This is the draft electrical presentation that I use in the OSHA 10 hour classes. I put it up here to give the reader an idea what I cover in the one hour. I want to thank John Gryzwacz and Bob Lomastro for helping me with this presentation. They are the best electrical trainers in the country. Both teach the OSHA 3095 class at the OSHA ed centers. Bob is at www.safetywizard.com John is www.oshaprofessor.com These presentation are always in continual improvement so I put a date on the draft. There are many earlier versions of this.

1. Industrial Electrical
Safety
John Newquist
Draft 4 26 2015

2. Dec 2013

3. Oct 2013

4. June 2014 – Wet Location
 42-year-old Lynden Endress was washing
cattle on his farm.
 That's when the power washer he was using
short-circuited, electrocuting him.

5. November 2014 - Troubleshooting
Dietrich believes the man was electrocuted by his wedding ring after it made
contact with a copper wire in the back of the machine.
Albert Washington, his brother-in-law, told officers that he turned the power
off to the room. He asked for the power to be put back on to test the machine
and then when a fault was noticed he tried to fix it without turning the
electricity off again, at which point he was electrocuted, according to the
Daily Mail.

6. March 2014 – Use as Approved

7. 1. Fall Protection in Construction (1926.501) 8,241 violations
2. Hazard Communication (1910.1200) 6,156 violations
3. Scaffolding in Construction (1926.451) 5,423 violations
4. Respiratory Protection (1910.134) 3,879 violations
5. Electrical – Wiring Methods (1910.305) 3,452 violations
6. Powered Industrial Trucks (1910.178) 3,340 violations
7. Ladders in Construction (1926.1053) 3,311 violations
8. Lockout/Tagout (1910.147) 3,254 violations
9. Electrical – General Requirements (1910.303) 2,745 violations
10. Machine Guarding (1910.212) 2,701 violations

8. Who needs
training?
1910.332(a)
Employees in occupations listed
in Table S-4 face such a risk
and are required to be trained.
Other employees who also may
reasonably be expected to face
comparable risk of injury due to
electric shock or other electrical
hazards must also be trained.
 At a minimum, be trained in and familiar
with the following:
 The skills and techniques necessary to
distinguish exposed live parts from other
parts of electric equipment.
 The skills and techniques necessary to
determine the nominal voltage of exposed
live parts, and
 The clearance distances specified in
1910.333(c) and the corresponding
voltages to which the qualified person
will be exposed.

9. March 2015
• Issues?

10. Table S4
Typical Occupational Categories of Employees Facing a Higher Than Normal
Risk of Electrical Accident
 Blue collar supervisors
 Electrical and electronic engineers
 Electrical and electronic equipment assemblers
 Electrical and electronic technicians
 Electricians
 Industrial machine operators
 Material handling equipment operators
 Mechanics and repairers
 Painters
 Riggers and roustabouts
 Stationary engineers
 Welders

11. Ohm’s Law
The equations of Ohm’s Law are:
 Voltage = Current times Resistance
 Current equals Voltage divided by Resistance,
 Resistance equals Voltage divided by Current.
 13,800 Volts / 1000 Ohms = 13.8 Amps
 480 Volts / 0.1 Ohms = 4,800 Amps
 480 Volts / 0.01 Ohms = 48,000 Amps
E
I R

12. Determine the Current
Voltage is 120 volts. Resistance is 12 ohms =
amps.
Voltage is 480, resistance is 1 Ohm = amps
Voltage is 220 resistance is 2200 Ohm = amps

13. Electrical Current Effect
1 mA threshold for feeling
10-20 mA voluntary let-go of circuit impossible
25 mA onset of muscular contractions
50-200 mA ventricular fibrillation or cardiac arrest
E. A. Lacy, Handbook of Electronic Safety Procedures, Prentice- Hall: Englewood
Cliffs, New Jersey (1977)

14. Electricity and Conductors
• Electricity (or more specifically
current) does not flow to earth of
ground, it flows from its voltage
source back to its voltage source. –
John Gryzwacz www.oshaprofessor.com
• Electricity flows through conductors
• Water, Metal, the human body can be
conductors
• Insulators are not conductors

15. Ventricular Fibrillation
When the heart is in ventricular fibrillation, the
musculature of the ventricles undergoes irregular,
uncoordinated twitching resulting in no net blood flow.
The condition proves fatal if not corrected in a very
short space of time.
Normal

16. National Electric Code
 The National Fire Protection Code, got its
first electrical section in 1897
 Concern about many electrical fires and
conflicting codes

17. Knob & Tube
1881 NY Board of fire underwriters:
When it becomes necessary to carry wires through partitions
and floors, they must be secured against contact with metal,
or other conducting substance, in a manner approved by the
Inspector of the Board.

