Earthing, Safety Precautions and Maintenance of Electric Machine

Thermax Graduate Programme

How Electricity Works

Operating an electric switch is like turning on a water faucet. Behind the faucet or switch there must be a source of water or

electricity with something to transport it, and with a force to

make it flow. In the case of water the source is a pump, and the force to make it flow through the pipes is provided by the pump. For electricity, the source is the power generator. Current

travels through electrical conductors (wires) and the force to

make it flow, measured in volts, is provided by a generator.

Voltage, Current and Resistance

Voltage increases Resistance decreases Current increases Current increases
Ohms Law

Voltage = Current / Resistance -

The complete circuit

A complete Circuit or loop is

necessary for current to flow

Electrical Hazards
Basically, electrical hazards can be

categorized into three types.

The first and most commonly recognized hazard is electrical shock.

The second type of hazard is electrical burns

and The third is the effects of blasts which include

pressure

impact,

flying

particles

from

vaporized conductors.

A complete circuit
Complete Circuit or loop is necessary for current to flow

Current takes the path of least resistance

Electrical Shock
Received when current passes through the body
You become part of the circuit

Severity of a shock depends on:

Path of current through the body Amount of current flowing through the body Length of time the body is in the circuit

Step Potential

Step potential

Touch Potential

Effect of electricity on human body

Burns

Surface
Deep tissue Electric Shock Muscular Contraction Asphyxia Respiratory Arrest Ventricular Fibrillation

Electrical Burns
Most common shock-related, nonfatal

injury.
Occurs when you touch electrical wiring or equipment that is improperly used or

maintained.
Typically occurs on the hands Very serious injury that needs

immediate attention

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

Summary of Effect of Electric Current

Current 1 Milliampere 5 Milliamperes 6-30 Milliamperes 50-150 Milliamperes 1000-4,300 Milliamperes 10,000+ Milliamperes Reaction Perception level Slight shock felt; not painful but disturbing Painful shock Extreme pain, respiratory arrest, severe muscular contraction Ventricular fibrillation Cardiac arrest, severe burns and probable death

Clues that Electrical Hazards Exist

Tripped circuit breakers or blown fuses
Warm tools, wires, cords, connections, or junction boxes GFCI that shuts off a circuit Worn or frayed insulation around wire or connection

Causes of Electrical Hazards

Most are electrical caused of mishaps by a three

combination factors:
Unsafe

equipment

and/or

installation, Workplaces made unsafe by the environment Unsafe work practices

Overload Hazards
If too many devices are plugged into a

circuit, the current will heat the wires

to a very high temperature, which may cause a fire

If the wire insulation melts, arcing may occur and cause a fire in the area

where the overload exists, even inside

a wall

Preventing Electrical Hazards

Ways

of protecting workers and preventing electrical

hazards are: Safe work practices Insulation Grounding Electrical protective devices (GFCI)

Safe Work Practices Moisture provides a conductive path that could result in death.

Never work with wet tools or clothing.

Remove Your Jewelry Watch bands, bracelets.

Insulation
Check insulation prior to using cables, tools, or equipment Remove from service any tools or equipment with damaged insulation

Cabinets, Boxes, and Fittings

Junction boxes and fittings
must have approved covers Unused openings in cabinets, boxes and fittings must be closed (no missing knockouts)

Hand-Held Electric Tools

Hand-held electric tools pose a potential

danger because they make continuous contact

with the hand To protect you from shock, burns, and

electrocution, tools must:

Have a three-wire cord with ground and be plugged into a grounded receptacle, or

Be double insulated

29 CFR 1910.304(f)(5)(v)(C)(3)

Panel Boxes
Panel boxes are used to house circuit breakers that block or isolate energy
Ensure panel boxes remain clear Label all circuits for what they control Label panel boxes for what they control

Improper Grounding
Tools plugged into improperly

grounded
energized

circuits

may

become

Broken wire or plug on extension cord Some of the most frequently violated OSHA standards

Grounding and Earthing

Grounding creates a low-

resistance path from a tool to the

earth to disperse unwanted current When a short or lightning occurs,

energy

flows
you

to

the

ground,
electrical

protecting

from

shock, injury and death

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.

