An Enduring Approach to Temporary Power

In circumstances that call for temporary power, the long-standing approach has been to cobble together an electrical system using whatever extension cords and portable power supplies may be on hand. Although applications that call for portable power are inherently impermanent, it’s important not to sacrifice safety and increase the risk of trip-and-fall, electrical shock or other injuries. In fact, since these temporary power scenarios are typically found outdoors in the elements and require a significant amount of handling and transportation, extra attention should be paid to make sure the portable power equipment is safe, reliable and built to survive. According to a 2015 report from the Fire Protection Research Foundation, the leading cause of non-fatal electrical injuries from 2003 through 2010 was from contact with the electrical current of a machine, tool, appliance or light fixture (7,450 injuries). When combined with the secondary cause – contact with wiring, transformers or other electrical components (7,130 injuries) – the two groups account for 72 percent of all non-fatal electrical injuries from that time period. Ensuring your outdoor power equipment provides maximum safety protection can not only help prevent injuries but help protect your company’s reputation from harm. Up to the Task For safe and reliable use in outdoor environments like construction sites, petrochemical facilities and disaster relief areas, portable power equipment needs to be able to withstand inclement weather and potentially caustic substances. Also a staple at outdoor festivals and concerts, the power network should safely operate in heavy-traffic areas with large numbers of people. Unlike a home or business, where the power network is concealed in a wall and protected, when working on large-scale, outdoor power projects, the power network is out amongst everyone, and there have to be special considerations for distributing the power so that it is available at multiple locations. Efforts must also be made to protect the cables, preventing trips and falls by people and maintaining the integrity of the cables as they may be run over by large trucks and other vehicles.  Out-of-the-Box Thinking Traditionally made from painted steel, portable power boxes can become dented and cracked after frequent moves, making them more susceptible to rust, weakening connections and increasing potential for liability concerns. Because of these limitations, portable power boxes and their associated wiring devices have become viewed as temporary, somewhat disposable products due to the increased downtime and administrative hassle associated with the frequent reordering of components from multiple suppliers. Shifting to a power distribution box made exclusively of vulcanized rubber can provide exponentially better durability, safety protection and weather resistance. advertisement A portable power system featuring a 100 percent rubber construction is resistant to shock, impact and corrosion, and is lighter in weight than steel boxes providing easier transport. Rubber boxes also pay dividends in terms of performance for abrasion, chemical exposure and temperature extremes. While perhaps necessitating a higher up-front cost, products that utilize vulcanized rubber and are fully designated for temporary indoor or outdoor power, can ultimately lead to a lower total cost of ownership. Built for maximum reuse with higher grade componentry than traditionally offered in the marketplace, products can be used over far longer periods of time and the downtime and costs associated with product reorder and replacement can be avoided. A Sturdy, Secure Connection When drawing various levels of current in a portable power application, it is also important to consider power management and ensure a balanced AC current load between phases. Systems that offer dual-identifier numbered and color-coded receptacles allow users to mentally distribute higher current loads and build a better-running portable power network and reduce the risk of power outages. For safe and reliable use in outdoor environments, power boxes should be Type 3R weather resistant, UL-certified and meet NEC regulatory compliance by featuring legs that keep electrical components 6 inches above ground level. Safety is also ensured with the proper use of heavy-duty polyurethane ramps to protect power and data cables, as well as air or water hoses. Built to withstand loads in excess of 16,000 pounds per tire, and featuring non-slip tread patterns, ramps prevent cables and hoses from being crushed or punctured allowing important functions to continue while eliminating safety hazards.  In applications that call for temporary indoor or outdoor power, maintaining the same level of safety and reliability one would expect from a permanently installed circuit breaker or panel is essential. Choosing products that offer maximum durability and safety protection can go a long way toward helping to reduce the risks of a power outage as well as any potential injuries. Article originally published Nov. 13, 2017, and updated for accuracy and relevance .

