assessment for electrical work reduces the risk of accidents or incidents, which can prevent costly lawsuits and fines. Proper documentation and controls help demonstrate due diligence and reduce legal exposure.

  • Protect Your Team: An electrical assessment identifies hidden dangers like faulty wiring or outdated equipment, helping to safeguard workers from serious injuries. By addressing these hazards through preventive measures, the safety of your team is significantly improved.

Electrical Risk Assessment Step-by-Step Procedure

Step 1: Identify All Electrical Systems and Equipment

The first step in an electrical risk assessment is to create a complete inventory of all electrical systems, electrical equipment, and electrical components within the facility. This includes documenting important details such as the specifications, voltages, and power ratings of each asset. It’s essential to also map out the electrical distribution system, including both the main and subsidiary panels, while noting the age, condition, and maintenance history of the equipment.

Step 2: Determine Potential Electrical Hazards

Once the inventory is in place, the next step is to assess potential electrical hazards. An electrical risk assessment checklist will help identify both visible and hidden dangers, such as faulty wiring, exposed energized electrical components, or degraded insulation that might not be obvious during a visual inspection. It's important to consider hazards that might be concealed, such as wiring behind walls or inside panels, that could pose a significant threat during maintenance activities. 

In my experience, these scenarios often indicate gaps in safety practices and can create significant hazards: 

• • Devices running near maximum load but never formally inspected.

  • Panels that were updated in the field but not reflected in the documentation.

  • Temporary electrical installations that end up becoming permanent.

  • Outdated lockout/tagout points that give a false sense of security.

Step 3: Assess Risk Level for Each Hazard

In this step, the identified hazards are evaluated based on their severity and likelihood of occurrence. A risk matrix is created to categorize each potential hazard, helping to prioritize them accordingly. This allows the team to focus on the highest-risk hazards, ensuring that proper control measures are applied to mitigate them, while lesser risks can be handled with standard safety precautions.

Step 4: Implement Control Measures

At this stage, the appropriate safety measures are applied to manage the identified risks. There is a common misconception in occupational safety that personal protective equipment (PPE) is the first line of defense. However, this is not the case. According to OSHA’s Hierarchy of Controls, risks should first be addressed at their source. For example, the hazard could be eliminated entirely or replaced with safer alternatives. 

If eliminating or substituting the hazard is not feasible, the next step is to implement engineering controls. An example is the lockout tagout (LOTO) procedure, which is designed to isolate electrical energy sources using physical LOTO devices like padlocks, hasps, and breaker locks.

Only after these measures have been taken should administrative controls come into play. These might include revising employee qualifications, providing specific training, or creating new work procedures to manage any remaining risks. After applying these controls, another round of assessment may be needed to ensure their effectiveness. Finally, PPE should be selected based on the residual risk and calculated incident energy, ensuring that the protective gear chosen is appropriate for the situation.

Step 5: Document and Report

A comprehensive documentation process is essential for tracking the findings of the electrical risk assessment and the steps taken to mitigate risks. This includes creating standardized forms for risk assessments and developing permit-to-work documents for high-risk tasks. Clear and consistent record-keeping allows for better oversight, future audits, and a system for reviewing and improving safety practices over time.

Proper documentation of electrical risk assessments should include:

Step 6: Continuous Monitor and Review

The final step in the process is to incorporate a system of continuous review and improvement. This involves periodically revisiting the electrical safety risk assessment to update it as new equipment is installed, maintenance is performed, or any safety incidents occur. Continuous improvement helps ensure that any new hazards are identified, risks are reassessed, and controls are adjusted to meet evolving safety standards and operational changes.

Importance of Verifying Zero Energy State

A zero energy state means that all electrical energy sources are fully isolated, preventing hazards like electric shocks, arc flashes, or electrocution. Before maintenance begins, a thorough risk assessment identifies potential dangers, and confirming zero energy ensures those risks are properly managed. Lockout tagout, or the Control of Hazardous Energy, is the process of disabling electrical equipment or machinery to avoid the unplanned release of hazardous energy while electrical maintenance procedures are being performed. 

The LOTO procedure involves preparing the equipment for shutdown, notifying all affected personnel, and safely de-energizing the system using lockout devices and LOTO tags. After implementing the LOTO procedure and before starting any maintenance activity, it is essential to ensure the system is fully locked out. The equipment, machine, or process controls should be activated, and the result should be observed. No response means a zero energy state, and the controls must be returned to the safe (OFF) position.

By following these practices, workers are protected from electrical risks, and safety is maintained throughout the maintenance work.

Electrical Risk Assessment FAQs

What are the 5 main electrical hazards?

The five main electrical hazards are electric shock, arc flash, arc blast, electrical fires, and electrocution. These hazards can cause serious electrical injuries or fatalities if proper precautions aren't taken.

How do you manage electrical risks?

Electrical risks are managed by identifying hazards, assessing the risks, implementing control measures such as lockout/tagout, using personal protective equipment (PPE), and ensuring proper training and maintenance procedures. Regular inspections and safety audits also help manage these risks.

What is an electrical wire risk assessment?

An electrical wire risk assessment involves evaluating the risks associated with electrical wiring, including potential hazards like exposure to live wires, poor insulation, and incorrect wiring. It helps determine necessary safety measures to prevent electrical accidents during installation or maintenance.

When must a risk assessment be carried out?

A risk assessment must be carried out before starting any electrical work, whenever new equipment is installed or modified, and whenever there are changes to the work environment or process that could introduce new risks. It should also be revisited periodically.

What is the most important rule of electrical safety?

The most important rule of electrical safety is to always ensure that equipment is properly de-energized and locked out before performing maintenance or repairs. This prevents accidental electrical shocks and other related hazards.