Earthing

Types of Earthing
Plate Earthing Pipe Earthing

Fuses, RCDs &GCFI

Fuses
essential for safety, will cut off supply at a certain current level i.e. 16A, 10A, 5A mains supply fuse Fuse has a fuseable wire element which heats up when current flows Excessive current = excessive heat & wire melts preventing current flow

RCDs
Residual current device Compares current in Live & Neutral if different and above a certain value supply switched off

Ground fault circuit interrupters (GFCIs)

A GFCI is not an overcurrent device like a fuse or
circuit breaker GFCIs are designed to sense an imbalance in current flow over the normal path

Ground fault circuit interrupters (GFCIs)

GFCI contains a special sensor that

monitors

the

strength

of

the

magnetic field around each wire in the circuit when current is flowing The field is proportional to the amount of current flow
T

Ground fault circuit interrupters (GFCIs)

If the current flowing in the black (ungrounded) wire is within
5 milliampers of the current flowing in the white (grounded) all the current will flow in the normal path

If the current flow differs by more than 5mA +/- 1mA, the
GFCI will quickly open the circuit

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

Electric Shock - Treatment

Isolate supply immediately Call the doctor

If you cannot isolate DO NOT attempt to touch casualty

Physically remove victim using non-conducting implements Check for pulse / breathing, give artificial respiration if necessary

Electrical Rescue Techniques

Approaching the accident:
Never rush into an accident situation. Call the doctor as soon as possible. Get the aid of trained electrical personnel if possible. Approach the accident scene cautiously.

Electrical Rescue Techniques

Examining the scene:
Visually examine victims to determine if they are in contact with
energized conductors. Metal surfaces, objects near the victim or the earth itself may be energized. You may become a victim if you touch an energized victim or conductive surface. Do not touch the victim or conductive surfaces while they are energized. De-energize electrical circuits if at all possible.

Electrical Rescue Techniques

Methods to de-energize:
An extension or power cord probably powers portable electrical equipment. Unplug portable electrical equipment to remove power. Open a disconnecting device or circuit breaker to de-energize fixed electrical equipment.

Electrical Rescue Techniques

Hazards and solutions:
Be alert for hazards such as stored energy, heated surfaces and fire. If you cant de-energize the power source use extreme care: Ensure that your hands and feet are dry. Wear protective equipment such as low voltage gloves and overshoes if available. Stand on a clean dry surface. Use nonconductive material to remove a victim from the conductor.

Electrical Rescue Techniques

High voltage rescue:
Special training is required for rescues if high voltage is present. Protective equipment such as high voltage gloves and overshoes must be worn. Special insulated tools should be used

Electrical Rescue Techniques

Insulated tools:
Insulated tools, with high voltage ratings, are a lifesaver! Use devices such as hot sticks(insulated pole of fibreglass) or (high quality fibreglass) shotgun sticks to remove a victim from energized conductors. In some cases, nonconductive rope or cord may be used to remove a victim from a conductor.

Electrical Rescue Techniques

Rescuing the victim:
Stand on a dry rubber blanket or other insulating material if possible. Do not touch the victim or conductive material near the victim until the power is off. Once power is off, examine the victim to determine if they should be moved. Give First Aid.

Electrical Rescue Techniques

First Aid:
A victim may require Cardio-Pulmonary Resuscitation (CPR).
If the victim is breathing and has a heartbeat, give first aid for injuries and treat for shock. Ensure the victim gets medical care as soon as possible. Provide medical personnel with information on voltage level, shock duration & entry/exit points. The treating/attending physician must have detailed specific information to properly diagnose and care for the victim. The physician must determine whether the victim should be sent to a Trauma or Burn Center.

Stay with the victim until help arrives.

REMEMBER!
The results of a mistake with electrical energy occur at the speed of light. There is not time to react after the error is made. You must think ahead. Pre-job briefs, planned work instructions, and facility requirements are not optional. Pay attention and obey

all the rules, not just the ones that are convenient. They
provide the edge you need to be safe with electrical energy.

Post-job reviews help keep us from repeating errors

participate in them. You are responsible for your safety.