18. Electrical Grounding
 1928 NEC "Grounding
required in conductive
locations such as in
basements or in walls
containing metal lath,
even if the equipment was
fed by Knob and Tube
wiring, nonmetallic cable
lacking a grounding
conductor.
 Current travels both paths. Grounding involves providing
a conductor to carry most of the current into the ground rather
than into a body.

19. 120 Volts on the body
• Current = Volts/Resistance
• If you are sweaty and barefoot,
then your resistance to ground
might be as low as 1000 ohms.
Then the current would be:
• I = 120 V/1000 ohm or 120 mA
– ventricular fibrillation
• “The fact is in the US there are
more electrocutions annually at
120 volts than any other
voltage.” – John Gryzwacz

20. Equipment Grounding
• 1928 NEC "Grounding required
in conductive locations
• How does it work?
• The equipment grounding
conductor provides a safe path
for the fatal fault current to flow
back to its source and
instantaneously trip the circuit
protection device (circuit
breaker or fuse). – Gryzwacz
• Current travels both paths.
• Grounding involves providing a
conductortocarrymostofthe
currentintothegroundratherthan
intoabody. -BobLomastro
•What’s its function or purpose?
• To prevent electrocution in the
event of a short circuit or fault in the
tool or equipment.

21. The GFCI operates by sensing the difference between
the currents in the Hot (ungrounded) and Neutral (grounded) conductors.
Under normal conditions, these should be equal.
The GFCI will shut off at 5 mA in 1/40th of a second.
Imagecourtesy of Bob Lomastro www.safetywizard.com

22. GFCI’s –1971 NEC

23. Electrocution Deaths by Age Group
•244 Victims In The Study
N
u
m
b
e
r
NIOSH Fatality Assessment Control Evaluation (FACE)

24. Double Insulated
 Insulated from shock
 Square with square
 Watch out for no lab testing (NRTL)
Bottom two images courtesy of www.safetywizard.com

25. Power Taps
• 29 CFR 1910.305(g)(1)(iii)
reads as follows:
• "Unless specifically permitted
in paragraph (g)(1)(i) of this
section, flexible cords and
cables may not be used:
• (A) As a substitute for the
fixed wiring of a structure.

26. Fluorescent Lighting
Most common cause of electrocution
among electricians
- Changing ballast while live.
Workers not de-energizing
circuit nor wearing any PPE

27.  Shall be de-energized before
the employee works on or near
them, unless the employer can
demonstrate that de-energizing
introduces additional or
increased hazards or is infeasible
due to equipment design or
operational limitations.
 Testing live to find fault or
short is common reason.
Working Live
Insulated leads alones are not safe.
Wear rated gloves when testing.

28. #1 - Boxes with unused openings
Knockout Missing
1910.305(b)(1)
Note: Circuit breakers are designed to protect property not people.
Missing Dead Fronts

29. #2 – Exposed live parts over 50 Volts
1910.303(g)(2)(i) Exposed wiring - missing electrical housing

30. #3 – Missing covers
1910.305(b)(2)

31. #4 - Hanging pendant boxes
1910.305(g)(1)(iii)
Box has
strain relief
and no
knockouts
Knockouts
can get
pushed into
box
Impro
per
strain
relief

32. #5 — Missing Grounding Conductor
1910.304(f)(4)

33. #6 – Disconnects not labeled
Label is tattered
No labels on disconnects
1910.303(f)

34. #7 – Strain relief
Wire pulled out of shredder
1910.305(g)(2)(iii)
Missing on strain relief

