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Richard (Rick) Elwell Senior Operations and Safety Instructor and Consultant 419-961-8814

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2 Richard (Rick) Elwell Senior Operations and Safety Instructor and Consultant 419-961-8814

3 Explain how training can save your company money. Discuss proper safety guidelines while placing a work area in an electrically safe condition and restoring equipment to operation, including PPE Selection and the Live-Dead-Live process. Explain safety concerns while troubleshooting and the proper safety techniques for live diagnostic testing: – Voltage measurements – Current Measurements – Insulation Testing Discuss Effective Troubleshooting Techniques using a Systematic Troubleshooting Approach

4 Electrical Safety training can save lives by: – Regularly reinforcing safe work practices – Providing employees with the information needed to keep them safe – Helping to reduce the risk of electrical-related accidents

5 Initial insurance costs for medical treatment and disability payments. Indirect costs for investigation, production loss, overtime, replacement of equipment impact to site from a loss of experienced employee(s).

6 Minimize the potential loss of critical equipment through operational and technical training by: – Creating a more efficient operator/technician with the ability to understand system response and quickly restore system redundancy and reliability – Reducing the potential for personnel (human) error which can lead to unexpected loss of up-time – Eliminating guessing (Easter Egging while troubleshooting) which often leads to replacement of the wrong component, resulting in reduced part replacement costs


8 Lock-Out/Tag-Out and check equipment de- energized whenever: – Ohmmeter readings are taken – Connecting clamp-on ammeter probes – Disconnecting or reconnecting wires – Replacing an electrical component – Performing visual inspections and/or adjustments inside electrical enclosures

9 … of stored energies. – During the LOTO process, safety discharge capacitors whenever present. Do not rely of bleeder resistor circuits. – If troubleshooting removable ACB-type circuit breakers, discharge closing springs.

10 The appropriate level of shock/Arc Flash PPE is required. – Use installed Arc Flash Labels – Or NFPA 70E PPE Selection Tables Energized work permits are not required for diagnostic testing and troubleshooting.

11 Do not reclose breaker or replace fuse(s) unless: – It is known to be caused by an overload condition – Circuit has been inspected for down-stream shorts.

12 Daily by user = once per shift, unless damage is expected Visual and Air Check


14 14 Pressure Waves 200 lbs/sq inch Copper Vapor: Solid to Vapor Expands by 67,000 times Molten Metal Extremely High Temps 15,000- 35,000 °F Shrapnel @700 mph Sound Waves 135+ decibels at 2ft Intense Light

15 Boundaries should be set around the work area to prevent: – unqualified workers from coming into contact with live parts. – Injury to those not in the appropriate level of PPE. – Protect the worker 15

16 Note: shock boundaries dependent on system voltage level. For <600V the Limited Approach Boundary is 3.5 ft. Equipment Prohibited Shock Boundary:Authorized Qualified Persons Only. PPE as if direct contact with live parts. Restricted Shock Boundary:Authorized Qualified Persons w/PPE Limited Shock Boundary:Authorized Qualified Persons w/PPE. Unqualified allowed only when conducting OJT and accompanied by a qualified person

17 Flash Protection Boundary (FPB) – @ 1.2 Cal/cm2 Equipment Must wear appropriate PPE FPB based on available fault current and duration if an Arc Flash Analysis was performed. Values are listed on AF Label attached to equipment.

18 This incident energy exposure level shall be based on the working distance of the employees face and chest areas from a prospective arc source for the specific task to be performed. 480V MCC

19 Know meter functions and how it is protected. Know how to selected the right meter and its limitations: – Always use CAT 3 (or higher) meter. – A low-budget meter may kill you. Know how to use a device to verify the absence of voltage, including interpreting indications/readings. Inspect meters for safe use.

20 Conduct a Live-Dead-Live Test – Check meter on a know live source – Test the equipment (6-point check) Each Phase-to-phase Each Phase-to-Ground – Recheck meter on a know live source

21 7-Step Troubleshooting 1. Preparation 2. Observation 3. Defined problem area 4. Identify possible and probable causes 5. Test 6. Repair/replace and confirm 7. Follow-up




















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