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High Voltage Electrical Installations Risk Assessment

High Voltage Electrical Installations Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

High Voltage Electrical Installations Risk Assessment

Product Overview

Identify and control organisational risks associated with High Voltage Electrical Installations at a management and systems level, ensuring structured planning across governance, design, operation and maintenance. This Risk Assessment supports WHS Act due diligence obligations, strengthens WHS Risk Management and helps protect your business from regulatory and operational liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of officer due diligence, PCBU responsibilities, electrical safety obligations and the integration of high voltage (HV) risk into corporate WHS governance frameworks.
  • System Design & Engineering Integration: Management of design risks for LV and HV installations, including fault level coordination, protection grading, segregation, and safe access in accordance with engineering and electrical safety principles.
  • Procurement & Commissioning of HV Equipment: Controls for specification, selection and acceptance of high voltage switchgear, cables and associated equipment, including verification, factory/site acceptance testing and compliance certification.
  • Construction, Installation & Contractor Control: Oversight of installation works, construction phase risk management, contractor prequalification, supervision, and interface with principal contractor WHS systems.
  • System Documentation & Information Management: Protocols for single line diagrams, schematics, operating manuals, labelling, signage, and change control to ensure accurate, current and accessible HV/LV system information.
  • Competency, Licensing & Authorisation: Assessment of competency profiles, electrical licensing, HV operator authorisation, refresher training and competency verification processes for all HV and LV personnel.
  • Operating Procedures & Switching Programs: Development and control of standard operating procedures, switching programs, access permits and coordination of operating authorities to minimise human error and unauthorised operation.
  • Isolation, Lockout, Tagout & Earthing Systems: Management of isolation procedures, lockout/tagout hardware, portable and fixed earthing arrangements, and verification of de-energised states prior to work.
  • Testing, Commissioning & Energisation Management: Risk controls for HV and LV testing, staged commissioning, energisation planning, temporary supplies and coordination with network operators and third parties.
  • Inspection, Preventive Maintenance & Asset Management: Development of inspection regimes, condition monitoring, preventive maintenance schedules and lifecycle asset management for HV installations and associated plant.
  • Arc Flash, Electric Shock & Step/Touch Potential: Assessment of arc flash energy, electric shock exposure, step and touch potentials, PPE requirements, arc flash labelling and engineering/administrative risk controls.
  • Emergency Preparedness & Incident Response: Planning for HV electrical incidents, emergency isolation, rescue procedures, first aid for electric shock and burns, and coordination with emergency services.
  • Contractor, Visitor & Third-Party Interfaces: Management of network operator, service provider, contractor and visitor interactions with HV areas, including access control, inductions and permit-to-work systems.
  • Monitoring, Audit & Continuous Improvement: Systems for performance monitoring, incident and near-miss review, internal and external audits, and continuous improvement of the HV electrical safety management system.

Who is this for?

