Electrical Hazards and Safety

Compiled By: Arvind Thukral

Self Introduction

Name - Arvind Thukral

Qualifications:

B.E. (Electrical) REC Bhopal 1969

FIE

MAM (Mumbai University) 1986

Certified Energy Auditor - 2007

Self Introduction
Experience:

Tata Mills, Mumbai (Textile)

7 years (1970 76) in Electrical / Utilities

HLL / Unilever
5 years Maintenance
10 years in Electrical Design, installation
and commissioning for new factories.
Central support to factories.
10 years as Factory Manager in various
businesses.

Self Introduction

Experience (continued..)
Since Retirement in 2002 involved in
Electrical Safety Audits of factories / Offices
HUL, Cadbury, Bilcare Limited, United
Breweries, Cipla, Syngenta, Nestle,
Britannia, ITPL, Gokaldas Exports.
Electrical Safety Initiative in HUL.
Electrical Engineering Training various
levels

Self Introduction

Experience (continued..)
Since Retirement in 2002 ..
Consultancy in Electrical Engineering
HLL, Universal Capsules, Cadbury,
Syngenta, United Breweries Limited..

Energy Saving Initiatives:

Bilcare
Gokaldas
HUL

Electrical Hazards and

Safety

Is Electricity Dangerous?

Electrical Hazards

What are the Hazards?

Contact Hazard with Electricity

Earthing Helps.
Fuse Blows

Safe to touch
Current stops

Equipment
Earthed

6 A Fuse / MCB

Current - Hundreds
of Amp

Earthing is cut here!

Fuse Does not Blow

Equipment
Earthed

6 A Fuse / MCB

Current is 240
miliampere

Result

Electrocution

Human Body
Resistance 1000 ohm

Electrical current through human

body & its effect
What

happens when current passes through

human body:

Is DC Safer?

Electrical Hazards

Electrical Hazard

Defibrillator in Use

Electrical Hazard

Contact electrical burns.

The knee on the left was energized and the knee on the right
was grounded.

Electrical Hazards

Arm with third degree burn from High

Voltage Line

Contact Hazards
Hence

there is a need for user protection

through highly sensitive, fast tripping
devices based on detection of the Residual
Current to earth through human body or
otherwise.

For

human safety standardize on a device

which will detect 30-ma of residual current
and trip in 30-ms (BIS limit 200 ms).

Residual Current Protection

Principle of operation of a Residual Current Device.

Sensitivity 30 ma

Circuit is Safe now

Residual Current Protection

Principle of operation of a Residual Current Device.

Sensitivity 30 ma

Circuit Disconnected - Person is safe

Electrical Hazards Use of ELCBs

Consider ELCBs for the following circuit applications

All 3-phase and single phase plug points.

All portable tools,
Welding machines, movable plant equipment such as conveyors,
packing / wrapping machines , metal detectors, hydro-pack and
metering pump units etc. not permanently grouted on a 24*7
basis, light fittings, ceiling fans, air circulators, stitching machines
etc
Where maintenance of earthing is in doubt, particularly for the
high-risk areas like off site locations, project sites, contractors
sheds, temporary installations, trolley-mounted
pumps/equipment etc

Electrical Hazards. contd

Short

Circuit Hazards

Insulation failure
Unintentional contact of two/three phases (low
resistance path) or phase and earth
Energy released is proportional to the square of
current and proportional to the time it flows.
Released energy radiates heat and causes flash,
burns and damages equipment.

Flash Can kill

HV Isolator Arc

Transformer Failure - Movie

Damage Due to Short Circuit

Damage Due to Short Circuit

Electrical Hazards

Electrical Burns on Hands

and Arms

Electrical Hazards

How unsafe electrical installations affect safety of personnel and

plant

Low energy level faults leading to fatality

Caused by human contact (direct or Indirect) with live parts in the event of
insulation failure / ineffective earthing
Shock arising out of electrical current passing though human body (heart) :
current at 30 mA for more than a few mS has fatality potential. Higher the
current, lesser the time available for disconnection.

High energy level faults in damaged equipment / burns/ fatality

Insulation failures can result in a short circuit current (in kA) causing flash /
fire / explosion, damage equipment and/ or cause serious burn injuries to
personnel
Higher settings of relays / high fuse ratings increases time to isolate faulty
circuits, higher energy dissipation and corresponding damage

Electrical Hazards How to protect?

How should these be tackled?

Low energy level faults

Electrical Hazards How to protect?

How should these be tackled? ( Contd.)

Low energy level faults

Provide Enclosures with interlocks

Shrouds
effective insulation
Barricade

Proper PTW systems & management of change procedures by

competent persons/agencies
Ensure effective earthing at all times design of earthing system
No live working should be allowed.
Provide ELCBs of 30 mA sensitivity in mandated hazardous locations
and ensure their reliability
Effectively monitor higher hazard usage points (plug points) and
equipment used at these points (welding machines, hand tools, mobile
units etc)
Use safer voltages (less than 50 V / 25 V), wherever possible
Use of unearthed system

Electrical Hazards How to protect?

How should these be tackled..?

High energy level faults

Never

allow live working

Use PPE Nomax suit / shield
Reliable and proven design of electrical switchgear / equipment
Rigour in maintenance practices to reduce possibilities of
insulation failure
Provide reliable, closer protection for electrical circuits using
relays - maintain their reliability at all times, through tests & checks.

Electrical Hazards - Fire

Electrical Overload causes Fire

Electrical Hazards - Fire

Loose

Connections in switch gears

Loose Joints
High earth fault current in flameproof area
Storing flammable material near Distribution
Boards

Electrical Hazards - Fire

How

to tackle Fire Hazards:

Improved maintenance
Check switchgear connections regularly
Barricade DBs / MCCs
Thermography
Avoid use of jointed cables
For flameproof areas use special equipment to
reduce earth fault currents.

Electrical Hazards

These measures are only preventive.

Consider:

Lack of (proper) maintenance,

Carelessness
Improper earthing connections
Bypassing safety interlocks mechanical / electrical.
Normal (or abnormal) wear and tear of insulation; for
example, aging and abrasion of connecting leads,
Accidental contact,
Immersion in water, etc. - a situation in which insulation is no
longer effective.

Electrical Safety While Working

On Electrical Equipment

Always ensure positive isolation before handling any

electrical equipment.
Earth the terminals to be worked upon
Never work on live
Ensure shrouding of live parts

Switchgear terminals
Outgoing terminals

LOTO
Use insulated hand gloves.
Use double insulated hand tools drilling machines,
grinders etc. (Square in Square)

Electrical Safety While Working

On Electrical Equipment Contd.

Safe touch voltages:

50 V for dry areas

25 V for wet areas

Control voltage 110 V (+55, 0(E), -55)

Use safety shoes
Use of masks / suits
Avoid static electricity built up. Antistatic floors....
Licensing issues instrument technitians?
Designing issues Tripping to take place within safe limits
for 220/230 V

For touch voltage limits of 25 V 50 ms

For touch voltage limits of 50 V 170 ms