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# Electrical Hazards by Cooper Bussmann

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• Intended to be used with Safety BASICs handbook – starting on page 14
• Electricity has become such an integral part of our society that it often is taken for granted. Yet, electricity remains a very dangerous hazard for people working on or near it. Many electrical circuits do not directly pose serious shock or burn hazards by themselves. However, many of these circuits are found adjacent to circuits with potentially lethal levels of energy. Even a minor shock can cause a worker to rebound into a lethal circuit or cause the worker to drop a tool into the circuit. Involuntary reaction to a shock might also result in bruises, bone fractures, and even death from collisions or falls.
• The following are recognized as common electrical hazards that can cause injury, and even death, while a person works on or near electrical equipment and systems:
• Electrical shock
• Electrical burns from contact (current) and flash (radiant)
• Arc-blast impact from expanding air and vaporized materials
• The equation helps in the understanding of both the hazard of shock and short circuit currents. A bolted short circuit current has the phase conductors in contact (bolted) and the short circuit current is dissipated throughout all the circuit components. This type fault can create major mechanical and thermal stresses on all the components. If a component does not have sufficient short circuit ratings it may be damaged or rupture. An arcing fault is where two conductors, or a conductor to ground, faults but through air. An arc is created – i.e. the fault current path is through air. In this type of fault, most of the energy is dissipated in the arc, releasing tremendous amounts of thermal energy. Later in the slides there is a model of an arcing fault.
Workers can get injured when a bolted fault occurs if a component explodes.
A major hazard occurs if a worker is near electrical equipment and an arcing fault occurs. The tremendous amount of energy that is released in the arcing can be lethal. Arcing faults can occur if a worker is working on energized equipment and a metal part drops across live phase conductors.
• More than 30,000 non-fatal electrical shock incidents are estimated to occur each year. The National Safety Council estimates that from 600 to 1,000 people die every year from electrocution. Of those killed with voltages less than 600V, nearly half were working on exposed energized circuits at the time the fatal injury occurred. Electrocution continues to rank as the fourth highest cause of industrial fatalities (behind traffic, violence/homicide, and construction incidents).
Most personnel are aware of the danger of electrical shock, even electrocution. It is the one electrical hazard around which most electrical safety standards have been built. However, few really understand just how little current is required to cause injury, even death. Actually, the current drawn by a 7 W, 120V lamp, passing across the chest, from hand-to-hand or hand-to-foot, is enough to cause fatal electrocution. The effects of electric current on the human body depend on the following:
• Circuit characteristics (current, resistance, frequency, and voltage)
• Contact resistance and internal resistance of the body
• The current’s pathway through the body, determined by contact location and internal body chemistry
• Duration of the contact
• Environmental conditions that affect the body’s contact resistance
• To understand the currents possible in the human body, it is important to understand the contact resistance of skin (see Table V(A)(1) page 15). The skin’s resistance can change as a function of the moisture present in its external and internal layers, with changes due to such factors as ambient temperatures, humidity, fright, and anxiety.
Body tissue, vital organs, blood vessels and nerve (non-fat) tissue in the human body contain water and electrolytes, and are highly conductive with limited resistance to alternating electrical current. As the resistance of the skin is broken down by electrical current, resistance drops and current levels increase.
• The human body could be considered as a resistor with hand-to-hand resistance (R) of only 1,000 Ohms. The voltage (V) determines the amount of current passing through the body. While 1,000 Ohms might appear to be low, even lower levels can be approached by a person with sweat soaked cloth gloves on both hands and a full-hand grasp of a large, energized conductor and a grounded pipe or conduit. Moreover, cuts, abrasions or blisters on hands can negate skin resistance, leaving only internal body resistance to oppose current flow. A circuit in the range of 50V could be dangerous in this instance.
Ohm’s Law: I (amps) = V (volts) / R (ohms)
Example 1: I = 480 / 1000 = 480mA (or 0.480A)
Product standards consider 4 to 6mA to be the safe upper limit for children and adults (hence the reason a 5-milliamp-rated GFCI circuit).
Note: GFCIs do not protect against a line-to-neutral or a line-to-line shock.