Meet the Challenge of Electrical Safety in Industrial Areas

Risks are inherent in industrial plants and other settings where workers come into contact with heavy equipment and processes combining metal surfaces, electrical machinery and power systems. GFCI-compliance and watertight connections are critical wherever power components contact moisture, chemicals, weather and other harsh environmental conditions. Industrial operations are at risk anytime unprotected electrical connections are exposed to moisture, metals and harsh conditions. The improper use of wiring and electrical equipment can cause any number of problems, ranging from nuisance tripping or short circuits. These hazards can cause interruptions in power flow to major malfunctions that pose significant risk of injury and death due to electrocution or fire. Here are some reasons why electrical accidents happen and how to minimize the risk of those accidents by adhering to NEC and OSHA standards. Protect Workers in High-Risk Environments According to statistics from the Electrical Safety Foundation International (ESFI), food and beverage, construction, transportation, utilities and mining are among industries with the highest percentages of accidental electrical fatalities in the workplace. Each year, hundreds of U.S. workers die as a result of accidental contact with electrical current. Thousands more suffer shocks, burns and other injuries resulting from electrical hazards while on the job. Accidents take a toll on the victims and their families often in devastating ways, and employers in terms of medical and disability issues and lost productivity. The most high-risk environments for electrical hazards include: Food, beverage and chemical processing facilities Oil and gas refineries, mines and quarries  Water treatment plants, utilities and power distribution plants  Commercial construction and transportation sites  Automated agricultural plants and processes Indoor and outdoor event venues such as stadiums, convention centers and festivals Why Electrical Accidents Occur Human error and lack of knowledge or training are significant contributors to electrical mishaps and accidents in the workplace. Under pressure to meet a production schedule, some workers may attempt to justify overriding rules in order to complete an assigned task more quickly. Taking shortcuts can pose potentially lethal risks for those working around industrial power equipment. Another common culprit is the improper use of plugs, receptacles and other power components that are neither designed nor rated for wet and damp areas. Safety depends on choosing and deploying the right technologies for the job. Prevent Accidents by Following the NEC and OSHA Creating safer workplaces requires that employers follow electrical safety codes such as those set forth in the National Fire Protection Association’s (NFPA) NEC ‒ National Electrical Code. This code includes advisory guidelines published to safeguard persons and property from electrical hazards. OSHA (Occupational Safety and Health Administration) is a U.S. federal agency regulating overall workplace safety and health. Industrial companies are bound by law to follow OSHA regulations and many local authorities with jurisdiction have also adopted NEC standards for safety and best practices. In defining proper electrical safety practices, NEC and OSHA concur that electrical equipment must be free from hazards likely to result in dangerous conditions, injuries or fatalities. Worker protection must be provided in wet locations and those working in proximity to live equipment. Power devices must incorporate ground fault protection and be suitable for harsh conditions to provide adequate protection against dust and moisture ingress. Get Ground Fault Circuit Interrupters Up to Code An essential component of any safety program, ground fault circuit interrupters (GFCI) are designed to disconnect a circuit whenever it detects that the electrical current is not balanced between the energized conductor and the return neutral conductor. An imbalance can indicate current leakage through the body of a grounded person who accidentally contacts the energized part of the circuit. GFCI devices disconnect quickly enough to prevent injury. Among the industrial standards for GFCI components, NFPA’s NEC guidelines and OSHA regulations call for extension cords used with portable electric tools or temporary and portable lights to be 3-wire and rated hard or extra-hard usage cable. These rugged cords are constructed of heavier gauge wire and better insulated than light-duty cords commonly used in residential and office settings. In order to protect workers from accidental contact with live conductors, both NEC and OSHA require adequate strain relief for cables entering junction boxes, cabinets or fittings. Additionally, any openings through which conductors enter must be closed and sealed when not in use. All electrical components exposed to moisture, weather or harsh environments, whether indoors or outdoors, require a watertight connection to eliminate or reduce the risk of electrical shocks, short circuits and electrical fires. NEMA and IP designations apply to prevent moisture and water accumulation. They also outline protective standards for locations exposed to gasses, fumes, vapors, liquids or other agents which can have a deteriorating effect on power conductors and equipment. Make Safety a Top Priority Improper control of hazardous energy and problems associated with electrical, wiring methods, components and equipment were among the top 10 most frequently cited OSHA standards violations last year. Electrical safety must always be a top priority in the workplace. GFCI-compliant devices and a trusted supplier that adheres to industry standards are integral to equipment installations and maintenance. Proper utilization of the right technologies designed for the job can help prevent the causes of many electrical-related accidents and injuries. The opinions expressed in this piece are solely Molex's. They do not necessarily represent WESCO’s views.