INDUSTRIAL SAFETY 18ME753

MODULE-4: ELECTRICAL SAFETY

Introduction to Electrical Safety:

[Define electrical safety. List out the basic factors to be considered ensuring
electrical safety in general work place.]

The state of being safe and protected from danger or harm caused by unanticipated electric hazards
in surrounding environment is called electrical safety.

Example:

1. Protection against Fire caused by failure in an electrical circuit, when electricity travels along
the wrong route because of damaged wires or a fault in the connections between the wires.
2. Protection against the shock and electrocution.
3. Protection against the explosion caused due short circuits, electric hazards.

Electricity is widely recognized as a serious workplace hazard, exposing employees to

electric shock, burns, fires, and explosions. According to the Bureau of Labor Statistics, 250
employees were killed by contact with electric current in 2006. Other employees have been killed or
injured in fires and explosions caused by electricity.
It is well known that the human body will conduct electricity. If direct body contact is made
with an electrically energized part while a similar contact is made simultaneously with another
conductive surface that is maintained at a different electrical potential, a current will flow, entering
the body at one contact point, traversing the body, and then exiting at the other contact point, usually
the ground. Each year many employees suffer pain, injuries, and death from such electric shocks.

Electric Safety at General Work Place.

Electric Circuit Components.

CORDS
 Cords are in good condition.
 Arrange cords so they are placed out of traffic areas.
 Never nail or staple cords to the wall.
 DO NOT place cords under carpets.

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PLUGS

 Never force a plug into an outlet if it doesn't fit. Plugs should fit securely into outlets.

 Never remove the ground pin (the third prong) this could lead to an electrical shock.
EXTENSION CORDS

 Do not overload cords.

 Use extension cords on a temporary basis.

OUTLETS

 Check for outlets that have loose-fitting plugs, which can overheat and lead to fire.

 Replace any missing or broken wall plates.

 Make sure there are safety covers on all unused outlets.

 Avoid overloading outlets with too many appliances.

GROUND FAULT CIRCUIT INTERRUPTERS

 Use GFCIs in any area where water and electricity may come into contact.

WATER SOURCES

 Do not leave plugged in appliances where they might fall in contact with water.

 If a plugged-in appliance falls into water, never reach in to pull it out.

 If you have an appliance that has gotten wet, don't use it until it has been checked by a
qualified repair person.

LIGHT BULBS

 Make sure all bulbs in light fixtures are the correct wattage for the size of the fixture.

 Make sure bulbs are screwed in securely; loose bulbs may overheat.

CIRCUIT BREAKERS AND FUSES

 Make sure circuit breakers and fuses are the correct size current rating for their
circuit. Label the size to be used.

 Always replace a fuse with the same size fuse.

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APPLIANCES

● If an appliance repeatedly blows a fuse, trips a circuit breaker or if it has given you a
shock, unplug it and have it repaired or replaced.

OUTDOOR SAFETY
● Always use an extension cord marked for outdoor use.

● Remember to unplug all portable power tools.

● Since metal ladders conduct electricity, watch out for overhead wires and power lines.

STORMY WEATHER
During an electrical storm:

● DO NOT use appliances (i.e., hairdryers, radios) or telephones (except in an

emergency).

● DO NOT take a bath or shower.

● Keep batteries on hand.

SPACE HEATERS
● Keep space heaters at least 3 ft. away from any combustible materials .

● DO NOT use space heaters in rooms where children are unsupervised.

● Remember! turn off and unplug heaters when not in use.

ELECTRICITY SAFETY
● Electrocution is mainly due to serious injury of the heart.
● Before using an electrical appliance, one should check if the tool is functioning properly. An
portable electrical tool should be earthed unless it is of double-insulated construction. Earthing of
an electrical tool can reduce the risk of electric shock. The marking of “回” on a portable
electrical tool means it is of double-insulated construction. Double-insulation of electrical tools
can avoid current leakage.
● An electrical appliance should be repaired after the power supply has been completely isolated. A
failed electrical appliance should be repaired by a competent electrician. Improper repairing of an
electrical appliance may cause explosion, burnt or electric shock.

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1 Practices/Situations Leading To Electrical Accidents:

● Repair electrical tools by an unqualified person.

● Unauthorized modification of electrical tools.
● Allow live parts of electric wires to expose.
● Directly connect wires to power supply without using an electric plug.
● Conduct arc welding in a humid environment.