• Electrical currents can cause muscles to lock up, resulting in an inability of a person to release his or her grip from the current source. This is known as the “let-go” threshold current. At 60Hz, most females have a “let-go” limit of about 6 milliamperes (mA), with an average of 10.5mA. Most males have a “let-go” limit above 9mA, with an average of 15.5mA. (These limits are based on smaller average size of females. Therefore, a small man could have a lower limit, or a larger woman a higher limit.)
Sensitivity, and potential injury, also increase with time. A victim who cannot “let go” of a current source is much more likely to be electrocuted than someone whose reaction removes them from the circuit more quickly. The victim who is exposed for only a fraction of a second is less likely to sustain an injury.
• The most damaging path for electrical current is through the chest cavity (see A and D in Figure V(A) page 16) and head. In short, any prolonged exposure to 60Hz current of 10mA or more might be fatal. Fatal ventricular fibrillation of the heart (stopping of rhythmic pumping action) can be initiated by a current flow of as little as several milliamps. These injuries can cause fatalities resulting from either direct paralysis of the respiratory system, failure of the rhythmic heart pumping action, or immediate heart stoppage.
During fibrillation, the victim might become unconscious. On the other hand, he or she might be conscious, deny needing help, walk a few feet, and then collapse. Death could occur within a few minutes or take hours. Prompt medical attention is needed for anyone receiving electrical shock. Many of these people can be saved, provided they receive proper medical treatment, including cardiopulmonary resuscitation (CPR) with Automatic External Defibrillation (AED) devices quickly.
• Think of electrical shock injuries as “icebergs,” where most of the injury is unseen, below the surface. Entrance and exit wounds are usually coagulated areas and might have some charring, or these areas might be missing, having “exploded” away from the body due to the level of energy present. The smaller the area of contact, the greater the heat produced. For a given current, damage in the limbs might be the greatest, due to the higher current flux per unit of cross-sectional area.
Within the body, the current can burn internal body parts in its path. This type of injury might be difficult to diagnose, as the only initial signs of injury are the entry and exit wounds. Damage to the internal tissues, while not apparent immediately, might cause delayed internal tissue swelling and irritation. Prompt medical attention can minimize possible loss of blood circulation and the potential for amputation of the affected extremity, and can prevent death.
• 80% of electrical injuries are burns - source:
C. M. Kent and H. L Floyd, “Managing the Other Electrical Hazard: Electrical Arcs,” American Society of Safety Engineers Forum titles “Safety Technology 2000,” Orlando, Florida, June 19 ,1995
Only recently has the industry started to recognize arc-fault energies as an electrical hazard. Only recently has the industry started to develop safety standards to address them.
In addition to severe burns to exposed skin, the heat generated from the arc energy can cause molten metal to be thrown from the arc. If inhaled, severe damage to the lungs will occur.
The bright flash of light from an arc can also cause eye damage.
• Injury can occur from:
Impact with objects
shrapnel from damaged electrical circuit components
impact with solid objects as victim is thrown from arc fault area
hearing damage
concussion
• Let’s examine the two types of faults.
(Mouse click to trace current flow of bolted fault.)
A bolted short circuit is characterized by the conductors of different potential being “bolted” together. Remember, for all practical purposes, the load is no longer in the circuit.
(Mouse click to trace current flow of an arcing fault.)
An arcing fault is characterized by the electric current going through the air. In the case of an arcing fault the air contains contaminates that permits the electrical potential to break down the normally good air insulation. An arcing fault has current flowing through the air. An arc quickly vaporizes the normal conductors at the points of the arc and this conductive vapor adds to the conductive nature of the “air path”.
Either type of fault can be devastating since the energy of the source is only abated by the resistance (impedance) of the circuit components. The bolted fault dissipates the large amount of energy along the path of the circuit components. The smaller, higher resistance components take more of the stress. With an arcing fault, the circuit components also take on significant stress since a large fault current is flowing through them. However, a major difference is that a tremendous amount of energy is released at the point of the arc.
One last point. In both cases the tremendous release of damaging energy can occur in a few thousandths of a second.