35. #8 – Equipment not used per listing
Receptacle box not mountedBox used as an extension cord
1910.303(b)(2)

36. Nov 2013
 Citation 2 Item 1 Type of Violation: Willful
 29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not
used or installed in accordance with instructions included in the listing
or labeling:
 On or about May 24, 2013, and at times prior thereto, Spiral "final"
department, employees are allowed to use foreign material to operate
control panels.
 Employees are using makeshift instruments, including but not limited
to clip binders and welding wire bent in the shape of shepherd's hooks
to override the "forward" limit switch on the pipe conveyor console
panel, so that the pipe can continue horizontally down the conveyor
and the incoming pipe can immediately be worked on to reduce
workload buildup.
 The practice of overriding the limit switch on the console panel
exposes employee(s) to hazards associated with being struck by and
caught-in between conveyed piping, stopping blocks and other
stationary or transported objects.

37. #9 – 3’ Clear spaces
Storage in front of panel box
1910.303(g)(1)(ii)
Panel box blocked

38. #10 – Electrical Free of Hazards
1910.303(b)(1)
Ground prong stuck in receptacle Open wiring spliced out of box

39. #9 – 3’ Clear spaces
• 1910.303(g)(1)(ii)
Panel box blocked Storage in front of
panel box

40. Receptacles
Receptacles will have hot, neutral, and a
grounding conductor

41. Insulated Gloves
 Electrical gloves can protect the worker who must test circuits live.
 Gloves can be bought for work with voltages under 500 volts. These are
Class 00 gloves.
 Gloves must be sized for each employee.
 Test every six months.

42. Voltage
Detectors
• “Senses the steady state
electrostatic field
produced by AC voltage
through insulation without
requiring contact to the
bare conductor.
• A red glow at the tip and a
beeping noise (if not
switched OFF) indicates
the presence of voltage.” -
FLUKE
The detector will not work
on dc
Workers must test for the
absence of voltage.

43. AC Voltage
Detectors
Source: Fluke
Read the safety limitations
from the tester mfr

44. •Worker died when shocked pulling out barrel fuse with pliers
•Electrical circuits must be locked out before doing any work on the
circuits if possible.
Fuse Pulling

45. Outdoor signs
Worker found unconscious taking out electric
receptacle while still energized. Breakers were
not locked out. No labels in panel

46. Air Handlers
Worker touched an energized horizontal heating coil

47. Daily Checks
 Cord and plug connected
equipment should be check
daily before use.
 1910.334(a)(2)(i)
 Portable cord and plug
connected equipment and
flexible cord sets (extension
cords) shall be visually
inspected before use on any
shift for external defects

48.  For example, if an internal fault
should occur in the wiring as
shown in the figure below, the
equipment would not stop when
the switch is released or would
start as soon as a person plugs
the supply cord into the
improperly wired outlet. This
could result in serious injury.
Reverse Polarity
On October 30, 2004,
Employee #1 was apparently
trying to use a portable electric
grinder at a work site when he
was electrocuted from
ungrounded and reverse
polarity electrical sources.

49. Capacitors
Pleasant Prairie WI
OSHA’s investigation found the temp
worker had inadvertent contact with
electrical equipment while trouble-
shooting an electrical failure on a heat-
sealing machine.
Company failed to require personal
protective equipment for employees
working near exposed, energized
electrical parts.
The company also did not develop
procedures to de-energize circuits and
equipment safely or ensure stored
energy capacitors were grounded.
Capacitors store
electricity
indefinitely. They
must be properly

50. Clear Space again
1926.403(i)(1)
Sufficient access and working
space shall be provided and
maintained about all electric
equipment to permit ready and
safe operation and maintenance
of such equipment.

