Industrial Electrical Safety L2

Industrial Electrical
Hazard Awareness
Glenn Kwabena Gyimah (PhD)

Accra Technical University
Mechanical Engineering Department
What does hazard mean?
Hazard means:
• any potential or actual threat to the wellbeing of people,
machinery or environment
Electrical hazard safety means:

• taking precautions to identify and control electrical hazards
www.dmp.wa.gov.au/ResourcesSafety
Introduction
Definitions:
• Electricity – movement
of the free electrons between
atoms;
– Related terms: Source:
• Current – the movement of

NIOSH
electrical charge
• Resistance – opposition to current flow
• Voltage – a measurement of electrical force
Introduction
• Conductors – substances, such as metals, that have
little resistance to electricity
• Insulators – substances, such as dry wood, rubber,
glass and Bakelite, that have high resistance to
electricity
• Grounding – a conductive connection to the earth
which acts as a protective measure
Electrical Hazards
Serious injuries and death can be caused by electrical hazards such as arc flash, shocks, burns, falls, and fires. Source of graphics: OSHA
Electrical Hazards
BE SAFE:
• Burns
• Electrocution
• Shock
• Arc flash/arc blast
• Fire
• Explosions
Electrical Hazards
Burns:
• Most common shock-related injury
• Three types of electrical burns:
– Electrical
– Arc flash
– Thermal contact
Source:
OSHA
Electrical Hazards
Electrocution:
• Is fatal
• Meaning: to kill with electrical shock
• Results when a human is exposed to a
lethal amount of electrical energy
Electrical Hazards
Shock:
• Body becomes part
of electrical circuit
• Reflex response to
passage of electric Source:
OSHA
current through the body
Electrical Hazards
Arc Flash/Arc Blast
• Arc flash
– Sudden release of electrical energy through air
when a high-voltage gap exists and there is a
breakdown between conductors
– Gives off thermal radiation (heat) and bright,
intense light that can cause burns
– Temperatures as high as 35,000°F
Electrical Hazards
• Arc blast – high-voltage arcs can also
produce considerable pressure waves
by rapidly heating the air and creating
a blast
Electrical Hazards
Fire:
• Most result from problems with "fixed
wiring”
• Problems with cords, plugs, receptacles,
and switches also cause electrical fires
Electrical Hazards
Explosions:
• Occur when electricity ignites explosive
mixture of material in the air
• Note:
– Electricity is source of these hazards
– All hazards are of equal importance
– Lesson focuses on eliminating electrical
hazards
Electrical Hazards
Examples of fatal accidents:
• Case #1: Worker electrocuted when the ladder
came in contact with overhead power lines
• Case #2: Worker electrocuted when mast
came in contact with high voltage overhead
lines
Electrical Hazards
• Case #3: Worker changing energized ballast
on light fixture was electrocuted and fell to
the concrete floor while working from an 8'
fiberglass stepladder.
Types of Electrical Hazards
Contact with overhead power lines:
• Overhead and buried
power lines carry
extremely high voltage
• Risks
– Electrocution (main risk)
– Burns and falls
Source: NIOSH
• Cranes are not the only
equipment that can reach
overhead power lines.
• Use of ladders or suspension
in a man-basket under or near Source:
OSHA
power lines are risks.
• Important: the covering on an overhead
power line is primarily for weather
protection; therefore, workers need to
know that if they touch a power line,
covered or bare, death is probable.
• https://www.osha.gov/dts/vtools/constructi
on/ladder_powerline_fnl_eng_web.html
Contact with energized
sources:
• Live parts
– The major hazards
• Electrical shock and burns
• Electrical shock occurs
when the body becomes
part of the electric circuit
Source:
OSHA
– Severity and effects of an electrical shock
depend on a number of factors
• Pathway through the body
• Amount of current
• Length of time of the exposure
• Whether skin is wet or dry
– Water
• Great conductor
• Allows current to flow more easily in wet conditions
and through wet skin
(1,000 milliamperes = 1 amp; therefore, 15,000 milliamperes = 15 amp circuit)
Chart
Below 1 milliampere
Current
Generally not perceptible
Reaction
1 milliampere Faint tingle