• Following is a graphical model of an arcing fault and the physical consequences that can occur. The unique aspect of an arcing fault is that the fault current flows through the air between conductors or a conductor(s) and a grounded part. The arc has an associated arc voltage because there is arc impedance. The product of the fault current and arc voltage in a concentrated area, results in tremendous energy being released in several forms.
The resulting energies can be in the form of radiant heat, intense light, and tremendous pressures. Intense radiant heat from the arcing source travels at the speed of light. The temperature of the arc terminals can reach approximately 35,000°F, or about four times as hot as the surface of the sun. No material on earth can withstand this temperature. The high arc temperature changes the state of conductors from solid to hot molten metal and to vapor. The immediate vaporization of the conductors is an explosive change in state from solid to vapor. Copper vapor expands to 67,000 times the volume of solid copper. Because of the expansive vaporization of conductive metal, a line-to-line or line-to-ground arcing fault can escalate into a three-phase arcing fault in less than a thousandth of a second.
The extremely high release of thermal energy superheats the immediate surrounding air. The air also expands in an explosive manner. The rapid vaporization of conductors and superheating of air result in high pressure waves and a conductive plasma cloud, that if large enough, can engulf a person. The thermal shock and pressures can violently destroy circuit components. The pressure waves hurl the destroyed, fragmented components like shrapnel at high velocity; shrapnel fragments can be expelled in excess of 700 miles-per-hour. Molten metal droplets at high temperatures typically are blown out from the event due to the pressure waves.
• 35,000 degree F can occur at the arc tips. 35, 000 degrees is approximately four times the temperature on the surface of the sun.
This high temperature vaporizes and melts the adjacent copper conductors and other materials.
The high temperatures and molten metal can ignite improper clothing such as polyesters.
Remember the thresholds for second and third degree burns. Later actual tests are shown that capture the resulting temperatures from arc faults on simulated workers. These values will be important to compare to the results measured from the tests.
• The vaporization of the metals and super heating of air creates a pressure blast. This blast can exert tremendous pressures on equipment and people.
Medical research has shown that ear drums can rupture at the threshold levels shown. The angle of the ear opening can alter the effects.
Lung damage such as collapse can occur at the threshold level shown.
Remember the eardrum and lung damage thresholds to compare to results of upcoming tests.
• If an arcing fault occurs while a worker is in close proximity, the survivability of the worker is mostly dependent upon (1) the characteristics of the overcurrent protective devices, (2) the arc-fault current, and (3) precautions the worker has taken prior to the event, such as wearing personal protective equipment appropriate for the hazard. The selection and performance of overcurrent protective devices play a significant role in electrical safety. Extensive tests and analysis by industry have shown that the energy released during an arcing fault is related to two characteristics of the overcurrent protective device protecting the affected circuit:
The time it takes the overcurrent protective device to open. The faster the fault is cleared by the overcurrent protective device, the lower the energy released.
2. The amount of fault current the overcurrent protective device lets through. Current-limiting overcurrent protective devices may reduce the current let-through (when the fault current is within the current-limiting range of the overcurrent protective device) and can reduce the energy released.
Lowering the energy released is better for both worker safety and equipment protection. The videos and recorded sensor readings from actual arcing fault tests illustrate this point very well.
• An ad hoc electrical safety working group within the IEEE Petroleum and Chemical Industry Committee conducted these tests to investigate arc-fault hazards. These tests and others are detailed in “Staged Tests Increase Awareness of Arc-Fault Hazards in Electrical Equipment,” IEEE Petroleum and Chemical Industry Conference Record, September 1997, pp. 313-322. This paper can be found at www.bussmann.com under Services/Safety BASICs. One finding of this IEEE paper is that current-limiting overcurrent protective devices reduce damage and arc-fault energy (provided the fault current is within the current- limiting range).
• - View of the test area
Testing in both combination starters(left) and MCC(rear)
Mannequins to simulate workers
Mannequins with sensors were used to capture data
• This is the first test we will review. It is Test 4.
