This invention generally relates to systems and methods for safely determining if electrical power is removed from an electrically powered apparatus, so that the electrically powered apparatus may be safely serviced. More specifically, this invention relates to systems and methods which are accessible from the outside of the electrically powered apparatus to protect an operator of the electrically powered apparatus from the electrical power connected to the device.
High voltage machinery can pose a danger to an operator of the machinery during a malfunction, service or adjustment of the machinery. One common danger by which the operator can be injured due to the electrical power to the machine not being properly turned off is the failure of currently available electrical power indication safety devices on the machinery. These safety devices may give a false indication of the electrical power being off or they may malfunction. A second common danger is inexperience of the operator in determining if the electrical power is on or off in situations where the safety device fails and in situations where the machinery does not have an electrical power indicator. One solution to such dangers is to not allow the operator to work on the machinery until electrical power shutdown is verified by a qualified electrician. Waiting for a qualified electrician can incur additional operating costs, due to down time and the labor of the electrician.
To ensure safety during servicing of electrical systems and circuits which carry high voltages, a “lockout/tagout” procedure is typically followed. A circuit breaker or ON/OFF switch that delivers power to the circuit to be serviced is opened or disengaged to disconnect electrical power from the circuit, and the breaker is physically locked into the opened or disengaged position using a padlock or other device (the “lockout”). Additionally, the servicing technician affixes a tag to the physically locked breaker that provides information such as the technician's identity and contact information, service authorization information, and the like (the “tagout”).
The lockout/tagout procedure greatly reduces the possibility of human error causing inadvertent application of power to the circuit under service. However, safety can be compromised even when the lockout/tagout procedure is properly followed, due to various potential sources of dangerously high voltages in the isolated circuit. For example, potential unexpected sources of energy include line capacitance, bypass capacitors, or power factor correction banks. Potential unexpected sources of energy also include standby power generators, motor back-EMF, or human operation of an associated switch. Moreover, power ON/OFF switches and circuit breakers are not immune to failure, and the locked out breaker could potentially still be transmitting power.
These procedures apply to products that are often known as convenience interfaces or panel interfaces. A convenience interface provides a convenient method for personnel to access devices that reside inside a cabinet or an enclosure without opening the enclosure door.
Industrial and commercial facilities typically have electrical cabinets providing access to line voltages. The electrical cabinets remain closed except when access is needed by maintenance personnel. When maintenance personnel open the electrical cabinets there is the risk of electrical accidents causing injury or death. Various safety measures can be taken and protocols followed to reduce the risk of electrical accidents but these measures may not always be taken and protocols followed due to the reduction in productivity associated with doing so. When these measures are taken and protocols are followed there may be a reduction in productivity.
The National Fire Protection Association (NFPA) recently published a Standard for Electrical Safety in the Workplace, and that document generated essential changes in the way both electrical and mechanical maintenance is performed in today's industrial and commercial facilities. NFPA 70E specifically sets forth standards for electrical safety in the workplace. Compliance with such standards reduces injuries and deaths, but in a manner which often reduces productivity experienced prior to NFPA 70E. For example, service technicians often don personal protection equipment (PPE) when accessing electrical enclosures, cabinets and other equipment. Unfortunately, the use of PPE is time consuming, cumbersome and inefficient.
Non-contact voltage detectors (NCVD) typically in the form of a test pen are a well-known means to attempt to determine the absence or presence of voltage. NCVD's are disclosed in U.S. Patent Publication Nos. 2012/0098522 and 2013/0127440, each hereby incorporated by reference entirely. In a NCVD, changes in an electric field associated with the presence of an AC voltage may be detected capacitively without direct contact between the test pen or instrument and the potentially voltage carrying circuit, conductor, wire or other device. But, because of the possibility of false negatives, meaning that the voltage tester falsely indicates that there is not a voltage when there actually is, NCVD's have not been considered a reliable means in determining electrical isolation. NCVD relies on capacitance and external factors not related to the tested conductor may also affect the voltage reading which creates a potential false negative situation when voltage is present.
There are numerous other problems associated with present NCVD designs. A NCVD must have a completed circuit between the live conductor, conductor insulation, NCVD tip, NCVD circuit, NCVD case, worker and ground. Presently NCVD systems available do not know the state of the live conductor or the insulation. The only remaining unknown is the worker or the NCVD connection to ground. Thus, the NCVD may become more reliable if these components of the circuit could also become a known.
When a handheld NCVD is positioned next to an energized conductor, two capacitive circuits are created. A smaller capacitance exists between the energized conductor and the NCVD, while a larger capacitance exists between the NCVD through the electrical worker's body to ground. If voltage is applied across a capacitor, then the voltage drop across a small capacitor is bigger than the voltage drop across a larger capacitor. By comparing both of these voltages using a specific non-contact voltage detector circuit, the NCVD decides if the conductor is energized. However, because this circuit is somewhat sensitive, other electrical energy within an enclosure will change the effective capacitance and ultimately the operation and reliability of NCVD. A false-negative reading is the worst case scenario when stray parasitic capacitance from other energized components and/or to ground change the overall capacitance of the circuit in question.
