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The Petroleum Institute

30-hr Lab Safety Training

HSE/LS-13: Electrical Safety

Learning Objective
Attendees will be able to:
1. Define common electrical terminologies
2. Discuss the dangers of electricity
3. Explain the concepts of arcing, ampacity, bonding and grounding
4. List the types & functions of protective devices
5. Recognize safety features/requirements of commonly used
electrical equipment
6. Use/apply basic safety practices when working with electricity
7. Outline the different wiring methods
8. Identify hazardous location classification for installation/use of
electrical equipment

Major Components
29 CFR 1910.300 Become familiar with OSHA Subpart S (www.osha.gov) &
applies to installations designed or installed after March 1972

Examination of Equipment
Working Clearances
Overcurrent Protection
Grounding
Wiring Methods
Electrical Boxes
Flex Cord & Cable
Hazardous Locations
Safe Work Practices

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Most Frequently Cited

Conductors entering cabinets, boxes, fittings protected
from abrasion

Live parts
Grounding path
Electrical box covers
Flexible cords & cables Strain relief

Electrical Issues
An average of one worker is electrocuted on
the job every day
There are four main types of electrical injuries:
Electrocution (death - electrical shock)
Electrical shock
Burns
Falls

Electrical Terminology
Current (C) the movement of electrical charge
(amps)
Resistance (R) opposition to current flow (ohms)
Voltage (V) a measure of electrical force (volts)
V = IR

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Electrical Terminology
Conductors substances, such as metals,
that have little resistance to electricity
Insulators substances, such as wood,
rubber, and glass, that have high resistance to
electricity

Electrical Terminology
Grounding - A highly conductive path to ground intended to
prevent electrical shock
Bonding is the joining of metallic parts to form an electrically
conductive path
Arcing - Current flows through air between conductors that are
not in contact. Arcing is a function of distance, voltage and
conductivity medium
Ampacity amount of current a conductor can safely conduct
10 gauge 30 amps; 12 gauge 20 amps; 14 gauge 15 amps

Electrical Shock
Electric shock occurs when the body
becomes a part of the circuit
Electric shock occurs when an individual
is in contact with the ground and
contacts:
1. Both wires of an electric circuit, or
2. One wire of an energized circuit and
the ground, or
3. A metallic part that has become
energized by contact with an
energized conductor

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Electrical Shock

(cont)

Current will flow between two wires of if there is a potential

difference (voltage)
The hot or live wires are at 220-240 volts relative to
ground (red, brown, orange etc.)
The neutral wires are at zero volts to ground
(black, blue, white, etc.)
Ground (earth) wire is usually yellow and green, or it just
could be green.

Electrical Shock

(cont)

If you are in contact with an energized live wire AND

with the neutral or ground wire, you will incur a
shock
If your body is grounded, (bare, wet, or not properly
isolated) feet for example, and you touch the live
wire, you can get a bad electric shock.
With more voltage, skin conductivity increases.

Human Resistance to Electric Current

Source: Accident Prevention manual for business and industry, 2001 Hagan, Montgomery & OReilly

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Effects of Electrical Contact

Source: Accident Prevention manual for business and industry, 2001 Hagan, Montgomery & OReilly

Electric Shock Severity

Severity of the 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
LOW VOLTAGE DOES NOT MEAN LOW
HAZARD

Dangers of Electricity
Currents > 75 mA* can cause
ventricular fibrillation
Death in a few minutes unless a
defibrillator is used
75 mA is not much current a small
power drill uses 30 times as much
Low voltages can be extremely
dangerous because, all other factors
being equal, the degree of injury
increases the longer the body is in
contact with the circuit.
* mA = milliampere = 1/1,000 of an ampere

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Possibility of Success Vs Elapsed Time

Source: Accident Prevention manual for business and industry, 2001 Hagan, Montgomery & OReilly

Electrical Dangers

(cont)

Dry skin has a fairly high resistance, but when moist,

resistance drops radically, making it a ready conductor.
Pure water is a poor conductor, but small amounts of
impurities, such as salt and acid (both are contained in
perspiration), make it a ready conductor.
A small current that passes through the trunk of the body
(heart and lungs) is capable of causing severe injury or
electrocution.