2 Practices/situations to avoid electrical accidents:

● Repair electrical tools by a competent electrician.

● Regularly inspect electrical tools.
● Adopt “permit-to-work” for repairing electrical appliances.
● Use an appropriate plug to connect power supply.
● Stand on an insulated mat.

Electric Hazards:
[Write a note on electric hazards / List and explain the various hazards associated with
electricity.]
Electricity has long been recognized as a serious workplace hazard, exposing employees to electric
shock, electrocution, burns, fires, and explosions.
When electrical tools are working properly a complete circuit is maintained between the tool and the
energy source. However, if the tool is damaged the person may come in contact with the electricity and
can become a path for the current. The person will be shocked!

The following is a list of common electrical hazards found on construction sites:

● Improper grounding
● Exposed electrical parts
● Inadequate wiring
● Damaged insulation
● Overloaded circuits
● Wet conditions
● Damaged tools and equipment.
● Overhead power lines

1. Improper grounding
Grounding is the process used to eliminate unwanted voltage. A ground is a physical electrical
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connection to the earth. Electrical equipment must be properly grounded. Grounding reduces the risk
of being shocked or electrocuted. The ground pin safely returns leakage current to ground. Never
remove the ground pin. Removing the ground pin removes an important safety feature. You can get
shocked!

2. Exposed electrical parts

Exposed wires or terminals are hazardous. Report these conditions to your supervisor.

This electrical panel has missing circuit breakers. Never use a panel that has exposed wires. All
openings must be closed. Outer insulation on electrical cords must be intact. On construction sites,
temporary lighting must be properly guarded and protected to avoid contact with broken bulbs and
avoid potential shocks.

3. Inadequate wiring
Use properly rated extension cords. Make sure your power tools are being used with a
properly rated extension cord.

Different types of wires with their electrical current rating.

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4. Damaged insulation
Defective or inadequate insulation is a hazard. Insulation prevents conductors from contacting each
other or you. Never attempt to repair a damaged cord with tape. Never use tools or extension cords
with damaged insulation. Never hang extension cords from nails or sharp objects. Do not run
extension cords through doors or windows.

5. Overloaded circuits
Overloaded circuits can cause fires. Use proper circuit breakers. Never overload an outlet.

Do not use power strips or surge protectors on construction sites. Use a 3-way extension with a GFCI
instead.

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6. Wet conditions
Wet conditions are hazardous. Damaged insulation increases the hazard. Always avoid using tools in
wet locations. Water increases the risk of electric shock.

7. Damaged tools and equipment.

Do not use electric tools that are damaged. You may receive a shock or be electrocuted.

Double insulated tools are labeled. It will be marked “Double Insulated”. It will have the following
symbol:

8. Overhead power lines

Survey the site for overhead power lines. Never store materials or equipment under overhead power
lines. Maintain a distance of at least 10’ between tools and equipment and overhead power lines.
Shocks and electrocutions occur where physical barriers are not in place to prevent contact with the
wires. Maintain safe distances between scaffolding and overhead power lines. Overhead power lines
are very dangerous. Never attempt to contact an overhead power line.

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Effect of Electric Current on Human Body:

Just 1 second of an electric shock can result in anything from a slight tingling sensation to
immediate cardiac arrest. The severity depends on the following:

● The amount of current flowing through the body,

● The current’s path through the body,

● The length of time the body remains in the circuit, and

● The current’s frequency.

Current through the body, even at levels as low as 3 milli amperes, can also cause injuries ofan indirect
or secondary injuries in which involuntary muscular reaction from the electric shock can cause bruises,
bone fractures and even death resulting from collisions or falls.

Shock Current, Not Voltage causes Electric ShockHand to Hand Resistance = 1000W

• Common voltage is 120 Volts

• Ohm’s Law: I = E/R

• 120/1000 = .12 Amps • (480/1000= .48 Amps)

• Voltage=AmpsXOhms(resistance)

• Converting voltage to amps

• Typical Industrial Voltages

1 110/120Volts=60milli-amps (mA)

2 220/240 Volts = 120 mA

3 440/480 Volts = 240 mA

This table shows the general relationship between the amount of current received and thereaction when
current flows from the hand to the foot for.

