posted on 10.27.14

While employed by USDOL/OSHA, I often viewed fatality scene photos. A particularly gruesome series of shots showed a young man who was electrocuted by 13,800 AC volts (or thereabout). Clothing was burned off, and the skin of this Caucasian victim had been darkened dramatically by the severe burns. The photos were horrendous to see. Several years earlier, I had looked at photos of two men who had been electrocuted by 110 AC volts or 220 AC volts. They lay on the ground, appeared to be sleeping, and bore no major, visible marks (from the accident). Perhaps the two men who died together had open caskets. I can’t imagine the other man did. One thing is certain: all three are gone. The accurate, pertinent adage is that “volts don’t kill, amps do.” More persons die from 110-220 AC volts than from the “high numbers.” The lesson is simple and emphatic: do not get too comfortable with any notion that 110 or 220 is harmless. Remember, too, that electrical hazards can result in other types of hazards, including fire and vapor ignition.  The following is a checklist of electrical hazards you need to ensure are not present in your plant.

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-Impeded access to disconnects and breakers

-Unlabeled disconnects and breakers

-Missing knock-outs, and other unused openings

-Stripped, gouged, crimped, split, and cut insulation on cords

-Cords and cables not properly secured to equipment

-Ungrounded equipment, including portable tools that are not double-insulated

-Flexible cords concealed, subject to damage, attached to building surfaces, and run through walls, ceilings, floors, and doorways

-Flexible cords presenting tripping hazards

-Improper use of extension cords

-Open wiring (generally capped wires and/or inner colored conductors are visible)

-Exposed live parts (generally bare copper), including (but not limited to) in breaker panels lacking breaker or filler, below dials inside timer boxes, and associated with knife switches

-Reversed polarity in receptacles

-Knock-out type receptacle boxes, designed for mounting in a permanent location, attached to extension or suspended cords, and subject to damage

-Lack of strain relief devices or grommets, including for suspended pushbutton stations (pendants) where the station is not suitably supported to protect the conductors

-Lack of ground fault circuit interrupters

-Lack of (or not properly secured) covers/plates for boxes, switches, receptacles, and similar fixtures, including where there is no lock or substantial hardware

-Damaged receptacles, switches, covers, plates, and frames

-Improper splices

-Lack of training regarding safety-related work practices (do not forget arc flash/blast hazards), including for lockout/tagout, recognition and testing, lighting, clearance, housekeeping, metal ladders and other metal items, wet and damp locations, insulated tools, personal protective equipment

-Unsuitable equipment in hazardous locations (vapor, dust, other ignition)

-Unsuitable equipment in harmful environments (weather, wet, extreme heat, corrosion+)

-Lack of magnetic controls, manual resets, or equivalent, mainly for woodworking machines and mechanical power presses (although your sites generally do not have these machines, the concept is still relevant; in fact, there are similar requirements for cranes)

-Overhead lines when near cranes and other vehicles that are tall, extensible or articulating, or when near long metal parts, such as associated with scaffolds, ladders, poles, and long-handled tools (also consider the exposed, energized electrical parts associated with cranes, but not readily appearing to be dangerous)

Article provided by Rick Kaletsky, MTI’s Official Safety Consultant. If you have any questions on the article or would like more information, you can contact Rick Kaletsky at 800-451-6172 or rkaletsky@gmail.com.