Electrical Injuries
Burns
Common type of electrical
injury
Typically occurs on the hands
Serious injury that needs
immediate attention
Indirect or secondary injuries
Falls due to shock from
elevated locations can result in
injury or death

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Unsafe Action
Ladder not meant for 2 workers

Metal Ladder

Identification of Conductors
The grounded conductor is an energized circuit that is
connected to earth through the system ground. It is
commonly referred to as the earth.

The grounding conductor is not energized under normal

conditions. It is energized only if there is a leak or fault
in the normal current path and directs current back to
the source.

Identification of Conductors
The live (hot) wire should have a hot color (R,B,Y)
The neutral wire should have a cold color (B)
The equipment grounding conductor be G, or G with Y
stripes

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Grounding Requirements
Service or system ground is the grounding of the neutral
conductor or grounded conductor. In an ordinary lowvoltage circuit, the white (or gray) wire is grounded at the
generator or transformer and again at the service entrance
of the building. This type of ground is primarily designed to
protect machines, tools, and insulation against damage.
Equipment ground must be furnished by providing another
path from the tool or machine through which the current
can flow to the ground. This additional ground safeguards
the electric equipment operator if a malfunction causes the
metal frame of the tool to become energized.

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Sample Electrical Citations

The path to ground from circuits,
equipment, and enclosures must
be permanent and continuous
EX: Ground prong missing
Hand-held electric tools must:
Have a three-wire cord with
ground and be plugged into a
grounded receptacle, OR
Be double insulated

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Grounding Hazards
Most frequently violated standards
Metal parts of an electrical wiring system (switch
plates, ceiling light fixtures, conduit, etc.) should be at
zero volts relative to ground
Housings of motors, appliances or tools that are
plugged into improperly grounded circuits may
become energized
Shocks will result if contact is made

Double Insulated Tools

Tools and appliances protected that are double
insulated, need not be grounded

They must be distinctively marked

Work with Ground Fault Circuit Interrupters (GFCI)
Casing must be labeled
Tool must be inspected
Extension cord must be three-prong

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Hazards of Portable Electric Tools

Currents as small as 10 mA can paralyze, or freeze
muscles
Person cannot release tool
Tool is held even more tightly, resulting in longer
exposure to shocking current

Power drills use 30 times as much current as what

will kill.

Polarity of Connections
No grounded conductor may be attached to any
terminal or lead so as to reverse designated polarity

Reversed polarity is a condition when a neutral

conductor is incorrectly connected to the hot
terminal of a plug, receptacle or other connector.

Protective Devices
These devices shut off electricity flow in the event of
an overload or ground-fault in the circuit
Fuses and Circuit breakers are over-current devices. If
there is excessive current:
Fuses melt
Circuit breakers trip open
Ground-fault circuit-interrupters (GFCIs) are leak
detectors

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Overcurrent Protection
600 volts or less

Conductors and equipment must be protected from

overcurrent

Overcurrent devices must be readily accessible

Must not be located where they will be exposed to
physical damage or in the vicinity of easily ignitable
material

Fuses and Circuit Breakers

If the circuit breakers or fuses are too big (high current
rating) an overload in the circuit will not be detected and
the current will not be shut off. This is a hazard.
A fuse gets destroyed before another part of the system
In a circuit breaker, a set of contacts opens the circuit
A circuit breaker can be re-used by re-closing the contacts
Fuses and circuit breakers protect equipment and facilities

Earth Leakage Circuit Breaker

The ELCB detects a difference in current
leakage (ground fault), between the hot
and neutral circuit wires
If a leak is detected (as little as 5 ma), the
ELCB can shut off electricity flow in as little
as 1/40 of a second, protecting you from a
dangerous shock
ELCBs are different from circuit breakers
and fuses because they detect leakage
currents rather than overloads
Note: Only an ELCBs(also called a Groundfault circuit-interrupter ) protects individuals

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Residual Current Circuit Breaker (RCCB)

The RCCB detects a difference in current
between the hot (live wire) and the neutral
wire.
Its safer than ELCB because it can detect
electricity leakages through earth, other
equipment, etc.
RCCB can replace Earth Leakage Circuit
Breaker (ELCB), and Molded case circuit
breakers (MCCB)

Equipment for General Use

A receptacle installed in a wet or damp location must
be suitable for the location.