Effects of Electric Current on Human Body

Current [mA] Effect on Person

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0.5 - 3 Tingling sensations

3 – 10 Muscle contractions and pain

10 – 40 “Let-go” threshold

30 - 75 Respiratory paralysis

100 – 200 Ventricular fibrillation

200 – 500 Heart clamps tight

1500 + Tissue and Organs start to burn

Burns suffered in electrical accidents can be very serious.

These burns may be of three basic types:

• Electrical burns,

• Arc burns, and

• Thermal contact burns.

Electrical burns are the result of the electric current flowing in the tissues, and may be either skin deep
or may affect deeper layers (such as muscles and bones) or both. The heat generated from the current
flow; if the energy delivered by the electric shock is high, the body cannot dissipate the heat, and the
tissue is burned causes tissue damage. Typically, such electrical burns are slow to heal. Arc burns are
the result of high temperatures produced by electric arcs or by explosions close to the body. Finally,
thermal contact burns are those normally experienced from the skin contacting hot surfaces of
overheated electric conductors, conduits, or other energized equipment. In some circumstances, all
three types of burns may be produced simultaneously.

If the current involved is great enough, electric arcs can start a fire. Fires can also be created by
overheating equipment or by conductors carrying too much current. Extremely high-energy arcs can
damage equipment, causing fragmented metal to fly in all directions. In atmospheres that contain
explosive gases or vapours or combustible dusts, even low-energy arcs can cause violent explosions.

The number of electrons we are willing to let across the circuit at one time is called "current". We
measure current using amperes, or "Amps". One AMP is defined as 625,000,000,000,000,000,000

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(6.25 x 1018) electrons moving across your circuit every second! Since no one, wants to remember
such a big number, that big number is called a "coulomb," after the scientist Charles A Coulomb who
helped discover what a current of electricity is. The amount of charge between the sides of the circuit
is called "voltage." We measure Voltage in Volts. The word volt is named after another scientist,
Alexander Volta, who built the world's first battery.

Current through the body, even at levels as low as 3 mill amperes, can also cause injuries of an
indirect or secondary injuries in which involuntary muscular reaction from the electric shock can cause
bruises, bone fractures and even death resulting from collisions or falls.

Each year many employees suffer electric shocks while using portable electric tools and equipment.
The nature of the injuries ranges from minor burns to electrocution. Electric shocks produced by
alternating currents (ac) at power line frequency passing through the body of an average adult from
hand to foot for 1 second can cause various effects, starting from a condition of being barely
perceptible at 1 milli ampere to loss of voluntary muscular control for currents from 9 to 25
milliamperes. The passage of still higher currents, from 75 milliamperes to 4 amperes, can produce
ventricular fibrillation of the heart; and, finally, immediate cardiac arrest at over 4 amperes. These
injuries occur when employees contact electrically energized parts. Typically, the frame of a tool
becomes accidentally energized because of an electrical fault (known as a ground fault) that provides a
conductive path to the tool casing. For instance, with a grounded electric supply system, when the
employee contacts the tool casing, the fault current takes a path through the employee to an electrically
grounded object. The amount of current that flows through an employee depends, primarily, upon the
resistance of the fault path within the tool, the resistance of the path through the employee's body, and
the resistance of the paths, both line side and ground side, from the employee back to the electric
power supply. Moisture in the atmosphere can contribute to the electrical fault by enhancing both the
conductive path within the tool and the external ground path back to the electric power supply. Dry
skin can have a resistance range of anywhere from about 500 to 500,000 ohms and wet skin can have
a resistance range of about 200 to 20,000, depending on several factors, such as the physical
characteristics and mass of the employee. More current will flow if the employee is perspiring or
becomes wet because of environmental conditions. If the current is high enough, the employee will
suffer a ground- fault electrocution.

One method of protection against injuries from electric shock is the ground-fault circuit interrupter
(GFCI). This device continually monitors the current flow to and from electric equipment. If the
current going out to the protected equipment differs by approximately 0.005 amperes (5-milliamperes)
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from the current returning, then the GFCI will de-energize the equipment within as little as 25
milliseconds, quickly enough to prevent electrocution.

Rules of Electricity
• Electricity travels in a completed circuit

• Electricity always travels in the path of least resistance

• Electricity tries to travel to Ground
•
Effects of Electricity on Human Body
Burns

The most common shock-related injury is a burn. Burns suffered in electrical incidents maybe one or
more of the following three types:

– Electrical Burns cause tissue damage, and are the result of heat generated by the flow of electric
current through the body. Electrical burns are one of the most serious injuries you can receive and
need to receive immediate medical attention.

