Wired for Danger: Understanding the startling truth about electrical safety
Did you know that every employer should have an electrical safety plan—even if your workers only perform non-live work? In today’s modern workplaces, electrical safety is critical to maintaining a safe and secure environment for employees.
From portable generators to electric equipment clearance distances, understanding and implementing proper electrical safety measures can prevent accidents, injuries, and even fatalities. Explore critical considerations and best practices from the safety event in the next section to ensure workplace safety through an effective electrical safety program.
Electrical Incident
A factory worker and his coworker were employed at a plant that used thermoforming machines to make plastic inserts for cosmetic packaging. These machines created a great deal of residual heat, so management ordered the installation of fans to exhaust the heat from the room. The two employees worked from a scissor lift to install the non-live wiring for the fans, which a licensed electrician would later inspect, connect, and energize.
As the workers ran conduit along the room’s ceiling, they approached a partially exposed, 480-volt, three-phase electrical bus bar that supplied power to the thermoforming machines. The worker reportedly used a voltmeter in the scissor lift to test the exposed electrical conductors at the uncovered end of the bus bar. He connected the voltmeter across two phases, which overloaded the meter and caused it to explode.
The explosion ignited the worker’s clothing and caused an electrical breaker to trip, plunging the area into darkness. The coworker managed to lower the lift, but his clothing ignited while trying to extinguish the other worker’s burning clothing.
Another employee put out the fires with a fire extinguisher. The first worker was taken to the area burn unit, where he died of complications 14 days later. Following the incident, plant management brought in a crisis counselor to help with the psychological impact on the employees who witnessed the incident.
Accident prevention recommendations
Investigators concluded that to prevent similar accidents, employers should:
- Develop, implement, and enforce an electrical safety program;
- Permit only adequately trained and qualified persons to carry out electrical work; and
- Inspect work areas before permitting employees to work near electrical or other hazardous equipment.
Electrical safety program
In this event, the plant used licensed electrical contractors to do their electrical work. However, the plant mechanic and other personnel responsible for maintaining machinery may come close to electrical circuits. This is not unusual at many companies.
To ensure the safety of these workers, companies need to develop, implement, and enforce an electrical safety program. This program should include training in electrical safety practices, lockout/tagout procedures, circuit testing (to ensure that circuits are de-energized), and other safety training commensurate with the duties of the workers. This would include correctly storing electrical test equipment away from unauthorized personnel.
Qualified person
The two workers were injured in this incident as they installed an electrical conduit near an exposed electrical bus bar. The workers had little or no training in electrical hazards and were unqualified to do electrical work.
Even though they were doing non-live wiring and were clearly instructed not to make any electrical connections, the victim’s inexperience and lack of training were evident in his failure to recognize the danger of the exposed bus bar.
Therefore, only properly trained and authorized employees should be permitted to work on electrical circuits. Close supervision may be necessary to ensure unauthorized employees are kept safe from electrical circuits.
Work area inspection
The electrical contractor who installed the electrical bus bar neglected to place an end cap on the bus enclosure, exposing the electrical conductors. This hazard was not known to plant management. As such, the work area should have been closely inspected by a qualified person before allowing employees to work there.
This inspection should be done as part of a formalized job-hazard analysis, which examines each task for potential mechanical, electrical, chemical, or any other hazard a worker may encounter.
Key to Remember
Management should have provided a comprehensive electrical safety program, adequate electrical safety training, and safe work areas for employees. The shocking truth is that the company overlooked electrical safety. Follow the lessons learned from this safety event to prevent a similar occurrence at your workplace.