This Risk Assessment is designed for Business Owners, Officers, Electrical Engineers, Asset Managers and Safety Managers responsible for planning, operating and maintaining High Voltage Electrical Installations across industrial, commercial and infrastructure sites.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Electrical Safety Compliance
  • • Lack of clear governance structure for high voltage (HV) electrical safety leading to unclear accountability for due diligence under WHS Act 2011 and relevant Electrical Safety legislation
  • • Failure to identify and comply with applicable standards and codes (e.g. AS/NZS 3000, AS/NZS 3017, AS 2067, AS/NZS 4836, state/territory electrical safety regulations) for HV installations and operation
  • • Inadequate integration of HV risks into the organisation’s WHS management system, risk registers and consultation processes
  • • Insufficient resourcing (budget, competent persons, time) for safe design, installation, testing, commissioning, operation and maintenance of HV switchgear and associated low voltage (LV) systems
  • • Poor change management when introducing or modifying HV installations, leading to uncontrolled new or changed risks
  • • Lack of documented authorisation framework for HV system owners, controllers, and persons in control of a business or undertaking (PCBUs)
2. System Design, Engineering and Integration of LV and HV Installations
  • • Inadequate HV system design leading to overvoltages, fault energy levels and arc flash hazards not being properly controlled
  • • Poor coordination between HV and LV systems creating backfeed risks, touch and step potential issues, and unsafe fault clearing times
  • • Lack of discrimination and protection coordination between HV switchgear, transformers and downstream LV protective devices, increasing likelihood of widespread outages and equipment damage
  • • Inadequate segregation and insulation between HV and LV components, creating inadvertent contact hazards for LV workers
  • • Insufficient consideration of earthing and bonding design for combined LV and HV systems leading to hazardous touch voltages and ineffective fault current paths
  • • Failure to design for safe access, test points, isolation points and working space around HV switchgear and associated control panels
  • • Design not adequately considering future expansion, resulting in unsafe ad‑hoc additions or overloading of existing HV and LV equipment
3. Procurement, Selection and Commissioning of High Voltage Switchgear and Equipment
  • • Procurement of non-compliant or unsuitable HV switchgear, protection relays, cables or test equipment that do not meet Australian standards or site requirements
  • • Insufficient specification of performance, insulation level, fault rating and environmental protection (IP rating) for HV equipment resulting in accelerated degradation or failure
  • • Lack of manufacturer documentation, type test certificates and instructions making safe installation and operation difficult
  • • Inadequate factory acceptance testing (FAT) and site acceptance testing (SAT) of HV switchgear and integrated control/protection systems
  • • Failure to verify compatibility between new HV switchgear and existing HV/LV infrastructure (e.g. fault level, control voltages, communication protocols)
  • • No formal commissioning procedure leading to inconsistent testing, inadequate functional checks and incomplete safety verifications
4. Installation, Construction Management and Contractor Control
  • • Installation work carried out by persons without appropriate HV competencies, licences or authorisations, leading to unsafe terminations, clearances and earthing
  • • Poor coordination between multiple contractors (civil, mechanical, electrical, controls) resulting in damaged cables, compromised segregation, or mislabelled equipment
  • • Inadequate site supervision and quality assurance during installation of HV switchgear, cables and earthing systems
  • • Deviation from design specifications, drawings and standards during installation without proper engineering assessment and approval
  • • Uncontrolled energisation of partially installed or untested HV equipment during construction or upgrades
  • • Insufficient management of construction-phase hazards at HV/LV interfaces, such as temporary supplies, backfeeds and bypasses
5. HV and LV System Documentation, Labelling and Information Management
  • • Outdated or inaccurate single line diagrams and schematics leading to incorrect assumptions about supply sources, isolation points and fault levels
  • • Inconsistent or missing labelling on HV switchgear, transformers, LV boards, cables and earthing points causing confusion for operators and testers
  • • Lack of readily accessible operating manuals, switching programs and test procedures for HV equipment
  • • Poor document control causing obsolete procedures, drawings and protection setting files to remain in circulation
  • • Inadequate recording of protection settings, relay configurations and test results leading to difficulty in verifying performance or investigating incidents
6. Competency, Licensing, Authorisation and Training for HV and LV Personnel
  • • Unqualified or inadequately trained personnel performing HV switching, testing, installation or fault response activities
  • • Lack of a formal authorisation system for HV operators, switching officers, test officers and electrical safety observers
  • • Insufficient understanding of HV and LV interaction hazards such as induction, backfeed, capacitive coupling and step/touch potential
  • • Inadequate training on organisational procedures, permits, switching programs and emergency response related to HV installations
  • • Competency not maintained over time due to infrequent exposure to HV tasks or system changes
7. Operating Procedures, Switching Programs and Access Control
  • • Uncontrolled or ad-hoc switching of HV switchgear leading to energisation of equipment where people are working or where plant is not ready
  • • Lack of standardised operating procedures for normal, abnormal and emergency operations of HV and LV systems