– High temperatures near the body produced by an electric arc or explosion cause Arc or Flash Burns
(also need prompt medical attention)

– Thermal Contact Burns occur when skin comes in contact with overheated electric equipment, or
when clothing is ignited in an electrical incident.

Internal Injuries

▪ Our bodies use small electrical currents to transmit signals through the nervous system and contract

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muscles, Extra electrical current flowing through the body can cause serious damage.

▪ Medical problems can include internal bleeding, tissue destruction, and nerve or muscle damage.

▪ Internal injuries may not be immediately apparent to the victim or observers; however, left untreated,
they can result in death

Electric shock occurs when a body becomes a part of electric circuit.

• A person may come in contact with both the conductors

• A person may provide a path between an ungrounded conductor and the ground.
• A person may provide a path between the ground and a conducting material that in contact with an
ungrounded conductor.
The extent of accompanying electric shocks depends on three factors:

1 The amount of current conducted through the body.

2 The path of the current through the body.

3 The length of the time a person is subjected to the current.

4 The amount of current depends on the potential difference and the resistance.

5 The effect of low current on human body range from a temporary mild tingling sensation to the death.

6 An electric shock can injure you in either or both the following.

7 A sever shock can stop the heart or breathing the muscle, or both.

8 The heating effects of current can cause severe burns, especially at points where the electricity enters and
leaves the body.

9 Other effects include severe bleeding, breathing difficulty and ventricular fibrillation.

An electric shock may injure the human body in several ways:

• Contraction of chest muscles causing interference with breathing, leading to asphyxiation.

• Temporary paralysis of the nerve center leading to breathing failure.
• Ventricular fibrillation which is an irregular movement of heart muscles leading to failure of
blood circulation.
• The heart cannot spontaneously recover, causing death.
• Hemorrhage and destruction of nerves, tissues and muscles, caused mainly by heat.
• When electricity passes through the body, it can interfere with the normal electrical signals

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between the brain and other body systems.

• Arc flashes result in intense heat causing burns or ignition of other materials.
• Contact with high voltage can cause burns in internal tissues.

Precautions to be taken while working with electricity

• Check for damage on power plugs, wire and other electrical fittings. If found damaged, repair
or replace damaged equipment immediately.

• Keep electrical wires of equipment away from hot surfaces to prevent damage of the
insulation.

• Do not lay electric wires along passage. It can be a trip hazard. Further contact with sharp edges
can cause damage to insulation leading to short circuit.

• Know the location of switches/circuit breaker boxes for use in case of an emergency.

• All circuit breakers in the switch board must be clearly labelled for easy identification.

• Access to circuit breakers must not be blocked.

• Extension cords must be used only to supply power temporarily.

• Do not handle electrical equipment when hands, feet or body are wet or perspiring, or when
standing on a wet floor.

• Consider all floors as conductive unless covered with insulating matting of suitable type for
electrical work.

• Whenever possible, use only one hand when working on circuits or control devices.

• Do not wear rings, metallic watchbands, chains etc. when working with electricalequipment.

Precautions to be taken while using power tools

• Before connecting the tool to the power supply, switch the tool OFF.

• Disconnect power supply before making adjustments.

• The tool must be properly grounded with a 3-wire cord with a 3-prong plug. Use double insulated
tools wherever possible.

• Do not use electrical tools in wet conditions or damp locations unless the tool is connected to an

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Earth Leakage Circuit Breaker.

Causes Of Electrical Accidents:

[List and explain the various causes of electrical accidents]
Electricity travels in closed circuits, normally through a conductor. Sometimes a person’s body - an
efficient conductor of electricity - mistakenly becomes part of the electric circuit. This can cause an
electrical shock. Shocks occur when a person’s body completes the current path with:

• Both wires of an electric circuit;

• One wire of an energized circuit and the ground;

• A metal part that accidentally becomes energized due, for example, to a break in its insulation; or

• Another “conductor” that is carrying a current.