The fault is on the line side of the 30A branch overcurrent protective device (OCPD)
The feeder OCPD is the device that will be called upon to react to this overcurrent. The feeder OCPD used in this test is a power circuit breaker with a short time delay (there is no instantaneous trip). Short time delay (STD) devices are used to achieve coordination between the branch and feeder OCP devices. Where continuity of service is important or critical, and where using circuit breakers, the feeder and main circuit breakers must be equipped with short time delay options. A short time delay option allows a circuit breaker to intentionally hold off opening when a fault occurs; this allows downstream devices to clear faults on their circuits without opening the circuit breaker with the STD.
However, when a fault does occur on the circuit of the circuit breaker with a short time delay, the fault is permitted to flow for the time of the short time delay settings. This can allow a great deal of energy to flow while the short time delay times out.
Industrial plants and commercial buildings that have circuit breakers and that require coordination, typically will have short time delays on their feeder and main circuit breakers.
The users of the IEEE committee that participated in these tests typically use STD’s on their feeder circuits when they use circuit breakers as their feeder OCPD’s. In other words, this is a common application of circuit breakers.
Notice the fault is created on the line side of the 30 amp fuse. So the 30 amp fuse is not in the faulted circuit. The fault has to be cleared by the 640 amp feeder circuit breaker.
• - Mention the noise level with this video
This is a video in normal speed. (This video file is linked to this PowerPoint slide. If you keep this PowerPoint presentation and video file in the same folder they should run alright. If you are showing this on a video projector connected to your computer, you may need to transfer video from your laptop screen to video projector by using the appropriate “function keys” to toggle between laptop screen and the port to the video projector.) Move mouse over picture until the hand appears and then click on the picture.
NOTE:
Have Volume turned up on computer to display sound levels!
• Test set up prior to initiation of arc-fault. Mannequin nearest to combination motor starter is equipped with sensors. The mannequins have been propped up with 2x4’s. The closest mannequin’s hand is positioned near the screwdriver used to initiate the arcing fault.
• Note the intense light and plasma.
• Notice the wire way cover is blown off the wall and moving towards the mannequin’s head. Also not the molten metal spray.
• Now the wire way cover can be seen hitting the mannequin in the head.
• The closest mannequin is again engulfed in the plasma as the arc releases more energy.
• The mannequin closest to the arcing fault had sensors affixed to specific parts. The readings from the test can provide great insight to the hazards of arcing faults.
Sound, pressure, and temperature measurements on the worker were recorded
&gt; 2160 lbs/sq. ft would damage the lungs and eardrums(remember thresholds)
Temp (T1) and (T2) were well above the 3rd degree burn level of 205 deg F
Sound intensity level well above shotgun level
Temp (T3) read under cotton shirt. The shirt provided a good barrier against the high level temperatures
The recorded results show that bare skin of the hand and neck would have incurred very serious burns since the recorders were pegged well above the incurable burn level. The pressure on the chest also was very severe. The pressure pegged the meter so it was beyond the threshold for lung damage.
• Test # 3 is the same as Test # 4 except the feeder overcurrent device is now a 601 ampere current-limiting overcurrent device (601 A Class L fuse). The fault again occurs on the line side of the 30 amp branch circuit OCPD.
• - Notice the dramatic reduction in activity
• There is very little energy released, only a small spatter of metal.
• Sound, pressure, and temperature measurements on the worker, were recorded
Pressure dropped below level of eardrum rupture
Temp (T1) still above the 3rd degree burn level of 205 deg F
Temp (T2) dropped below second degree burn level (175 deg F)
Sound intensity level at shotgun level
The results when compared to the prior Test 4 are significantly less. It shows the benefit of limiting the current in magnitude and time (achieved in this test by 601 current limiting fuses).
• Next is Test 1. This is the same test circuit. However, the difference is that the arcing fault is created on the loadside of the 30 amp current limiting fuses.
Test no. 1 had 22,600 amps available at 480 volts
Test number 1 is similar to tests 3 &amp; 4 except that the short is created on the load side of a 30 ampere current limiting Class RK1 fuse. Why is this important?(Now the branch device is relied upon to clear the fault)
Even more current limitation is utilized in this test
• - Dramatic reduction in activity
• Measurements of sound, pressure, and temperature were minimal.
Drastic reduction of time and energy limited activity down to the point that no changes from ambient were detected.