Maintenance of Machine
Dirt and Corrosion Lubrication Heat, Noise and Vibration Windings and Winding Insulation Brushes and commutators

Dirt and Corrosion Wipe brush, vacuum or blow accumulated dirt from the frame and air passages of the motor. Dirty motors run hot when thick dirt insulates the frame and clogged passages reduce cooling air flow. Heat reduces insulation life and eventually causes motor failure. Feel for air being discharged from the cooling air ports. If the flow is weak or unsteady, internal air passages are probably clogged. Remove the motor from service and clean. Check for signs of corrosion. Serious corrosion may indicate internal deterioration and/or a need for external repainting. Schedule the removal of the motor from service for complete inspection and possible rebuilding. In wet or corrosive environments, open the conduit box and check for deteriorating insulation or corroded terminals. Repair as needed.

Lubrication Lubricate the bearings only when scheduled or if they are noisy or running hot. Do NOT over-lubricate. Excessive grease and oil creates dirt and can damage bearings.

Heat, Noise and Vibration Feel the motor frame and bearings for excessive heat or vibration. Listen for abnormal noise. All indicate a possible system failure. Promptly identify and eliminate the source of the heat, noise or vibration
Winding Insulation When records indicate a tendency toward periodic winding failures in the application, check the condition of the insulation with an insulation resistance test. Such testing is especially important for motors operated in wet or corrosive atmospheres or in high ambient temperatures.

Brushes and Commutators (DC Motors) 1. Observe the brushes while the motor is running. The brushes must ride on the commutator smoothly with little or no sparking and no brush noise (chatter). 2. Stop the motor. Be certain that:
a. The brushes move freely in the holder and the spring tension on each brush is about equal. Every brush has a polished surface over the entire working face indicating good seating. b. The commutator is clean, smooth and has a polished brown surface where the brushes ride. c. There is no grooving of the commutator (small grooves around the circumference of the commutator). If there is grooving, remove the motor from service immediately as this is a symptomatic indication of a very serious problem.

3. Replace the brushes if there is any chance they will not last until the next inspection date. 4. If accumulating, clean foreign material from the grooves between the commutator bars and from the brush holders and posts.

5. Brush sparking, chatter, excessive wear or chipping, and a dirty or rough

commutator indicate motor problems requiring prompt service.

Brushes and Collector Rings (Synchronous Motors)

Black spots on the collector rings must be removed by rubbing lightly with fine sandpaper. If not removed, these spots cause pitting that requires regrinding the rings. An imprint of the brush, signs of arcing or uneven wear indicate the need to remove the motor from service and repair or replace the rings.

Bearing Lubrication

Modern motor designs usually provide a generous supply of lubricant in tight bearing housings. Lubrication on a scheduled basis, in conformance with the manufacturer's recommendations, provides optimum bearing life.

HEAT

Excessive heat is both a cause of motor failure and a sign of other motor problems. The primary damage caused by excess heat is to increase the aging rate of the insulation. Heat beyond the insulation's rating shortens winding life. After

overheating, a motor may run satisfactorily but its useful life will be shorter.
For maximum motor life, the cause of overheating should be identified and eliminated.

NOISE AND VIBRATION

Noise indicates motor problems but ordinarily does not cause damage. Noise,

however, is usually accompanied by vibration.

Vibration can cause damage in several ways. It tends to shake windings loose and mechanically damages insulation by cracking, flaking or abrading the material.

WINDlNGS Care of Windings and Insulation

Except for expensive, high horsepower motors, routine inspections generally do not involve opening the motor to inspect the windings. Therefore, long motor life

requires selection of the proper enclosure to protect the windings from

excessive dirt, abrasives, moisture, oil and chemicals.

When the need is indicated by severe operating conditions or a history of winding failures, routine testing can identify deteriorating insulation

Maintenance
Checklist to maintain motor efficiency
Inspect motors regularly for wear, dirt/dust
Checking motor loads for over/under loading

Lubricate appropriately
Check alignment of motor and equipment

Ensure supply wiring and terminal box and properly

sized and installed Provide adequate ventilation