• When a person receives a shock, electricity flows between parts of the body or through the body to
a ground or the earth.
Common Causes of Electrical Accidents Are as Follows:

1. Defective Equipment: types of equipment frequently involved in electrical accidents include

motor driven equipment, control devices, portable electric tools, switches, panels, cut-outs,
conductors, plugs and fuses, and electric extension cords. A variety of unsafe conditions involving the
different types of equipment creates many electrical hazards. Some of the common defects of tools and
equipment are listed as follows:

a) Improperly grounded equipment (ground wires missing, broken or improperly connected);

b) Open conduits, switch boxes, damaged or worn connections, and exposed live wires;

c) Insulation, which is defective, inadequate, worn, frayed, wet, oily or deteriorated, creating
short circuit possibilities and energizing equipment, frames;

d) Defective switches, receptacles, extension cords, and lamp sockets;

e) Dirty motor windings, improperly adjusted brushes, and worn commutators;

f) Improperly connected power tools and defective insulation in portable tools;

g) Broken housings, loose or vibrating machine parts which might contact and energize tool or
machine frames and expose “live” surfaces to operator.

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2. Unsafe Practices: Unsafe practices and work procedures result in electrical accidents and fires.
Some of the common unsafe acts committed in the shop are:

a) Using ungrounded equipment and portable tools (except double insulated tools) or
removing ground connections;

b) Using defective tools or equipment in need of repair;

c) Using equipment which does not meet the approval of the Underwriters Laboratories for
the intended use;

d) Unsafe cleaning of electrical panels, switch boxes, motors, and other electrical equipment
with water or dangerous solvents;

e) Overloading of circuits or over-fusing circuits by the use of wrong size or type of fuse;

f) Failure to use explosion-proof or other special wiring methods in hazardous locations.

g) Failure to positively lock out or otherwise de-energize and tag equipment or circuits to be
worked on. Do not rely on gloves, rubber mats, etc., for electrical installation and repair.

h) Installation or extension of electrical facilities in a manner not meeting the National

Electrical Code;

i. Repetitive closing of switches or circuit breakers when there is a fault on the circuit.

ii. Using light duty, ungrounded extension cords for industrial service;

iii. Failure to maintain clear access to electrical panels. The Federal Code requires
clearance of30 inches.

iv. Use of extension cords in place of permanent wiring extensions;

v. Work practices which overload motors, insulation, wires or electrical accessories;

vi. Disconnecting of electric cords by pulling on the cords rather than on the plug;

vii. Use of metal ladders while working on electrical equipment; p. Failure to label switch
panels and boxes.

3. Lack of knowledge: Teaching a basic understanding of electrical safety is part of a Technology/

Engineering Educational Program. Ground Fault Protection – a recent development that can save lives.
Devices are now readily available which give sure protection against electrocution or serious shock
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from defective portable tools or cords. Their use should be encouraged in all areas, but particularly
where there is a serious shock hazard from wet conditions or other conditions causing massive
grounding of the student.

AC & DC CURRENT SHOCKS

AC stands for alternating currents while DC stands for direct currents.

Dangers of AC and DC Current

DC supply is more dangerous on the body and can cause more harm as it continuously flows in one direction
whereas AC keeps on changing direction but is more dangerous to the heart. DC voltage can cause muscle
spasms in one direction. For example, if you were touching an electrical fence with the bottom of your fingers,
the shock causes your muscles to spasm and as a result, your fingers rap around the electric wire, sending in
more shocks – in basic terms, you can’t let go. 240v AC has the same heating effect as a 240v DC current but
AC voltage alternates as 240v is an average value; it is the potential between two phases of a three-phase
distribution system. Whereas a 240v DC is the potential between and single wire and ground. Both AC and DC
voltages can cause burns, electrocution, shocks, muscle spasms, unconsciousness and in serious cases, death.
Electrocution, by both AC and DC voltages, causes a violent disturbance of the nervous system, thus affecting
all muscles of the body. It is most common when a person touched an active wire and there are two types of
wire: the neutral wire and the active wire (hot wire). The neutral wire is connected to the earth at the power
station and is maintained at earth potential because of this. The active wire is one of the wires that bring
electricity from the power station to the house, making it more dangerous. Electric currents can cause the
muscles to contract. This is especially dangerous if the muscles that are contracting are required for breathing -
it can cause breathing to cease and this can lead to death. However, the effects of mains AC currents on the
heart are more complicated. Fibrillation can be caused by AC mains and is when the heart stops beating
regularly and oscillates rapidly, and cannot pump blood, meaning death follows in minutes. Currents above 200
mA (milliamps) will not cause fibrillation, but will cause the heart to clamp. This is where AC is more
dangerous than DC because DC does not lead to fibrillation. Both are lethal but more DC current is required to
have the same effect as AC current at the same voltage but deep tissue burns are common in DC shocks than

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compared to AC shocks. Therefore, AC current is more dangerous to the heart and DC current is more
dangerous to the body, specifically human flesh.

