During our over 20 years as electricians servicing industrial and manufacturing facilities across the Adelaide metropolitan area, we’ve developed a heightened awareness of just how many electrical hazards exist in factory environments. From high energy distribution systems and powerful machinery to harsh operating conditions and human error risks, the potential for electrical fires, arc flashes, shocks and electrocutions is ever-present on production floors if proper safety protocols aren’t followed diligently.
As electricians tasked with installing, maintaining and repairing electrical systems in these high-risk workplaces, we’ve made it our mission to promote a culture of electrical safety first. Here is our perspective on the biggest electrical hazards in Adelaide factories and the essential prevention and mitigation steps that must be taken.
Common electrical hazards
Some of the top electrical hazards we routinely encounter in manufacturing plants and factories include:
- Exposed live parts: Exposed electrical terminals, conductors or circuit components without proper insulating barriers or enclosures create serious electrocution risks if contacted.
- Arc flash hazards: Faults in high energy electrical systems can trigger extremely hot arcing events and plasma explosions capable of causing severe burns and injuries to anyone in proximity.
- Overloaded circuits: Circuit overloads from excessive electrical demands can lead to overheated conductors or arcing faults that may ignite fires or explosions.
- Electrical shocks: Faulty machinery, damaged insulation, improper grounding or failure to follow lockout/tagout procedures enables shock path exposure for workers.
- Fire/explosion risks: Electrical arcs or sparks combined with combustible dusts, flammable gases or ignition sources found in many industrial processes are a recipe for devastating fires and explosions.
- Static discharges: Static electricity buildup due to lack of proper grounding and bonding allows static discharges that can ignite fires or damage sensitive electronics.
- Mitigating electrical risks: To address these multitude of electrical threats, a multilayered approach to electrical safety involving engineering controls, personal protective equipment (PPE), comprehensive procedures and training is absolutely critical:
- Safety by design: As electricians working with electrical engineers and equipment manufacturers, we ensure electrical components and distribution systems are designed from the outset with safety in mind – including arc-resistant equipment, insulated enclosures, adequate spacing, circuit protection, etc.
Electrical safe work practices
Facilities must implement and stringently enforce NFPA 70E and AS/NZS 3000 compliant safe work practices like:
- Lockout/tagout (LOTO) control of hazardous energy
- Energised electrical work permits
- Flash protection boundaries and PPE requirements
- Electrical safety training and auditing
Personal Protective Equipment (PPE)
When electrocution, arc flash or shock hazards cannot be eliminated, providing and mandating use of proper PPE for electrical workers is essential:
- Fire-resistant clothing
- Insulated tools and handling equipment
- Arc-rated face/body protection
- Voltage-rated gloves and footwear
Arc flash studies
Conducting an arc flash risk assessment and study calculates and labels the potential incident energy from a prospective arc flash at each electrical component. This enables setting appropriate PPE, boundaries and work procedures.
Preventative maintenance
Through regular infrared thermography, cable testing and visual inspections of electrical systems, we can detect hot spots, degradation and impending failures before they occur – allowing proactive repairs and preventing breakdowns.
Safety audits and training
Even with engineering controls, procedures alone are not enough. Facilities must empower an electrical safety program with ongoing hazard audits, re-assessments and mandatory refresher training to ingrain a culture prioritising electrical safe work practices.
As electricians immersed in these factory environments, we’ve witnessed the catastrophic aftermath that can occur when electrical safety is compromised. From burnt equipment and production downtime to tragic personal injuries and fatalities – the consequences are unacceptable.
Tackling electrical risk management requires a collaborative effort between electricians, engineers, safety professionals and plant personnel to identify and mitigate every possible hazard scenario through comprehensive prevention strategies. It’s a continuous improvement process as standards and best practices evolve, but one that absolutely pays dividends in avoided costs and incidents.
Conclusion
Electrical safety cannot be an afterthought in the industrial world. With our experienced perspective, we urge all Adelaide factory facilities to prioritise developing a robust electrical safety program that protects your people, productivity and profitability. An electrician can guide you through conducting studies, shoring up procedures and training to build a proactive safety culture protecting all from electrical risks.