5 milliampere Slight shock felt; not painful but disturbing. Average
individual can let go. Strong involuntary reactions can
lead to other injuries
6-25 milliamperes (women) Painful shock, loss of muscular control
9-30 milliamperes (men) The freezing current or “let-go” range. Individual cannot
let go, but can be thrown away from the circuit if extensor
muscles are stimulated.
50-150 milliampres Extreme pain, respiratory arrest, severe muscular
contractions. Death is possible.
1,000-4,300 milliamperes Rhythmic pumping action of the heart ceases. Muscular
contraction and nerve damage occur; death likely
10,000 milliamperes Cardiac arrest, severe burns; death probable
This table shows the body’s reaction when exposed to various levels of current. Source: OSHA
• Damaged or bare wires
– Fault current may travel through a body,
causing electrical burns or death, if
• Power supply is not grounded
• Path has been broken
• There are live parts or bare wires
– Extreme conditions and rough treatment can
change electrical equipment from safe to
hazardous
• Defective equipment or tools
These photos show examples of defective equipment/tools. Source of photos: OSHA
• Improper repairs
– Examples of incidents
• Ballast strap not replaced after repair = Electrocution of
11 year old boy
• Cutting off bleed resistor on capacitor= causes 370-volt
shock
• Removing and leaving off terminal insulator on capacitor
= causes 440-volt shock
Improper use:
• Extension and flexible cords
– Care
– Connection
– Capacity
Source: TEEX SH 46F1-

HT06
– Capacity affected by
• Size of wire
– 14 gauge = 15 amps
– 12 gauge = 20 amps
• Length of the cord
– UL tag capacity
– In general any cord over
100 ft. requires one size
larger cord
(14 gauge to 12 gauge) Source:
OSHA
• Power strips:
– Can be over loaded
because of multiple
plug arrangement
– Most have overload protection Source: UBATC
but often malfunction causing fire

– Use fixed wiring when possible
• Portable heaters and appliances:
– Manufacturer recommendations
not followed
– Do not plug into a power strip!
This causes overloads and fires.
Source of photos: UBATC
Electrical Protection Methods
Maintain safe distance from
overhead power lines:
• Staying away
• Following table shows the safe
power line clearance distance
for various line voltages.
• https://youtu.be/Y2MwX738e1Y
Source of graphics: OSHA
Voltage Minimum Clearance Distance
(nominal, kV, alternating current) (feet)
Up to 50 10
Over 50 to 200 15
Over 200 to 350 20
Over 350 to 500 25
Over 500 to 750 35
Over 750 to 1000 45
Over 1000 (As established by the power line
owner/operator or registered
professional engineer who is a
qualified person with respect to
electrical transmission and
distribution)
This table shows the minimum clearance distances, in feet, for different power line voltages. Source: OSHA
Use ground-fault circuit
interrupters (GFCI):
• Designed to protect people
from electrical shock
• Detects ground faults and
interrupts electric current
• Limits duration of electrical
shock
Source: OSHA
Three types of GFCI:
• Receptacle GFCI
• Temporary/portable GFCI
• Circuit Breaker GFCI
These photos show examples of the three types of GFCI. Source of photos: OSHA
Inspect portable tools and extension cords:
• Workers need to inspect extension cords prior
to their use for any cuts or abrasion.
• Electric hand tools that are old, damaged, or
misused may have damaged insulation inside.
Use power tools and equipment as
designed:
• Follow tool safety tips to avoid misusing
equipment
• Follow manufacturer’s instructions
• Common examples of
misused equipment
Source: TEEX SH 46F1-

HT06
Source of photos: OSHA Source of photos: OSHA
These photos show examples of equipment misuse.
Tool safety tips
• Never carry a tool by the cord.
• Never yank the cord to disconnect it.
• Keep cords away from heat, oil, and
sharp edges.
• Disconnect when not in use and when
changing accessories such as blades
and bits.
• Avoid accidental starting. Do not hold
fingers on the switch button while carrying
a plugged-in tool.
• Use gloves and appropriate footwear.
• Store in dry a place when not using.
• Don’t use in wet/damp environments.
• Keep working areas well lit.
• Ensure that cords do not cause a tripping
hazard.
• Remove damaged tools from use.
• Use double-insulated tools.
Follow lockout/tagout (LOTO)
procedures:
• Lockout/tagout
– Essential safety procedure
– Protects workers from injury while
working on or near electrical
circuits and equipment Source:
OSHA
– Prevents contact with operating

equipment parts such as, blades,
gears, shafts, etc.
– LOTO prevents the unexpected
release of hazardous gases, fluids, or
solid matter in areas where workers
are present.
Source of photos: OSHA
Power source identification:
• Mark all breakers accordingly for the circuits
they protect
• Mark all disconnect means accordingly for
the equipment they service
• Identify all voltages with proper labeling
Employer Requirements
Employer requirements to protect workers:
• Ensure overhead power line safety
• Isolate electrical parts
• Supply ground-fault circuit interrupters (GFCI)
protection
• Establish and implement an AEGCP
• Ensure power tools are maintained in a safe
condition
Employer Requirements
• Ensure proper guarding
• Provide training
• Enforce LOTO safety related work practices
• Ensure proper use of flexible cords and
power strips
• Ensure proper identification of power
sources
Why know about it?
Because failing to take the necessary precautions can lead to:

• injury or death
• fire or property damage
What are the safety priorities?
Electrical hazards exist in almost every workplace. Common

causes of electrocution are:
• making contact with overhead wires
• undertaking maintenance on live equipment
• working with damaged electrical equipment, such as extension
leads, plugs and sockets
• using equipment affected by rain or water ingress
How do you respond to electrical incidents?
If you come across a person receiving an electric shock:

• if possible, disconnect the electrical supply (switch?)
• assess the situation – never put yourself at risk
• take precautions to protect yourself and anyone else in the
vicinity
• apply the first aid principles (e.g. DRSABCD)
• assess the injuries and move the casualty to a safe area if
required
• administer first aid if trained
• seek urgent medical attention
Do you want to be a victim?
You could be the victim if you:

• don’t follow proper procedures around electricity
• use electrical equipment improperly
• use faulty electrical equipment
What are the types of injuries?
• Burns
• Shocks
• Falls
KEEP SAFE
KNOW HOW TO CONTROL ELECTRICAL HAZARDS
What are the levels of effect of current?
AC current (mA) Effect on human body
1 Slight tingling sensation

2-9 Small shock
10-24 Muscles contract causing you to freeze
25-74 Respiratory muscles can become
paralysed; pain; exit burns often visible
75-300 Usually fatal; ventricular fibrillation; entry &
exit wounds visible
>300 Death almost certain; if survive will have
badly burnt organs and probably require
amputations
What should you do in an electrical emergency?
For low voltage electricity >50 V AC and 110 V DC

• remove the source of electricity supply
• commence CPR if trained
• call the emergency number on site
For high voltage electricity >1000 V

• call the emergency number for your site
• don’t go near the casualty
• don’t touch the casualty or try to free them with anything
Should you report electrical incidents?
• Electricity is invisible – this in itself makes it dangerous

• It has great potential to seriously injure or kill
• The company has a duty of care to its employees and
contractors
• Everyone is exposed to electrical hazards, not just electricians
• Report all electrical shocks and near misses
ALL EMPLOYEES CAN BE EXPOSED TO ELECTRICAL

HAZARDS. THEY SHOULD RECEIVE ELECTRICAL HAZARD
TRAINING AT THE COMMENCEMENT OF THEIR
EMPLOYMENT AND REGULAR REFRESHER TRAINING.
Can you protect yourself from electricity?
• Don’t wear metal objects

• Turn power off
• Wear appropriate clothing
• Don’t touch live parts
• Don’t install or repair electrical equipment
• Use qualified personnel
• Clean and dry leads and plugs before use
• Use PPE
What are other safety measures?
• Heed warning signs

• Use the right equipment
• Study the operation manual
• Take care of extension leads
• Use only approved extension lamps
• Don’t pull on leads
• Use residual current devices – RCDs
• Use the proper fuses and circuit breakers
Regular safety inspections
are a part of YOUR job...

• Electrical equipment should be checked each time
before use for defects
• If not tagged or the tag is out of date then report it and
place it out of service
Should you be aware of powerlines?
• Do you know if there are overhead powerlines on your site?

• Do you know where they are located?
• Do you know what the safe work clearance is?
• Strict regulations are laid down to cover any work that may have
to be performed close to overhead powerlines
What is a powerline corridor?
MSI Regulation 5.28 defines a powerline corridor as the area under

any overhead powerline that has not been properly isolated, and 10
metres either side of the powerline.
• It is essential that these areas are respected. They are there for
the safety of everyone
• Do not store equipment, machinery, buildings
or structures in powerline corridors
• Do not construct, fabricate or maintain
structures, buildings, machinery or
equipment in powerline corridors
LOOK UP AND LIVE
Can a powerline be approached safely?
Up to and including to 33 kV
• 2.3 m when passing underneath and 3 m when passing to the side
Above 33 kV
• 4 m when passing underneath and 6 m when passing to the side
Who can access substations?
• Only trained and authorised personnel may enter and work

inside a substation
• To enter a substation you must complete the substation entry
training
• Access is restricted for any cabinet with exposed energized parts
ALL ELECTRICAL WORK MUST TO BE RECORDED AND

ENTERED INTO THE ELECTRICAL MINES RECORD BOOK,
AND THE ELECTRICAL SUPERVISOR INFORMED
What are electric shock hazards?
• Arc welding can and has killed people in high risk environments
• Everyone involved needs to better understand the hazards,
adopt sound practice and use appropriate safety devices
• Study and adhere to the Code of Practice: WTIA Tech Note 7-04
• Use safety devices such as manual trigger switches and voltage
reducing devices (VRDs)
• Under adverse conditions, strive to improve control measures
(e.g. presence of moisture as sweat or rain)
A welding incident…
• Assistant hands welder a metal object.