Effects of Ac and Dc Current on Human Body

The three basic factors that determine what kind of shock you experience are the amplitude of the current, the
duration of the current passing through the body, and the frequency.

Direct Currents actually have zero frequency, as the current is constant. However, there are physiological
effects during electrocution no matter what type of current. The factor deciding the effects of the AC and DC
current is the path the current takes through the body. If it is from the hand to the foot, it does not pass through
the heart, and then the effects are not so lethal. However DC current will make a single continuous contraction
of the muscles compared to AC current, which will make a series of contractions depending on the frequency it
is supplied at. In terms of fatalities, both kill but more milliamps are required of DC current than AC current at
the same voltage. If the current takes the path from hand to hand thus passing through the heart it can result in
fibrillation of the heart. Fibrillation is a condition when all the heart muscles start moving independently in a
disorganized manner rather than in a state of coordination. It affects the ability of the heart to pump blood,
resultingin brain damage and eventual cardiac arrest.

Either AC or DC currents can cause fibrillation of the heart at high enough levels. This typically takes
place at 30 mA of AC (rms, 60 Hz) or 300 – 500 mA of DC.

Safety Precautions in Small and Residential Building Installations

1. Do not use outlets or cords that have exposed wiring.

2. Do not use portable cord-and-plug connected power tools if the guards are removed.
3 . Do not block access to panels and circuit breakers or fuse boxes.
4. Do not touch a person or electrical apparatus in the event of an electrical incident.
5. Don’t over-plug a single outlet
6. Never plug a bunch of different wires and cords into one single outlet or extension cord. It could
damage the electrical system in your house and is a major fire hazard. It is also a waste of energy
and not very environmentally friendly.
7. Keep electrical cords out of reach
8. Keep electrical cords out of reach of curious babies and toddlers and teething pets. Make sure that
all electrical cords are tucked away and kept neat and tidy. Otherwise, teething babies and pets

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can chew on them, not knowing any better, and people might even trip on them and fall.
9. Keep children and pets away from any electrical fences
10. Make sure that children and pets are kept away from any electrical fences and, in the case of
children; they know never to touch or climb them.
11. Call the electric company if a ball or pet gets inside the fence, or tell your children to call the
nearest grown-up to do so. The electric company will come and help them. They should know
they don’t have to try to get it themselves as it is extremely dangerous.
12. Don’t yank cords out of the outlet.
13. Pulling on a cord too hard can damage the appliance, whether the plug or the outlet, so don’t yank
cords out of the outlet.
Be Smart About Power Lines
Looking out for power lines is an important outdoor electric safety tip. If your child is out flying kites,
make sure there aren’t any power lines or substations nearby, as kites can conduct electricity and send
it down to your child on the ground. Also tell your child to look out for power lines if they are out
climbing trees.
Be Smart About Thunderstorms
Thunderstorm safety is another important outdoor electric safety tip. If your child is outside swimming
and you see a bolt of lightning, or even if you hear a clap of thunder, get them out of the water and as
far away from the water as possible. Also, if you and your child are caught outside in a thunderstorm,
don’t wait it out under a tree. Get away from any trees and to the nearest shelter.
Keep Electrical Equipment Away From Water
Make sure that all electrical cords, wires, or equipment are kept away from any water. Most indoor
electrical incidents happen because people use electricity near water.
Don’t Put Metal In Outlets
Make sure that your child is not putting anything metal inside of outlets, such as forks.
Use Safety Caps
To expand on the last point, always put safety caps on all unused electrical outlets. Covering outlets
will not only keep your children and pets safer, it will help save you energy by stopping cold drafts
from getting in your home.
In Doubt, Ask A Grown Up
Tell your child that if you are not nearby and they have a question or problem related to electricity, or
if they need to use something that’s electrical but don’t know how, that they should always ask the
nearest grown-up for assistance. If they can’t find a nearby grownup, then they shouldn’t try it on their

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own.

