Risks due to not following procedures of electrical isolation and ‘test for dead’ at petroleum facilities | Resources Safety & Health Queensland
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Petroleum & Gas Inspectorate | Alert | No.123 V 1 | 29 September 2025

Risks due to not following procedures of electrical isolation and ‘test for dead’ at petroleum facilities

Summary

  • An inappropriately isolated electrical cable remained live and arced while staff were reinstating equipment.
  • Preliminary investigations indicate possible issues associated with use of inaccurate or outdated wiring diagrams, inadequate/failure to follow isolation procedures and failure to effectively test for dead prior to starting work.
  • Not following electrical isolation and test for dead procedures at petroleum and gas facilities creates risks of serious incidents and injuries.

Issue Explained

  • A generator was taken out of service and removed for major maintenance and repair.
  • The permit to work documentation included a job hazard analysis, wiring diagrams, and isolation signoffs. According to the documentation, the generator and its associated circuits were appropriately isolated before being sent off site.
  • Upon returning from major maintenance, staff attempted to reposition the equipment. During repositioning and preparing the cables, an electrical arc occurred, resulting in minor burns to the associated wiring and protective covering. No one was injured.
  • This was a serious near miss.
  • The following potential issues were identified, including:
    • The electrical wiring information was incorrect or outdated.
    • The isolation procedure was not appropriately followed or was ineffective.
    • The ‘test for dead’ procedure was not appropriately followed or effective, during both disconnection and reconnection processes.

Learnings

The investigation is not yet complete, but preliminary lessons are:

  • Adhering to isolation and ‘test for dead’ procedures is crucial for avoiding serious incidents or injuries from electrical hazards.
  • Failure to maintain currency of all documentation, implement fully developed operation and maintenance procedures will result in an ineffective safety management system, exposing workers to harm.

Investigations are ongoing and further information may be published as it becomes available. The information in this publication is what is known at the time of writing.

We issue Safety Notices to draw attention to the occurrence of a serious incident, raise awareness of risks, and prompt assessment of your existing controls.

References and further information

Authorised by Shoena Messner - Chief Inspector – Petroleum & Gas

Contact:

Issued by Resources Safety & Health Queensland

Safety: This information is a guide only and is issued to promote safety through experience. It is not to be taken as a statement of law and must not be construed to waive or modify any legal obligation.

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Acknowledgement of Country

RSHQ respectfully acknowledges all Aboriginal peoples and Torres Strait Islander peoples as the Traditional Owners and Custodians of the country on which we live and work. We acknowledge their continuing connection to land, waters and culture and commit to ongoing reconciliation. We pay our respect to their Elders past and present.