• The approximate wave forms for tests 4, 3, and 1.
The energy released from an arc fault is related to the amount of current that flows and the time duration.
Current-limiting overcurrent protective devices can substantially reduce the energy. Test 4 let through the full fault current and did not clear for six cycles. Test 3, with 601 amp current limiting fuses, limited the current let thru and cleared in less than a ½ cycle. Therefore the energy released was less than Test 4. Test 1, with a 30 amp current limiting fuse, was much more current limiting than even Test 3 results. This is due to the the high degree of current limitation of a 30 amp fuse and it cleared in less than a ¼ cycle.
• ### Electrical Hazards by Cooper Bussmann

1. 1. Safety BASICs TM Electrical Hazards Bussmann® Awareness of Safety Issues Campaign ©2004 Cooper Bussmann
2. 2. Electrical Hazards What are the hazards as you approach electrical equipment to perform work? ©2004 Cooper Bussmann
3. 3. Electrical Hazards • Shock • Arc flash – Heat – Fire • Arc blast – Pressure – Shrapnel – Sound Example of an arcing fault ©2004 Cooper Bussmann
4. 4. Basic Electrical Theory I=V/Z • What happens with shock? • What happens when there is a fault? • What is the difference between a shortcircuit and an arcing fault? ©2004 Cooper Bussmann
5. 5. Electric Shock • Over 30,000 non-fatal electrical shock accidents occur each year • Over 600 people die from electrocution each year • Electrocution remains the fourth (4th) highest cause of industrial fatalities • Most injuries and deaths could be avoided ©2004 Cooper Bussmann
6. 6. Human Resistance Values Resistance (ohms) Condition Dry Wet 40,000 to 1,000,000 4,000 to 15,000 Hand holding wire 15,000 to 50,000 3,000 to 6,000 Finger-thumb grasp 10,000 to 30,000 2,000 to 5,000 Hand holding pliers 5,000 to 10,000 1,000 to 3,000 Palm touch 3,000 to 8,000 1,000 to 2,000 Hand around 1-1/2 inch pipe 1,000 to 3,000 500 to 1,500 500 to 1,500 250 to 750 Finger touch Two hands around 1-1/2 inch pipe Hand immersed 200 to 500 Foot immersed 100 to 300 Human body, internal, excluding skin 200 to 1,000 This table was compiled from data developed by Kouwenhoven and Milnor. ©2004 Cooper Bussmann
7. 7. Electric Shock Human body resistance (hand to hand) across the body is about 1000 Ω Ohms law: I = V / R amps = 480 volts / 1000 Ω = 0.48 amps (480 mA) Product safety standards consider 5 mA to be the safe upper limit for children and adults ©2004 Cooper Bussmann
8. 8. Electric Shock mA 0.5 - 3 3 - 10 10 - 40 30 - 75 100 - 200 200 - 500 1500 + ©2004 Cooper Bussmann Affect on person - Tingling sensations - Muscle contractions and pain - “Let-go” threshold - Respiratory paralysis - Ventricular fibrillation - Heart clamps tight - Tissue and organs start to burn
9. 9. Electric Current Pathways (A) Touch Potential (B) Step Potential (C and D) Touch / Step Potential Current passing through the heart and lungs is the most serious ©2004 Cooper Bussmann
10. 10. Electric Shock Injury ©2004 Cooper Bussmann
11. 11. Arc Flash As much as 80% of all electrical injuries are burns resulting from an arc-flash and ignition of flammable clothing Arc temperature can reach 35,000°F - this is four times hotter than the surface of the sun Fatal burns can occur at distances over 10 ft Over 2000 people are admitted into burn centers each year with severe electrical burns ©2004 Cooper Bussmann
