1. BAPHILIMALI BAUXITE MINES. UTKAL ALUMINA INTERNATIONAL LTD.
ELECTRICAL SAFETY OF FIXED CRUSHER PLANT AND CONVEYING SYSTEM AT BAPHLIMALI BAUXITE MINES

2. LAYOUT DIAGRAM OF FCP

3. ELECTRICAL SAFETY IN CONVEYING SYSTEM & ROTARY MOTOR SAFETY.
PCS (Pull Cord Switch)
BSS (Belts Sway Switch)
ZSS (Zero Speed Switch)
Limit Switch.
Motor Protection Numerical Relays.
Magnetic separator.
Metal detector.

4. PULL CORD SWITCH(PCS)
Pull cord switch (PCS) is used along the conveyor belt gallery line.
PCS is used to stop the plant in emergency by pulling a cord that is connected to it on the knob of the PCS.
Once the PCS is activated then the plant is stopped. & when the PCS is reset then the plant ready for start.

5. BELT SWAY SWITCH(BSS).
Belt sway switches are mounted along the longitudinal length of belt .
It will be activated when there is a sway or displacement in the path of the belt and the knob of the BSS is displaced from its own position.
Once the BSS is activated then the conveyor belt is stopped and that results in stopping of the plant

6. ZERO SPEED SWITCH(ZSS).
It is placed near the tail pulley .
It activates if the tail pulley is stopped a signal will be operated that will allow the plant to stop.
It is placed near tail pulley, crusher rotor fly wheels.

7. LIMIT SWITCHES.
These switches are placed near the guards fixed at different movable parts of the crusher plant i,e, near tail end guard, crusher motor guards , coupling guards etc.
When the switch is activated then the plant stops and the machines stops.
Once the guard is removed the plant cannot start

8. Motor Protection Relays
The thermal overload unit of the relay protects the motor against both short-time and long time overloading.
The high-set over current unit constitutes an interwinding short-circuit protection for the motor.
All-in-one relay featuring thermal overload protection, thermal start-up supervision, stall protection or time over current protection.
High-set over current protection, low-set earth fault protection, incorrect phase sequence and phase unbalance protection, loss-of-load protection and supervision of multiple start-ups.

9. Why do electrical accidents happens?
Lack of proper training.
Quickness of completion of work and interruption during work.
Use of improper equipments i,e. non tested and non certified equipments.
Over confidence in work.
Lack of commonsense.

10. Do’s
Earthing or Grounding the electrical equipment before use. Safety PPE to be used before working any electrical equipment
Portable equipments like Hand Blower, Welding machine, Grinder, Hand lamp should be earthed properly.
Ground fault circuit Interrupter like ELCB/RCCB to be used in any portable equipment.
Lock out and Tag out the circuit and equipment before working. Work Permit to be issued before working any electrical equipment
Enquiry and ensure the all safety precautions are taken at working area
Test the circuit to make sure the system is de-energized
Use proper wiring and connectors. Test GFCI’s/ELCB’s/RCCB’s monthly.
Make sure switches and insulation are in good condition
Use and maintain tools properly.Inspect tools before using them.
Damaged tools must be removed from service. Keep tool and cords away from heat, oil and sharp objects.
Call Immediately Security at and EH&S at in emergency. Notify your supervisor
Remove the person away from the electrical source using a non-conductive material
Alert your co-workers to any unsafe work practices
Report all problems to your supervisor
Know what to do in the event of an emergency.

11. Don’ts Don’t Work in Wet condition . Avoid Over head power Lines
Don’t start work without Work Permit. Don’t use Bare wire as a Connector. Don’t use portable equipment without earthing. Never use a three prong plug with the third prong broken off.
Don’t use the Damaged tools. Do not panic; remain calm In the event of a personal injury. If a person is being shocked, turn of the source of electricity. Do not touch someone being shocked. Do not attempt to repair electrical equipment unless you are trained and qualified
Do not use multiple cube taps in a standard outlet. Do not disable any electrical safety feature expecting that another safety feature will protect you
Do not use extension cords as a substitute for permanent wiring. Do not use metal ladders for or near electrical work.
Do not use wet hands when plugging or unplugging cords/equipment. Do not raise or lower the tools by the cord.
Unless equipment is designed for it, cannot be used in damp and wet locations.
Don’ts