Electrical Safety (Oil & Gas)

Electrical Safety
Table of Content

Part I:Introduction

Part Part Part Part

II: Electricity is Dangerous III: The Danger of Electrical Shock IV: Electrical Hazards V: Electrical Safety Measures

Objectives of the course

After completing this course, you will: Be familiar with the basic concepts of electricity. Understand the potential effects of electricity on the human body. Be able to recognize common electrical hazards and control measures

Part I : Introduction

Fundamentals of Electricity
Like Water In A Garden Hose

Resistance = Diameter of Hose Example Larger hose (less resistance), more water flows

Voltage = Water Pressure Example 45 PSI

What is electricity ?

A source of Energy Essential to Modern Life Extremely Dangerous Cannot be seen Cannot be smelt

Part II
Electricity is Dangerous

Take Electricity Seriously

Electricity is the second leading cause of death in construction. Electrocutions make up 12% of construction fatalities annually. Over 30,000 non-fatal shocks occur each year. Over 600 deaths occur annually due to electrocution.

Part IV: Electrical Hazards

muscle contraction leading to secondary injury which includes falls Fires Enough heat or sparks can ignite combustible materials Explosions Electrical spark can ignite vapors in the air Arc Flash - can cause burns ranging from 14,000 degrees f. to 35,000 degrees f Arc Blast In a short circuit event copper can expand 67,000 times. The expansion causes a pressure wave. Air also expands adding to the pressure wave

Shock Most common and can cause electrocution or

Electrical Fires / Arcs / Explosions

Fires

Overheating, arcing & sparking

Arcs

Generated during faults / flashover (Lightning) Very high temperatures / causing burns

Explosions

Flammable substances give off vapours Electrical sparks can ignite (ie. domestic light switch)

Arc Flash and Arc Blast

Arc Flash:

Arc Blast:

80%-Burns due to ignition of clothing Temperature-35,000 F Fatal Burns-10 ft. 2000 people hospitalized with burns Molten metal

Pressure Wave Heat Molten metal Destruction of structures and lif

Arc Blast

Cause

Short Circuit caused by working on energized equipment

Dropped Tool

Occurs in milliseconds Temp: 30,000 degrees Air expands very violently

15 tons of pressure

Arc Blast

ARC-BLAST. The three primary hazards associated with an arc-blast are: Thermal radiation. Pressure Wave. Projectiles.

Explosions.

Explosions occur when electricity provides a source of ignition for an explosive mixture in the atmosphere.

Fires

Electricity is one of the most common causes of fires both in the home and in the workplace. Defective or misused electrical equipment is a major cause.

Part II: 1: Terminology

VOLTAGE unit of measurement of electromotive force (EMF) CURRENT - Continuous movement of electrons past a given point. (measured in amperes) RESISTANCE Opposition to movement of electrons. Makes it possible to generate heat, control current flow, & supply correct voltage to devices

Direct Current vs Alternate Current

Always flows in one direction Used to charge batteries, run some motors, operate magnetic lifting devices and welding equipment.

More common in electrical work Changes rapidly in both direction and value Power companies produce power cheaper with alternating current

Electric Current

A flow of electrons ! Certain materials conduct better than others

Electric current

Conductors

Metals such as copper, silver, gold and aluminium. Loose electrons in abundance so charge can be transferred easily Copper very common on cost basis

Electric current

Summary

Movement of electrons Best in soft metals Measured in Amperes or Amps Symbolised by A

i.e. a 13A fuse

Potential Difference

Charge on an object Measured with respect to earth Also known as Pressure Water Analogy

Horizontal pipe water does not flow Raise one end water flows out A pressure difference exists

Potential Difference

Raising pipe created a pressure difference Raising electric charge has same effect only electric current will flow Amount of current that flows dependant on conductor (more water could flow in a bigger pipe)

Potential Difference

Summary

Difference of charge between two objects Causes a current to flow

(water analogy)

Measured in Volts Symbol V

i.e. 230V

Conductors and Insulators

Conductors conduct electricity Insulators dont Metals conduct Wood, plastic, air, oil and rigid glass do not conduct electricity (most of the time)

Resistance

Back to the water pipe again!

A larger diameter pipe allows more water to flow than a smaller one If a small diameter section of pipe is inserted into the large pipe the flow of water is restricted

Some materials conduct electricity better than others (atomic structure different)

Resistance

Small diameter wires (conductors) allow less electricity to flow than in similar bigger diameter wires The ease by which a material conducts electricity is known as resistance

Relationships

Electric Current - Amperes Potential Difference Voltage Electrical Resistance All above are related to each other

Ohms Law
French physicist Ohm studied the relationship between Potential difference (V), Amperes, and Resistance. I V

His findings became known as Ohms Law

Where V = I * R, I = V / R & R = V / I

Sources of power
Battery DC Mains Supply Portable Generators Solar panels

UK Electricity Supply System

Electricity supplied to factories, offices and homes at 230 volts Large factories at 11000 volts or above Supply has alternating current (a.c.) Alternates at (frequency) of 50 cycles per second (50 Hertz or Hz)

Power

When current flows energy is transmitted and usually consumed by a load Examples heaters, lights, motion

Such devices must consume electricity because we have to pay for it!