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Safety Violations

Electrical Hazards
A hazard exists when a conductor is too small to
safely carry the current
Example: Using a tool with an extension cord that
has a wire too small for the tool
The tool draws more current than the cord can handle,
causing overheating and a possible fire without tripping the
circuit breaker
The circuit breaker could be the right size for the circuit but
not for the smaller-wire extension cord

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Electrical Hazards (cont..)

Too many devices plugged into a circuit, will
heat the wires to a very high temperature,
which can cause a fire
If the wire insulation melts, arcing may occur
and cause a fire

Unsafe Conditions

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Regulatory (OSHA) Compliance

Guarding of live parts of electric equipment at 50
volts or more:
Approved cabinets/enclosures 1910.303(g)(2)(i),
OR
Permanent partitions making them accessible
only to qualified persons, 1910.303(g)(2)(i)(C)
OR
Elevation of 8 ft. or more above the floor or
working surface 1910.303(g)(2)(i)(D)
Mark entrances to guarded locations with
conspicuous warning signs 1910.303(g)(2)(iii)

Examination of Equipment
Safety of equipment must be determined using the
following considerations:
Suitability for installation and use
Mechanical strength and durability
Electrical insulation
Heating effects
Arcing effects
Classification

Leakage Test

Source: Accident Prevention manual for business and industry, 2001 Hagan, Montgomery & OReilly

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Continuity Test

Source: Accident Prevention manual for business and industry, 2001 Hagan, Montgomery & OReilly

Marking
Electrical equipment must be marked with the
manufacturers name, trademark or other
identification
Other markings must be provided giving voltage,
current, wattage, or other ratings as necessary
Markings must be durable enough to withstand
the environment

Signage on high voltage equipment

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Signage to high voltage electrical room

Identification
Each disconnecting means must
be legibly marked to indicate its
purpose, unless located and
arranged so that its purpose is
evident
Markings must be durable enough
to withstand the environment

Improperly labeled panel

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Proper Example!

Panel Labeling

Panel Labeling

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600 volts, nominal, or less -Working clearances

This section refers to a person qualified to work on
electrical equipment, usually an electrician
Working space in front of live parts (operating at 600
volts or less) must be at least 3 feet
The workspace in front of electrical equipment must
not be less than 30 inches wide
Working spaces may not be used for storage

Safety Violations

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Proper Clearances!

600 Volts or less

Guarding of live parts
Any person who is in the vicinity of electrical equipment
must be protected against accidental contact
Location must be accessible only to qualified persons
Permanent, substantial partitions or screens

600 Volts or less

Guard against accidental contact by:

Location on a suitable elevated balcony or platform

Elevation of 8 feet or more above the floor or other

working surface

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Unguarded Live Parts

Unguarded live parts above the working space must
be maintained at elevations not less than specified in
Table S-3 (1910.303)
http://www.osha.gov/SLTC/electrical/index.html
The minimum is 8 feet

Conductors entering boxes, cabinets, or fittings.

Conductors entering boxes, cabinets, or fittings must

be protected from abrasion.
Unused openings in cabinets, boxes, and fittings must
be effectively closed.

Electrical Box Covers

All pull boxes, junction boxes, and fittings must be
provided with approved covers
Metal covers must be grounded
Outlet boxes must have a cover or a faceplate
Outlet box covers with holes for flexible cords must
have bushings or smooth, well- rounded surfaces

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Wiring Methods
No wiring system of any type may be in ducts used
to transport dust, flammable vapors, or ventilation
of commercial-type cooking equipment.

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Temporary Wiring
Temporary electrical power and lighting wiring may be
of a class less than would be required for a permanent
installation.