Resultant current is 35 mA
I = V/R = 67/1900 = 35 mA
Result = Assistant survived but welder died
Do you have permission to dig?
Be aware of the potential hazard from buried electrical cables for

the following activities:
• excavation
• drilling
• trenching
• levelling
• digging
• driving of stakes or pegs
Do not commence excavation work near buried cables unless a

permit has been issued by an authorised person
Do you know what precautionary measures need to be taken?
What risk assessment?!
Is this a problem?
What’s Wrong?
Identify the hazards in these photos. Source of photos: TEEX SH 46F1-

HT06
What’s Wrong?
Identify the hazards in these photos. Source of photos: OSHA
Knowledge Check
1. What is electricity?
a. The movement of atoms within an object
b. The movement of free electrons between
atoms
c. Solid mass
d. Movement within the nucleus of an atom
Answer: b. The movement of free

electrons between atoms
Knowledge Check
2. “Electrocution” means ___.
a. received a mild electrical shock
b. killed by electrical shock
c. exposed to electrical current
d. any accident involving electricity
Answer: b. killed by
electrical shock R.I.
P.
Knowledge Check
3. Arc flash/arc blast can reach
maximum temperatures up to 350˚F?
a. True
b. False
Answer: b. False - temperatures

can reach up to 3,500˚F
Knowledge Check
4. Which gauge of wire will carry the
most current?
a. 14 gauge
b. 12 gauge
c. 10 gauge
d. 00 gauge
Answer: d. 00 gauge – the lower the

wire gauge number, the
more current it can carry
Knowledge Check
5. What does GFCI stand for?
a. Ground Flexible Conduit Insulator
b. Ground Flow Current Interceptor
c. Ground Fault Circuit Interrupter
d. Ground Floor Connection Intersector
Answer: c. Ground Fault Circuit

Interrupter
Knowledge Check
6. Which of the following is a safe practice?
a. Carrying power tool by the cord
b. Holding fingers on switch button while
carrying a plugged-in tool
c. Keeping cords away from heat, oil, and
sharp edges
d. Yanking cord to disconnect plug from outlet
Answer: c. Keeping cords away from
heat, oil, and sharp edges
Knowledge Check
7. Who is responsible for ensuring that
overhead power lines are de-energized?
a. Power company
b. Employer
c. Employee
d. Municipality
Answer: b. Employer
The key messages are…
• The risk of electric shock from correctly installed and maintained

power sources is negligible, provided that sensible precautions
are taken by the operator and correct work procedures are
followed
• Ensure that the right person is carrying out electrical work –
licensed versus competent
• Electricity is essential but, improperly used, it can be DEADLY!
To STAY ALIVE, you have to STAY ALERT

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Industrial Electrical

Glenn Kwabena Gyimah (PhD)

Electrical hazard safety means:

• Current – the movement of

power lines are risks.

1 milliampere Faint tingle

These photos show examples of defective equipment/tools. Source of photos: OSHA

Source: TEEX SH 46F1-

but often malfunction causing fire

Source of photos: UBATC

Source of graphics: OSHA

Source: TEEX SH 46F1-

Source of photos: OSHA Source of photos: OSHA

These photos show examples of equipment misuse.

– Prevents contact with operating

Source of photos: OSHA

Because failing to take the necessary precautions can lead to:

Electrical hazards exist in almost every workplace. Common

If you come across a person receiving an electric shock:

You could be the victim if you:

AC current (mA) Effect on human body

1 Slight tingling sensation

For low voltage electricity >50 V AC and 110 V DC

For high voltage electricity >1000 V

• Electricity is invisible – this in itself makes it dangerous

ALL EMPLOYEES CAN BE EXPOSED TO ELECTRICAL

• Don’t wear metal objects

• Heed warning signs

are a part of YOUR job...

• Do you know if there are overhead powerlines on your site?

MSI Regulation 5.28 defines a powerline corridor as the area under

LOOK UP AND LIVE

• Only trained and authorised personnel may enter and work

ALL ELECTRICAL WORK MUST TO BE RECORDED AND

• Assistant hands welder a metal object.

Be aware of the potential hazard from buried electrical cables for

Do not commence excavation work near buried cables unless a

Identify the hazards in these photos. Source of photos: TEEX SH 46F1-

Identify the hazards in these photos. Source of photos: OSHA

Answer: b. The movement of free

Answer: b. False - temperatures

Answer: d. 00 gauge – the lower the

Answer: c. Ground Fault Circuit

• The risk of electric shock from correctly installed and maintained

To STAY ALIVE, you have to STAY ALERT

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