Power

Power = Volts X Amps (work done) Measured in Watts (W) Example 2300 Watt electric kettle

Also referred to as 2.3 kilowatt (kW)

Electrical circuits

Consist of

Power Source Connecting cables Electrical equipment (energy converter)

Electrical circuits - Earthing

Very important for safety ! Prevents conducting parts of equipment (ie. metal frames or lids), which do not normally conduct electricity from becoming live during faults.

Part II 2. How to Receive Electrical Shock

Leading Causes of Electrical Accidents: Drilling and cutting through cables Using defective tools, cables and equipment Failure to maintain clearance distance of 10 feet Failure to de-energize circuits and follow Lock-out/Tag-out procedures Failure to guard live parts from accidental worker contact Unqualified employees working with electricity Improper installation/use of temporary electrical systems and equipment By-passing electrical protective devices Not using GFCI (ground fault circuit interrupters) devices Missing ground prongs on extension cords

Current Flows in a Loop or Circuit

Circuits are AC (alternating current) or DC (direct current). Current is usually AC. AC current has five parts:
(1) Electrical source (2) HOT wire to the tool. (3) The tool itself (4) NEUTRAL wire returns electricity from the tool (5) GROUND

How Shocks Occur

Current travels in closed circuits through conductors (water, metal, the human body). Shock occurs when the body becomes a part of the circuit. Current enters at one point & leaves at another.

Shocks Occur in Three Ways

Contact with both conductors Contact with one conductor and ground With a tool: contact with hot metal part and ground (1), (2) & (3)

Part III The Danger of Electrical Shock

Severity of Electrical Shock

Severity of the Shock depends on: Amount of current Determined by voltage and resistance to flow Path through the body Duration of flow through the body Other factors such as general health and individual differences.

Electric shock

0.5mA 6mA tingling sensation Threshold of perception. 10mA 16mA muscular contraction sets Threshold of danger 30mA 60mA & above prolonged exposure can be FATAL Death can occur in a fraction of a second

Effects of Current Flow

More than 3 milliamps (ma): painful shock More than 10 ma: muscle contraction More than 20 ma: considered severe shock More than 30 ma: lung paralysis - usually temporary More than 50 ma: possible ventricular fibrillation (usually fatal) 100 ma to 4 amps: certain ventricular fibrillation (fatal) Over 4 amps: heart paralysis; severe burns

Effect of electricity on human body

Burns

Surface Deep tissue Muscular Contraction Asphyxia Respiratory Arrest Ventricular Fibrillation

Electric Shock

Effect of Current Flow

Ventricular Fibrillation

Factors are Current / Time & Physiological Structure of body Can occur at 30mA (0.03 A) Causes heart to flutter Muscle cannot open / close properly Does not pump Lack of oxygen to brain - DEATH

IEC 479 Curves

IEC 479 curves

For info only

IEC 479 curves

Zone 1 - No danger Zone 2 - Usually No effects Zone 3 Reversible damage, no fibrillation, breathing difficulties Zone 4

5% chance of fibrillation C1- C2 50% chance of fibrillation after C3

For info only

Electric Shock - Treatment

Isolate supply immediately Dial 999 If you cannot isolate DO NOT attempt to touch casualty Physically remove victim using nonconducting implements Check for pulse / breathing, give artificial respiration if necessary

Part V: Electrical Safety and Control Measures

Employers must follow the Electrical Standards Electrical installation The Four Proactive Methods:

Electrical Isolation Equipment Grounding Circuit Interruption Safe Work Practices

Electrical Isolation
We can be safe by keeping electricity away from us. We can:

Insulate the conductors.

Example: The insulation on extension cords. Example: Overhead power lines.

Elevate the conductors.

Guard the conductors by enclosing them.

Example: Receptacle covers, boxes, & conduit.

Insulating the Conductors

The first way to safeguard workers from electrically energized wires is through insulation. Rubber and plastic is put on wires to prevent shock, fires, short circuits and for strain relief. It is always necessary to check the insulation on equipment and cords before plugging them in.

the smallest defect will allow leakage!

Remember, even

Double Insulation

Lots of portable equipment is Double Insulated Extra layer of insulating material over live conductors to prevent exposure of conductors Can mean that an earth conductor is not required risk reduced by additional insulation.

Defective Extension Cords

Defective Cord Incident

Worker attempted to climb scaffold with electric drill. Drills cord was damaged with bare wires showing. The bare wire contacted the scaffolding. The worker died!