12. 12. Arc Blast An arc fault develops a “pressure wave” Sources of this blast include: – Copper expands 67,000 times its original volume when vaporized – Heat from the arc, causes air to expand, in the same way that thunder is created from a lightning strike This may result in a violent explosion of circuit components and thrown shrapnel The blast can destroy structures, knock workers from ladders, or across the room ©2004 Cooper Bussmann
13. 13. Bolted Short Circuit Arcing Fault Current Thru Air A ©2004 Cooper Bussmann B A B
14. 14. Electric Arc 35,000 °F Molten Metal Pressure Waves Sound Waves Shrapnel Copper Vapor: Solid to Vapor Expands by 67,000 times Hot Air-Rapid Expansion Intense Light ©2004 Cooper Bussmann
15. 15. Personnel Hazards Associated With Arc Flash & Arc Blast • Heat – burns & ignition of material – Arc temperature of 35,000oF – Molten metal, copper vapor, heated air • Second degree burn threshold: – 80oC / 175oF (0.1 sec), 2nd degree burn • Third degree burn threshold: – 96oC / 205oF (0.1 sec), 3rd degree burn • Intense light – Eye damage, cataracts ©2004 Cooper Bussmann
16. 16. Personnel Hazards Associated With Arc Flash & Arc Blast • Pressures from expansion of metals & air • Eardrum rupture threshold: – 720 lbs/ft2 • Lung damage threshold: – 1728 - 2160 lbs/ft2 • Shrapnel • Flung across room or from ladder/bucket ©2004 Cooper Bussmann
17. 17. Overcurrent Protection Role Flash protection boundaries and incident energy exposure calculations both dependent upon: Duration of arc-fault or time to clear • Speed of the overcurrent protective device Arc-fault current magnitude • Available fault current • Current-limitation can reduce ©2004 Cooper Bussmann
18. 18. IEEE / PCIC & NFPA 70E • Ad Hoc Safety Subcommittee – Users – Consultants – Manufacturers – Medical experts • Following are some of the tests run – All of the devices used for this testing were applied according to their listed ratings ©2004 Cooper Bussmann
19. 19. IEEE / PCIC Staged Arc Flash Test Set-up ©2004 Cooper Bussmann
20. 20. Test No. 4 22.6 KA Symmetrical Available Fault Current @ 480V, 3 Phase 6 cycle STD Set @ 6 cycle opening 640A OCPD Non Current Limiting with Short Time Delay Fault Initiated on Line Side of 30A Fuse 30A RK-1 Current Limiting Fuse Size 1 Starter ©2004 Cooper Bussmann
22. 22. Test 4 Still Photo ©2004 Cooper Bussmann
23. 23. Test 4 Still Photo ©2004 Cooper Bussmann
24. 24. Test 4 Still Photo ©2004 Cooper Bussmann
25. 25. Test 4 Still Photo ©2004 Cooper Bussmann
26. 26. Test 4 Still Photo ©2004 Cooper Bussmann
27. 27. Test 4 Still Photo ©2004 Cooper Bussmann
28. 28. Test 4 Still Photo ©2004 Cooper Bussmann
29. 29. Results: Test No.4 Sound 141.5 db @ 2 ft. P1 T2 >2160 lbs/ft2 o o >225 C/437 F o T3 o T1 o 50 C/122 F >225 C/ o 437 F > Indicates Meter Pegged ©2004 Cooper Bussmann
30. 30. Test No. 3 22.6 KA Symmetrical Available Fault Current @ 480V, 3 Phase 601A. Class L Current Limiting Fuse Fault Initiated on Line Side of 30A Fuse 30A RK-1 Current Limiting Fuse Size 1 Starter ©2004 Cooper Bussmann
32. 32. Test 3 Still Photo ©2004 Cooper Bussmann
33. 33. Test 3 Still Photo ©2004 Cooper Bussmann
34. 34. Test 3 Still Photo ©2004 Cooper Bussmann
35. 35. Test 3 Still Photo ©2004 Cooper Bussmann
36. 36. Results: Test No.3 Sound 133 db @ 2 ft. T2 o o 62 C/143.6 F T3 (No Change From Ambient) P1 504 lbs/ft2 T1 > 175 C/ o 347 F > Indicates Meter Pegged ©2004 Cooper Bussmann o
37. 37. Test No. 1 22.6 KA Symmetrical Available Fault Current @ 480V, 3 Phase 601A. Class L Current Limiting Fuse 30A RK-1 Current Limiting Fuse Fault Initiated on Load Side of 30A Fuse ©2004 Cooper Bussmann Size 1 Starter