  • • Poor communication during switching activities leading to misunderstandings about plant status and isolation points
  • • Unauthorised access to HV switch rooms, kiosks, substations and restricted LV areas, increasing risk of inadvertent contact or tampering
  • • No clear procedures for managing parallel feeds, alternative supplies, and LV backfeed when operating HV equipment
8. Isolation, Lockout, Tagout and Earthing Systems
  • • Failure to achieve effective isolation of HV circuits prior to work, resulting in exposure to live conductors or unexpected energisation
  • • Inadequate lockout and tagging systems leading to removal or bypass of isolations without proper verification
  • • Incorrect or absent application of portable or fixed earthing on HV equipment and conductors resulting in hazardous induced or stored energy
  • • Complexity of LV and HV interfaces causing overlooked sources of energy such as backfeed through transformers, UPS systems or generators
  • • No consistent process for testing for de-energised status and verifying earthing before access is granted
9. High Voltage and Low Voltage Testing and Commissioning Management
  • • Inadequate control of HV testing activities (e.g. insulation resistance, pressure tests, primary/secondary injection, hi-pot tests) leading to exposure to dangerous voltages
  • • Poor coordination between testing personnel and operations, resulting in energisation conflicts or inadvertent testing on live or incorrectly isolated systems
  • • Use of inappropriate or uncalibrated test equipment that does not meet the voltage or category rating required
  • • Insufficient procedures for testing LV systems connected to HV equipment (e.g. control circuits, protection relays, metering) creating risks of incorrect configuration
  • • Lack of clear test boundaries and test status indication leading to other workers entering hazardous test zones
10. Inspection, Preventive Maintenance and Asset Management
  • • Deterioration of HV switchgear, insulation, cables, transformers and LV interfaces due to ageing, moisture, contamination or mechanical damage
  • • Failure of protective devices, interlocks or control systems not being detected prior to a fault or switching operation
  • • Lack of systematic inspection and maintenance program leading to unplanned outages, equipment failure and increased electric shock or arc flash risk
  • • Spare parts unavailability or use of incorrect/obsolete components compromising equipment integrity and safety
  • • Maintenance activities not adequately planned with respect to system configuration, resulting in unsafe operating conditions or overloading of remaining assets
11. Arc Flash, Electric Shock and Step/Touch Potential Risk Management
  • • Exposure of workers to arc flash energy due to switching faults, equipment failure or incorrect operation of HV or LV switchgear
  • • Electric shock from direct contact, indirect contact or induced voltages in LV and HV equipment and structures
  • • Hazardous step and touch potentials around earthing systems during fault conditions
  • • Lack of systematic assessment of arc flash and shock risks across the integrated LV and HV network
12. Emergency Preparedness, Incident Response and Recovery
  • • Inadequate emergency response capability for electric shock, arc flash, fire or HV equipment failure incidents
  • • Lack of clear procedures for isolating HV and LV supplies during emergencies to protect responders and other workers
  • • Poor coordination with external emergency services regarding HV installations and associated hazards
  • • Insufficient incident reporting and investigation processes leading to missed learning opportunities
13. Contractor, Visitor and Third-Party Interface Management
  • • Contractors performing HV or LV work without being adequately briefed on site-specific systems, procedures and hazards
  • • Visitors or non-electrical workers entering HV or restricted LV areas without understanding the risks and required controls
  • • Third-party network operators, customers or neighbouring facilities making changes that impact shared HV or LV infrastructure without coordination
  • • Inconsistent standards and work practices between PCBUs on multi-employer sites
14. Monitoring, Audit, Review and Continuous Improvement
  • • Degradation of control effectiveness over time if HV and LV safety systems are not periodically monitored and reviewed
  • • Systemic issues in incident trends not being detected due to poor data collection or analysis
  • • Non-compliance with legislation, standards or internal procedures remaining unidentified and unaddressed
  • • Failure to incorporate lessons from industry incidents and technological advances into the organisation’s HV and LV safety management

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Electrical Safety Act and associated Regulations (jurisdictional): Overarching duties for electrical safety and high voltage installations.
  • Safe Work Australia – Managing Electrical Risks in the Workplace Code of Practice: Guidance on managing electrical risks, including high voltage systems.
  • Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Framework for systematic risk management and due diligence.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS 3000:2018 (Wiring Rules): Electrical installations – design, construction and verification requirements.
  • AS 2067: Substations and high voltage installations exceeding 1 kV a.c. – safety and design requirements.
  • AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment.
  • AS/NZS 61439 Series: Low-voltage switchgear and controlgear assemblies – design and safety requirements relevant to LV components within HV installations.
  • AS/NZS 3019: Electrical installations – Periodic verification for ongoing inspection and maintenance regimes.
  • AS 1319: Safety signs for the occupational environment – requirements for electrical hazard and HV signage.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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