Elevating the Conductors

The second way to safeguard workers from electrically energized wires is by elevating them. Wires are often elevated by the power company. It is always necessary to check the location of overhead lines before you begin work each day. Remember, never allow yourself, your tools, or the materials you are working with to be within 10 feet of energized lines!

Working Near Overhead Lines

Clearance of worker and any equipment, tools, materials, or scaffold near uninsulated lines is

10 feet!

Overhead Line Incident

A worker was attempting to move mobile scaffold. Scaffold made contact with 7200 volt line. The worker died.

Guarding the Conductors

The third way to safeguard workers from electrically energized wires is by guarding them. Covers, boxes, and enclosures are often put around conductors to prevent worker contact. It is always necessary to check that electrical boxes and panels are covered and free from missing knock-outs. Remember, electric equipment operating at 50 volts or more must be guarded!

Guarding the Conductors

Guarding the Conductors

Equipment Grounding

We can be safe by providing a separate, low resistance pathway for electricity when it does not follow normal flow (grounding).
Grounding gives the stray current somewhere to go and keeps you from becoming part of the circuit

No earthing of equipment

No bonding Person can receive an electric shock if equipment becomes faulty

Can You Rely on Grounding?

Grounding will not work if the electricity can flow through you more easily than the ground. This can happen when:

Your tool doesnt have a ground pin. Youre working in wet locations. Youre touching a metal object

Equipment bonded together

All equipment bonded together No potential (voltage) difference between live casing and handrail If case becomes live fuse should blow
Equipotential Bonding

What Must be Grounded?

All circuits and extension cords. All noncurrent carrying metal parts. Portable & semiportable tools and equipment unless double insulated.

Do Not Eliminate the Ground!

Do Not Reverse Polarity

The prongs are different sized so you cant turn the plug around. If you do, the electrical fields within the motor are always energized. If there is moisture present, the case is likely to be hot. Even with double-insulated tools, you still could get a shock.

Circuit Interruption

We can be safer by automatically shutting off the flow of electricity in the event of leakage, overload, or short circuit. Ground Fault Circuit Interrupters (GFCI) are circuit protection (or overcurrent) devices that protect you, the worker. Circuit breakers & fuses protect equipment, not you, because they take too much current & too much time to trip.

Receptacle

Reverse Polarity

Reversed polarity is a condition when the grounded conductor (neutral) is incorrectly connected to the ungrounded (hot) terminal of a plug, receptacle, or other type of conductor

Reverse Polarity
Normal Wiring Reverse Polarity

Hot
Neutral

Neutral

Hot

Fuses and RCDs

Fuses

essential for safety, will cut off supply at a certain current level i.e. 13A, 5A, 3A mains supply fuse Fuse has a fuseable wire element which heats up when current flows Excessive current = excessive heat & wire melts preventing current flow Residual current device Compares current in Live & Neutral if different and above a certain value supply switched off

RCDs

Circuit Protective Devices

Circuit Breakers and Fuses Only protect the building, equipment, and tools from heat build-up! Never depend on circuit breakers or fuses to prevent shocks! Ground Fault Circuit Interrupter (GFCI) Is the only device which will protect the worker from shock and electrocution!

GFCI Protection

All temporary circuits are required to have GFCI protection or: Equipment & cords must be included in an Assured Equipment Grounding Conductor Program An extension cord is a temporary circuit. Types of GFCIs: receptacle, circuit breaker and portable Must be wired correctly and tested.

GFCI Protects People

How a GFCI Works

The GFCI detects leakage of 4-6 milliamps & opens the circuit in 1/40th of a second.
It will work without the ground plug but not fast enough if you are the ground .

Types of GFCI Protection

Types of GFCI Protection

A GFCI breaker must be installed to protect workers using 220V masonry saws.

GFCI Testers

Assured Equipment Grounding Conductor Program

Requires the following: -Written program and specific procedures -Program implemented by a Competent Person (one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. -Equipment grounding conductors must be tested (tools, extension cords, and circuits): At least every three months for cords & tools At least every six months for receptacles Results recorded - equipment coded (colored tape)

Grounding

There are two kinds of grounding:

1. Electrical circuit or system grounding 2. Electrical equipment grounding

Electrical System Grounding

Circuit

Equipment

One conductor of the circuit is intentionally grounded to earth

All metal frames & enclosures of equipment are grounded by a permanent connection or bond The equipment grounding conductor provides a path for dangerous fault current to return to the system ground at the supply source should a fault occur

Protects circuit from

lightning, or other high

voltage contact

Without Grounding

Grounded

Checking for Ground Continuity

Temporary Wiring

There must be separate circuits for electric tools and lighting, each labeled as such. Light circuits do not require a GFCI. Unless used in a wet location. Test branch circuits before use. Maintain vertical clearances. Insulate wires from their supports.