Temporary Wiring

Uses permitted, 600 volts or less

During and for remodeling, maintenance repair, demolition

or similar activities

For experimental or developmental work

For a period not to exceed 90 days for decorative lighting,

carnivals, and similar purposes

Only during tests, experiments and emergencies

Luminary Protection
Lamps for general illumination must be protected from
accidental contact or breakage.
Protection can be provided by an elevation of 7 feet or
by a suitable fixture with a guard.

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Flexible Cords and Cables 1910.305(g)

More vulnerable than fixed wiring
Do not use if one of the recognized wiring methods can be used
instead
Flexible cords can be damaged by:
Aging
Door or window edges
Staples or fastenings
Abrasion from adjacent materials
Activities in the area
Improper use of flexible cords can cause shocks, burns or fire

Flexible Cords
Flexible cords and cables must be protected from
accidental damage. Sharp corners or projections must
be avoided.
Protection must be provided when passing through
doorways or other pinch points.

Permissible Uses of Flexible Cords - Examples

1910.305(g)(1)(i)

Pendant, or
Fixture Wiring

Pendant, or
Fixture Wiring

Portable lamps,
tools or appliances

Stationary equipment to
facilitate interchange

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Prohibited Uses of Flexible Cords

As a substitute for the fixed wiring of a structure

Where run through holes in walls, ceilings or floors

Prohibited Uses of Flexible Cords Examples

1910.305(g)(1)(iii)

Substitute for
fixed wiring

Run through walls,

ceilings, floors, doors, or
windows

Concealed behind or
attached to building
surfaces

Flexible Cords
Flexible cords must be used only in continuous
lengths without splice (< No 12) or tap
Damaged cords must be properly repaired or
removed from service

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Flexible Cords Strain Relief

Flexible cords must be connected to devices so that
strain relief is provided to prevent pull off from
being directly transmitted to joints or terminal
screws

Flexible Cords Strain Relief

Flexible Cords Splicing

Hard service flex cords, No. 12 or larger, may be
repaired if spliced so that the splice retains the
insulation, outer sheath properties, and usage
characteristics of the original cord

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Splices
Conductors must be spliced with:
Splicing devices suitable for the use
Brazing, welding or soldering (with a mechanically
and electrically secure joint before soldering & then
soldered)

Splices
All splices and joints must be covered with an
insulation equivalent to that of the conductors

Hazardous Locations
Electrical installations
Equipment, wiring, and installations of equipment
in hazardous (classified) locations must be
intrinsically safe, approved for the location, or safe
for the location.

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Class I Hazardous Locations (presence of flammable

gasses or vapors)
Class I, Division 1: Location in which hazardous concentrations of
flammable gases or vapors may exist:
Under normal operating conditions
Because of repair or maintenance operations or leakage
Because of breakdown or faulty operation
Class I, Division 2: Location in which flammable gases or vapors are:
Normally confined within closed containers or systems
Normally kept below hazardous concentrations by ventilation
Normally kept below hazardous concentrations by positivepressure ventilation (adjacent to Division 1)

Class II Locations (presence of combustible dust)

Class II, Division 1:

Normal operations
Mechanical failure or abnormal operation of machinery
or equipment
Combustible dust of an electrically conductive nature may
be present
Class II, Division 2:
Combustible dust will not normally be in suspension in
ignitable quantities
Dusts may be in suspension as a result of an infrequent
malfunction of handling or processing equipment

Class III location (presence of fibers)

Class III Locations: Locations that are hazardous
because of the presence of easily ignitable fibers
but in which such fibers are not likely to be in
suspension in the air in quantities sufficient to
produce ignitable mixtures.
Class III, Division 1: Locations in which easily ignitable
fibers or materials producing combustible flyings
are handled, manufactured or used.

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Training
OSHAs electrical safety-related work practice requirements are
contained in 29 CFR 1910.331-.335
De-energizing electric equipment before inspecting or making repairs
LOTO (1910.147)
Using electric tools that are in good repair
Using good judgment when working near energized lines
Using appropriate protective equipment

Thank You!

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