In the hierarchy of controls PPE is the last line of defense after elimination, substitution, engineering controls, and administrative controls. Since eliminating high-voltage diagnostics isn’t feasible, substitution is key. Using drones for pylon inspections and high-performance cameras for thermal scans allows remote monitoring, reducing the need for personnel in hazardous areas. Engineering controls like supervisory and remote switching can significantly lower risks. If budget permits, implement remote low-voltage switching as well. Administrative controls are essential, including permit-to-work systems, toolbox talks, and LOTO procedures. Lastly, while PPE is crucial, it should only be used after all other controls are in place.

Yes, diagnosing high-voltage electrical systems is inherently risky due to the potential for severe injuries, equipment damage, and even fatalities if proper precautions are not followed. Here are some key considerations and precautions to mitigate these risks: Risks Involved 1. Electric Shock: High voltage can cause severe injury or death through electrical shock. 2. Arc Flash: Sudden discharge of energy can result in burns, fire, or explosions. 3. Equipment Damage: Improper diagnostics can lead to equipment malfunction or destruction. 4. Explosion Risk: Faulty systems can trigger explosions, especially in confined spaces.

The following points can help to ensure safety when dealing with high-voltage systems: Personal Protective Equipment (PPE): Wear insulated gloves, arc flash suits, and face shields. Maintain Safe Distance: Use insulated tools and maintain a safe boundary. Lockout-Tagout (LOTO): Ensure circuits are de-energized before work starts. Non-Contact Testing: Use voltage testers and infrared thermography to detect live wires and hot spots. Proper Grounding & Insulation: Reduce risk of stray currents. Qualified Personnel Only: Only trained staff should handle high-voltage systems. Safety Barriers & Signs: Place barriers and signs to warn others.

It's very true that diagnosing HV system is very risky and many mishaps have happened in the past. Most of the experts have commented on using PPEs and protocols, which are must. In addition, I believe that physical disconnection of the system needs to be done either by the operating person himself or, in front of his own eyes, to avoid any miscommunication. Secondly in case of any test either on a product or, system is to be conducted in such a way that the test object or, system is visible by the test engineers. Also during test, the test engineer must keep one hand on the emergency switch off button, in case something goes wrong. I was lucky enough to avoid two major mishaps by using emergency stop button during High Voltage Test.

To ensure safety when diagnosing high-voltage electrical systems, always follow proper safety protocols. Use insulated tools and wear appropriate personal protective equipment (PPE), such as rubber gloves and safety goggles. Before working on any system, de-energize the equipment and lock out/tag out power sources to prevent accidental shock. Always test the system for voltage before touching any components. Work with a qualified team and keep a safe distance from live circuits.