Extension Cords and Cables

Must be in good shape without splices. Cannot be secured with staples, nails or bare wire. Must be protected from damage. Must have a ground pin. Should be inspected regularly and pulled from service if defective. Cannot be repaired with electrical or duct tape. Must repair with heatshrink sleeve or bonding/vulcanizing tape to retain original insulation properties

Temporary Lighting

All bulbs must be guarded No broken bulbs or empty sockets Not suspended by wiring Low voltage for wet locations

Portable Generators

The frame of the portable generator need not be grounded if:

the generator supplies only cord and plug connected equipment. The non-current carrying metal parts of equipment and the equipment grounding conductor terminals of the receptacles are bonded to the generator frame. GFCI is required if >5kV or if generator provides 220V as well as 110V.

Safe Work Practices

Before work begins, the employer must determine where exposed and concealed electrical circuits are located. Once found, warning signs/labels must be posted. Workers need to know the location, hazards, and protective measures.

Safe Work Practices

Competent Person determines if performance of work could bring contact with energy. Distance of the worker to the energy source should be considered first. Tools, materials, and processes should also be considered to see if they could potentially shorten the safe separation distance. Examples: Metal Ladders, Re-bar, Forklift, Scaffold Frames, etc.

Safe Work Practices

Must not permit work near electric circuits unless the worker is protected by: De-energizing the circuit and grounding it. Guarding it effectively by insulation. Other means (maintaining safe separation) De-energized circuits and equipment must be locked/tagged out.

Safe Work Practices

No metal ladders for or near electrical work. No wet hands when plugging or unplugging cords/equipment. No raising or lowering tools by the cord. Unless equipment is designed for it, cannot be used in damp and wet locations.

Safe Work Practices: Work on Electrical Equipment

Always ISOLATE supply

Switch off using a device that will create an air gap that should not fail Lock off where possible to prevent inadvertent switching ON whilst work taking place Always test conductors in a reliable way before touching (ie. test the test device before and after use!)

Permit to work may be required for higher voltage or complex installations

Safe Work Practices: Safe values of Voltage

55 VAC systems have not caused anybody to be electrocuted Often referred to as a 110VAC centre tapped earth supply (CTE) yellow coloured equipment Less than 120 VDC considered to be safe

Safe Work Practices: Electrical equipment selection

Must be suitable for environment

Wet, dusty, flammable gases, mechanical strength, corrosive atmospheres (maggot farms) Must be maintained in good condition Failure to select suitable equipment and maintain it often results in incidents at a later date

Maintenance of Portable Electrical Equipment

Many accidents result from 230 volt portable equipment Pressure Washers / Vacuum Cleaners Resulting from

Incorrect selection Inadequate maintenance / poor repairs

Most important checks are easy to do !

Safe Work Practices: Maintenance of Portable Electrical Equipment

Visual Inspection

Check flexible mains cable for damage to insulation If insulation is damaged REPLACE DO NOT wrap conductors together and tape up So called Electrical Insulation Tape will not provide a sufficient barrier between you and a potentially fatal electric shock as has been proven on many occasions

Safe Work Practices: Maintenance of Portable Electrical Equipment

Plug

Check that only the outer insulation has been clamped / gripped. Clamping inner conductor insulation will potentially lead to exposure of live terminals. Is fuse correct rating (Instructions should advise correct current value DO NOT use a nail) Check that all 3 pins are present and in good condition

Safe Work Practices: Maintenance of Portable Electrical Equipment

Testing

Only by a competent person Earth bond test Insulation test On-load test

Guidance HSE HS(G) 107 (5)

Maintaining portable and transportable electrical equipment

Summary Hazards & Protections

Protective Measures Proper grounding Use GFCIs Use fuses and circuit breakers Guard live parts Lock-out/ Tag-out Proper use of flexible cords Close electrical panels by Competent Person Employee training Ensure Competent Person on site Use proper approved electrical equipment Qualified person install electrical devices Protective Measures Proper grounding Use GFCIs Use fuses and circuit breakers Guard live parts Lock-out/Tag-out Proper use of flexible cords Close electrical panels by Competent Person Employee training Ensure Competent Person on site Use proper approved electrical equipment Qualified person install electrical devices

Safeguards for personnel protection

Barricades shall be used in conjunction with safety signs where it is necessary to prevent or limit employee access to work areas exposing employees to uninsulated energized conductors or circuit parts

If signs and barricades do not provide sufficient warning and protection from electrical hazards, an attendant shall be stationed to warn and protect employees

Safeguards for personnel protection

The Law

Electricity at Work Regulations

Require

Safe construction, maintenance & work systems Capability, Environment, Insulation, Grounding, Connections, Fusing, Isolation, Making dead, Live working, Working Space, Competence. Covers ALL aspects at ALL voltages.