SAFETY PRECAUTIONS IN ELECTRICAL PLANT

When viewing flames or furnace conditions, always wear tinted goggles or a tinted shield to protect
the eyes from harmful light intensity and flying ash or slag particles.
1. Do not stand directly in front of open ports or doors, especially when they are being opened.
Furnace pulsations caused by firing conditions, soot blower operation, or tube failure can blow hot
furnace gases out of open doors, even on balanced draft units. Aspirating air is used on inspection
doors and ports of pressure-fired units to prevent the escape of hot furnace gases. The aspirating
jets can become blocked, or the aspirating air supply can fail.
2. Do not use open-ended pipes for rodding observation ports or slag on furnace walls. Hot gases can
be discharged through the open-ended pipe directly onto its handler.
3. When handling any type of rod or probe in the furnace, especially in coal-fired furnaces, be
prepared for falling slag striking the rod or probe. The fulcrum action can inflict severe injuries.
4. Be prepared for slag leaks. Iron oxides in coal can be reduced to molten iron or iron sulfides in a
reducing atmosphere in the furnace resulting from combustion with insufficient air. This molten
iron can wash away refractory, seals and tubes, and leak out onto equipment or personnel.
5. Be prepared for slag leaks. Iron oxides in coal can be reduced to molten iron or iron sulfides in a
reducing atmosphere in the furnace resulting from combustion with insufficient air.
6. Never enter a vessel, especially a boiler drum, until all steam and water valves, including drain and
blowdown valves, have been closed and locked or tagged. It is possible for steam and hot water to
back up through drain and blowdown piping, especially when more than one boiler or vessel is
connected to the same drain or blowdown tank.
7. Be prepared for hot water in drums and headers when removing manhole plates andhandhole coversDo not
enter a confined space until it has been cooled, purged of combustible and dangerous gases and properly
ventilated with precautions taken to keep the entrance open. Station a worker at the entrance
and notify the responsible person. 6.Be prepared for falling slag and dust when entering the boiler
setting or ash pit.
8. Use low voltage extension cords or cords with ground fault interrupters. Bulbs on extension cords
and flashlights should be explosion proof.

Case Study-1: Lorry Driver Suffers Burns

A lorry driver suffered extensive electrical burns to his head and body whilst delivering material to
cover a horse gallop at a farm. As a result he lost one of his arms below the elbow and part of his skull.
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He also sustained extensive burns to both legs when the raised body of his lorry touched an 11,000
Volt overhead power line. This accident happened 100 metres from where a spraying contractor had
been killed by the same overhead power line.

There is no evidence that the power lines were under specified height, or that they were defective in
any way.

Action

The farmer was prosecuted under Section 3(1) of the Health & Safety at Work etc Act 1974 and was
fined.

Following the accident he stated that he was so traumatised that he would no longer be carrying on
business. It should be noted that the injured person was fully aware of the overhead power lines and
was partly responsible for his own accident.

Comment

The farmer should have:

a. Ensured that no vehicle that was to go on the gallop had the capability to elevate or otherwise
contact power lines or

b. Erected a simple goal post type barrier at the start of the gallop to which drivers of high
tipping/elevating vehicles could have used to gauge heights and

c. Ensured that drivers of high or tipping/elevating vehicles were properly notified of the locations
of overhead power lines and the precautions that they needed to take to operate safely on the
gallop.

d. The downloadable guidance Avoidance of danger from overhead electric power lines describes
how to work safely near overhead power lines in a range of industries. You can also download a free
leaflet called Safe working near overhead power lines in agriculture.

Case Study-2: Contractor Sustains Electric Shock after Failure to Isolate Power
Supply
A self-employed contractor sustained 415 volt electric shock injuries from the bare electrical wires
supplying an overhead travelling crane whilst working from a 'cherry picker' installing computer
cabling. The defendant company failed to follow their procedures for safe isolation of the power
supply to the crane.

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 INDUSTRIAL SAFETY 18ME753

Action

The company was prosecuted under the Health and Safety At Work etc. Act 1974, Section 3, Sub
Section 1 and The Management of Health and Safety at Work Regulations 1992 (No 4) paragraph 1
due to the high risk of serious or fatal injuries from the energised electrical wires. This resulted in a
£15,000 fine.

Comment

• The company should have undertaken a risk assessment of the cabling activity that should have
identified the hazard from the electrical wires.

• The company should have taken action to warn the contractor of the presence of electrical wires
near where the work was being carried out.

• The company should have taken steps to only allow work when the electrical power had been
turned off and to ensure that power remained off for the duration of the work.

• The downloadable HSE booklet practices provide guidance on how the electrical risks of
working on or near equipment and machinery can be controlled.

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