Many businesses face serious risks from electrical incidents such as shocks and arc flashes. By gaining a more detailed picture of their systems, they can understand what steps they need to take to mitigate against these.
Given the inherent electrical risks of power systems, safety is a critical concern for any business that relies on it. Even a current as low as 5 milliamps (mA) – the amount drawn by a small LED or electronic sensor – is enough to produce a shock that would startle someone and potentially lead to an accident. When we consider that many power systems require inspection by staff carrying a range of tools, often in hard to access spaces, the electrical risks posed even by currents this small are already considerable – and can be exacerbated by the presence of fuel, paint and other industrial materials.
With higher electrical loads, safety concerns become progressively more serious. Any shock above 5 mA can make muscles freeze, meaning someone receiving one could be unable to let go of the equipment causing it. Relatively small currents can also produce burns, breathing difficulties and disruptions to a person’s heartbeat. A fatality would be likely from a shock of 1 amp – below the power used by a typical home fridge-freezer – and in some circumstances, can be caused at levels much lower than this. Sadly, these electrical risks are by no means theoretical. Within the UK, for instance, about 10% of all fatal accidents, and 6% of all major injuries, are related to electricity.
Given that large industrial facilities require power capacities totalling thousands of amps, it’s clear that responsible businesses need to be very careful about the electrical risks their infrastructure can create. Alongside shocks, other potential issues include equipment overheating – which can cause thermal burns in staff that get too close to it, or lead to a fire if not dealt with effectively. One of the most serious electrical risks is an arc flash – where a short circuit causes current to jump through the air, creating an explosion that can be several times hotter than the sun’s surface. Alongside fire, intense light and extremely loud blasts, arc flashes can cause problems such as jets of molten metal, flying debris and toxic fumes. Because the faults that lead to them develop gradually, they are difficult to detect. But they are far from uncommon: it’s thought that in the US, between five and ten arc flashes occur in electrical equipment every day.
Research in the US indicates that most work-related electrical fatalities take place in the construction industry. But there are also substantial numbers in other sectors, including manufacturing, transport and mining. These events clearly have a serious human impact from electrical risks. In addition, any accident, even if not fatal, will also have a considerable cost to a business in other ways. Alongside the financial and productivity losses that result from addressing its causes, an incident may affect the organisation’s reputation and recruitment efforts, for example. And concerningly, the world’s increasing demand for electrical power is increasing electrical risks by putting additional pressure on staff and equipment.
How can asset managers respond to electrical risks?
These issues are concerning – but by focusing on the right technology, people and processes, there are effective ways to mitigate the electrical risks. Strong organisational cultures and policies are an important part of this. Lockout/tagout (LOTO) procedures, for example, make sure that electrical equipment is isolated before staff work on it, helping avoid accidents. In addition, clear guidance can make sure that employees only access parts of the system that they need to – and have the right knowledge, tools, and personal protective equipment (PPE) to do so. Of course, even the best policies will not succeed unless people follow and understand them – so it’s also essential for businesses to invest in safety skills through training and recruitment.
Technology is also an important part of electrical risks mitigation. Enhanced protocols such as monitoring sensors which are employed to monitor once all isolation, locking, and permitting are in place with conformation of proving dead at all points of work. Within electrical infrastructure, intelligent circuit breakers offer a similar capacity to detect and prevent dangers. Arc fault detection devices, for instance, can identify the electrical issues that lead to arc flashes, and shut down circuits when these occur to protect equipment and people.
These include voltage arc monitoring and protection (Vamp) systems, which measure current and light using arc sensor channels. Should a fault occur, they minimise burning time by quickly cutting off the current feeding the arc. Short burning times are critical, especially when an arc develops during maintenance work on switchgear, creating serious electrical risks to personal safety and life. But traditional approaches do not provide fast enough protection. In contrast, Vamp systems’ unique arc fault breaker functionality brings a new dimension to the total safety of power systems and the reliability of their protection measures.
Understanding the root causes of electrical accidents
Components such as these are playing an increasing role in electrical power infrastructure. But ensuring safety is also about taking a wider view and considering the underlying causes of electrical risks. Many accidents have their roots in poor design or maintenance. It may be that a connection has become too loose, for instance, causing components to dangerously overheat. A substation could have been invaded by rodents or insects that are damaging equipment. Or perhaps scaling up the system’s capacity means that parts of it are now transporting more current than they can withstand.
Issues such as these occur frequently. Data from 400 on-site audits of electrical distribution systems by Schneider Electric reveals that almost all of them (98%) had direct safety risks such as accessible live parts, corroded cables or damaged insulation. About four in five (79%) included obsolete equipment. And almost nine in ten (89%) had no, or only a partial, single line diagram (which sets out all of a system’s electrical assets and how they connect). These and other findings indicate that a large proportion of businesses not only face significant electrical risks, but also have an incomplete understanding of what these are. The good news is that through this comprehensive analysis of their electrical infrastructure, these organizations have taken the first step to addressing the issues. Because once you know what the risks are, there are many ways you can effectively tackle them.
Proactive electrical asset management through continuous monitoring
At Schneider Electric, we’re experienced in carrying out expert studies of electrical systems, whether these focus on performance and safety generally, or more specific concerns such as the likelihood of an arc flash. This allows us to identify electrical risks such as those I discuss above and make recommendations to help prevent them. This could mean replacing or repairing components, or adding new ones. It may also involve mapping the system through an updated single line diagram or electrical digital twin, or changing the design of the infrastructure. But whatever specific measures are required, the biggest opportunity comes not from these immediate changes, but from the more proactive long-term approach that they can support.
As well as alerts about faults, internet-connected sensors – like those on intelligent circuit breakers – can also provide continuous data that gives electrical asset managers a more detailed understanding of their systems. Readings for metrics such as current, voltage and temperature provide a real-time picture of trends, helping organisations spot weak points and potential electrical risks before they become accidents. In addition, Schneider Electric’s AI-powered analytics can use this information to accurately assess the condition of equipment and recommend when it needs maintaining. This allows businesses to carry out maintenance more efficiently – based on the condition of components, rather than following fixed calendars or responding to emergencies.
Whether this data is monitored by businesses themselves, or remotely 24/7 by our experts, the system visibility it creates supports considerably safer facilities, as well as improving performance and efficiency. Electrical safety will always be about people and processes, as well as technology. And there are always steps that can be taken to reduce electrical risks. By working with Schneider Electric, businesses can have confidence that they are doing the best they can to keep their people and operations safe and secure as they power the industries of the future.
If you’re ready to explore how a proactive asset management strategy can yield quick benefits and a strong ROI, I invite you to connect with me on LinkedIn or complete the form for a complimentary 30-minute consultation. Let’s work together to secure a more reliable and efficient future for your electrical assets.
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