51. Classified Locations
Combustible dust &
exposed wiring.

52. 1. What mA typically causes muscle contractions? _____
2. A GFCI will shut off in _____ of a second.
3. When the musculature of the ventricles undergoes
irregular, uncoordinated twitching resulting in no
net blood flow is called ________ ________.
4. Live parts over ____ volts need to be guarded.
5. ____ feet of clear space must be maintained in front
of electrical panels.
Quiz

53. ELECTRIC ARC FACTS
•TYPICALLY LASTS
LESS THAN A SECOND
•EXTREMELY HIGH
RADIANT ENERGY
•EXPLOSIVE IN NATURE
CAN IGNITE AND/OR
MELT CONVENTIONAL
WORK CLOTHING

54. Electrical Statistics
• As many as 80 percent
of all electrical injuries
are from an arc-flash
contact and ignition of
flammable clothing.
• 2,000 people are
admitted to burn centers
• Source: Cooper
Bussmann

55. Arc Flash Incidents
 Estimated 5-10 arc flash incidents per day
 Numerous fatalities per year
 Estimates as to costs of burn injury medical (skin grafts,
therapy )and related costs (replacement worker,
rehabilitation,) average between 1.0 and 4 million dollars.
 And then we have a social cost!!!

56. Now which of you has seen this label?

57. The NEC 110.16, which reads: "Flash
Protection. Switchboards, panel boards,
industrial control panels, meter socket
enclosures, and motor control centers in
other than dwelling occupancies, which
are likely to require examination,
adjustment, servicing, or maintenance
while energized, shall be field marked to
warn qualified persons of potential
electric arc flash hazards*. The marking
shall be located so as to be clearly
visible to qualified persons before
examination, adjustment, servicing, or
maintenance of the equipment."
Field Marking

58. An arc flash is a short circuit
through the air
The temperature of an arc can reach approximately
35,000
degrees Fahrenheit or about four times as hot as the

59. If the marking is not there.
• The system was turned over without the appropriate hazard warnings.
• It is not in compliance with the 2002 – 2014 National Electrical Code
• Article 90 in the NEC specifically states that this code is not an
instruction manual for the untrained/unqualified persons (it’s for trained
qualified workers). - Gryzwacz
• If we need to label equipment to inform alleged “qualified” workers of
the hazards of electricity (including arc flash/arc blast) then perhaps they
shouldn’t be considered to be qualified.

60. Common Causes of Electric Arcs
 Dust and impurities
 Corrosion
 Condensation of vapor and water dripping
 Accidental touching phase to phase
or phase to ground
 Dropping conductive tools
 Over-voltage across narrow gaps
 Failure of insulating materials
 Improperly designed or utilized equipment
 Improper work procedures

61. An arc flash is a short circuit
through the air
The temperature of an arc can
reach approximately 35,000
degrees Fahrenheit or about
four times as hot as the surface
of the sun.

62. Electrical Processes Causing Flashes
 Removing or installing
circuit breakers or fuses
 Voltage testing
 Working on control circuits
when energized parts
exposed
 Applying safety grounds
 Racking circuit breakers
 Racking starters
 Removing bolted covers

63. Arc Rated PPE

64. NFPA 70E
Provides
additional
guidance to
determine Arc
Flash
Assessments and
clothing
requirements.

65. PPE Categories
PPE will depend on which boundary and task you are in.
FR clothing must be work first at Category 1 work.
Also FR
clothing is not
permitted for
arc flash/arc
blast hazard
protection, the
clothing must
be “arc rated
(per ASTM).

66. Power Lines
10 foot safe clearance up to 50,000 volts.
Avoid storing material under the lines.
Scaffold hits power lines video

67. Summary
Grounding involves providing a conductor to
carry most of the current into the ground rather
than into a body.

68. •Summary
Water and otherliquids are
good conductors of
electricity.

69. Lastly
A three-pronged plug
should never be
used in a two
pronged outlet

70. •Questions?
This is very unsafe!

71. Background
• Classes: OSHA 10/30 Hour,
Incident Investigation,
Confined Space, Excavation
Safety, Cranes Signaling and
Rigging, Fall Protection,
Scaffold Safety, and many more
• 2170 Trained in 2014!!
71
• 34 years working with top
companies to achieve ZERO
injuries
• Certified Safety Professional
• OSHA 1983-2012
• Founding Member of ANSI Z359
• 815-354-6853
• Johnanewquist@gmail.com
Services: Mentoring safety
professionals in hazard recognition
and auditing, Site Safety Audits,
Custom Training, OSHA Litigation
Consultation, Expert Witness,