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Identification of Electrical Hazards and Control of Risks in Industrial and

Utility Systems - A technical report and a short course

Technical Report · February 2018

DOI: 10.13140/RG.2.2.26738.20161

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Identification of Electrical Hazards and Control
of Risks in Industrial and Utility Systems
A technical report and a short course

By

Prof. Dr. Mohamed EL-Shimy Mahmoud

(http://shimymb.tripod.com)

Overview and Objectives

Preventing accidents and ill health caused by work is a key priority for everyone at
work. The orderly development of industry and the protection of community safety
necessitate the assessment and control of hazards and risks.

Safety audit (SA) is a systematic approach to evaluate potential hazards and to

recommend suggestions for improvement. SA is an important tool for identifying
deterioration of standards, areas of risks or vulnerability, hazards and potential accidents
in plants for determining necessary action to minimize hazards and for ensuring that
the whole safety effort is effective and meaningful. Industrial Health, Safety, and
Environment (HSE) deal with how to prevent injuries and accidents that occur in the
organizations.

A Hazard and Operability (HAZOP) study is a structured and systematic

examination of a planned or existing process or operation in order to identify and evaluate
problems that may represent risks to personnel or equipment, or prevent efficient
operation. Risk assessment and control have to be formulated and implemented within
safety planning processes that account for both the technical and the broader locational
safety aspects of potentially hazardous industries. These tasks are usually of the main
duties of planning department(s).

Occupational health and safety (OHS) is a cross-disciplinary area concerned with

protecting the safety, health and welfare of people engaged in work or employment. Health
and safety management systems are intended to help organizations to control occupational

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health and safety risks. OHS may involve interactions among many subject areas, including
occupational medicine, occupational (or industrial) hygiene, public health, safety
engineering, chemistry, and health physics.

This report/course covers the fundamentals and advances in the identification of

hazards, hazard analysis, and safety control of electrical systems. In addition, guidelines are
given for improving electrical safety in industrial and utility electrical systems. The
provided guidelines are carefully based on several related standards such as ISO 14000,
OHSAS 18001, OSHA, NEC, IEC, ANSI, and IEEE. The main covered topics include:

 Fundamentals of HSE and HAZOP,

 Occupational Health and Safety (OHS),
 Hazardous Area Classification,
 Electrical Safety Auditing (ESA),
 Earthing Systems for safety, operation, and lightening protection,
 Arc Flash Hazards and Control, and
 Electrochemical Hazards and Control.

The main objective of the course is to cover the above topics, but not limited to them.
Several practical examples and workshops are presented in the course. In addition,
occasional use of software for hazard minimization in electrical systems will be available
for the trainees.

Training means helping people to learn how doing something, telling people what
they should or should not do, or simply giving them information. This course is not just a
simple formal classroom course; it includes advanced up-to-date topics, example, and
workshops. The course will provide effective training that will contribute towards a safe
and healthy working environment. In addition, the course can help your business avoid the
distress that accidents and ill health cause. It can also help organizations avoid the financial
costs of accidents and occupational ill health.

Contents

Module 1: Introduction and Fundamental

1. Introduction
2. Overview of HSE and OHS requirements

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 3. HAZOP concept, process, and technique
4. Safety Survey
5. Accident costs, Investigating accidents and injury rates

Module 2: Hazardous Area Classification

1. Hazardous locations
a. Identification
b. Hazardous zones
c. Gas groups
d. Temperature classifications
e. Classification - ANSI/NFPA (NEC)
f. Classification -IEC and ATEX Standards
g. Protection concepts
2. Site Safety Management
a. Work Area Aspects Affecting Safety
b. Location of Work
c. Public Safety
3. Electrical Aspects Affecting Safety
a. Work Methods In Relation To Workers’ Safety
b. Number of Qualified Workers Per Hazard Exposure
c. De-energized line grounding
d. Energized line work

Module 3: Electrical Safety Auditing (ESA)

1. Need for ESA

2. Audit preparation
3. ESA checklists
4. Duration of electrical safety audits
5. Management briefing
6. Electrical safety auditing
7. Temperature detection and electrical accident control
8. Protection from electrical arc fires
9. Elements of electrical safety auditing programme
a. Pre-audit
b. Audit
c. Post-audit

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Module 4: Earthing Systems for safety, operation, and lightening protection

1. Need for earthing systems

2. Objectives
3. Typical shock situations
4. Basic Definitions and Preliminaries
5. Grounds System Audit: How To Identify Grounding Issues
6. Types and Properties of Standard Earthing Systems
7. Terms and Codes
8. Workshop: use of CAD for earthing systems

Module 5: Arc Flash Hazards and Control

1. Electrical Arc Hazards

2. Definitions
3. Regulating Authorities
4. Electrical switchgear and safety
5. Protection From Arc Flash Hazards
a. Comparison of Arc Flash Standards
b. NFPA Hazard Risk Determination
c. Data Collection for Arc Flash
d. Additional Considerations
6. General Steps for Performing Arc Flash Analysis
7. 3-Phase Bolted Fault Current
8. System Modes of Operation
9. Standards for Short-Circuit
10. Arcing Current
11. Arc Duration
12. Incident Energy
13. Flash Protection Boundary
14. Hazard / Risk Categories NFPA 70E
15. PPE Matrix
16. PPE Incident Energy Rating
17. Stoll Curve
18. FR Equipment Layering
19. Example of Layered System
20. Considerations for layering
21. ASTM Insulating Glove Voltage Classes

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 22. Arc Flash Hazard Labels
23. Solutions to Arc-Flash Problems
24. Case studies and examples

Module 6: Electrochemical Hazards and Control – Batteries

1. Battery usage
2. Battery types
3. Battery safety
4. Warnings
5. Electrolyte hazard
6. Explosive gas hazards
7. Electrical hazard
8. Accidental grounds
9. Normal safety procedures

Conclusions and Recommendations

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