Another way to test for voltages is to use a hardwired voltage indicator. Voltage indicators installed by qualified electricians are hardwired to the main power disconnect and earth ground. Installation is simple because a phase-neutral high impedance voltage detection circuit on each phase senses and illuminates AC/DC voltage. Two issues with hardwired voltage indicators are that (1) it is impractical to verify the voltage indicator to another independent voltage source as attempting to do so adds complexity and reduces reliability and (2) since the voltage indicator's sole purpose is to indicate voltage, any electrical connection issues between the source voltage and the voltage indicator increases the chance of a false negative voltage reading.
Therefore, it is apparent that a more reliable and convenient system and method for testing voltage in machinery or circuits is needed for compliance with NFPA 70E.
These and other shortcomings with prior systems and methods have been addressed with this invention. In one embodiment, this invention is an electrical safety system used on an electrical enclosure containing phase to phase and phase to ground electricity. The system may include a portable or handheld volt meter having one or more probes and a receptacle having a front surface, a mounting body and a rear surface. The receptacle has a number of ports each adapted to receive a probe of the volt meter. The receptacle is mounted to a panel or door of a cabinet or enclosure having at least one conducting wire therein as part of a circuit. The wire has an exposed section at a location from an outside face of the front of the receptacle, such that the depth is enough to prevent passing of electrical current, yet close enough to allow the probe of the volt meter inserted into one of the receptacle ports to contact the wire and be activated when electrical current is present in the wire. The device allows a worker to use a contact voltage detector to check for the presence or absence of voltage inside the closed electrical panel without opening the panel or enclosure.
In one embodiment, this invention may include the receptacle, the portable volt meter, a voltage indicator and a number of fuses and holders. These components, with the exception of the portable volt meter and associated probes, are mounted to the panel or within the electrical enclosure.
The receptacle may have a front side and an opposite back side configured to hold one or more wires in a fixed position within the closed electrical panel, and the ports in the front side allow for direct contact with a probe of the contact voltage detector for testing with the contact voltage detector. The particular configuration of the receptacle may vary, but according to various embodiments of this invention the receptacle is mounted to the exterior or deadfront panel of the enclosure or cabinet and has one or more ports for the direct contact of the volt meter probe to one of the conductors or wires within the enclosure. This is distinguishable from a proximity or non-contact capacitive voltage detection (NCVD) operation in which the probe does not contact the wires or conductors in the cabinet to measure voltage.
The hardwired voltage indicator mounted on the panel is an optional component of this invention. One aspect of the invention is a deadfront (i.e., exterior panel) contact (as opposed to non-contact or proximity) testing for live-dead-live, phases to phase and phase to ground voltage testing. Another aspect is the overall procedure or protocol for compliance with NFPA 70E utilizing such a device with a live-dead-live testing protocol. In such a protocol, the operational capabilities of the portable volt meter are tested on a live electrical source. If operational, the volt meter is then used on the electrical enclosure via the receptacle to verify that the electricity in the enclosure is off (i.e., dead). Finally, the portable volt meter is once again tested on a live electrical source to verify its continuing operational capabilities. If each step of the protocol is successful, the electrical cabinet or enclosure maybe opened and accessed by a technician for maintenance, repair or the like in compliance with the NFPA 70E. The live-dead-live protocol utilizing the receptacle of this invention may be accomplished without the need for the technician to don personal protection equipment (PPE), the use of which has proven to be both cumbersome and inefficient to satisfy the testing requirements, because the cabinet or enclosure remains closed during the test protocol.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Referring to
These enclosures 10 can include: (1) control devices with data ports, (2) network access ports, (3) human interface ports such as for a computer mouse or keyboard, (4) various I/O devices, (5) data storage devices, and (6) programmable devices.
As shown in various detail in
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Another component according to one aspect of this invention is a multi-line indicator 30 mounted on the panel 12 of the enclosure 10. The indicator 30 is tied directly to the incoming power without fuses and is used in conjunction with the receptacle 16 in an effort to eliminate the possibility of a false negative reading relative to voltage active in the enclosure 10. The indicator 30 allows for verification visually that voltage is or is not present in the line independent of the receptacle 16.
The indicator 30 according to one embodiment of this invention includes four indicator signals 30L1, 30L2, 30L3 and 30GRND, each of which includes dual redundant indicator lights 32 which when lit indicate active voltage in the associated line 34L1, 34L2, 34L3 and 34GRND of the electrical enclosure 10. In one embodiment of this invention, the indicator 30 may be a Grace Engineering part *Voltage Vision R-3W voltage indicator or similar device. The indicator 30 also may be as disclosed in U.S. Pat. No. 6,703,938 or U.S. Patent Application No. 2007/0132458, each incorporated by reference entirely herein.
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Another component on the various embodiments of this invention is shown in
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The receptacle 16 has an assembly which has a front side shown which includes a plurality of ports 24. The receptacle 16 may be formed of plastic or other non-metallic material. As shown in
One or more of the lines L1, L2, L3 may carry substantial or even lethal d.c. or a.c. electrical energy potentials due to charged capacitances in the load, undischarged power factor correction banks, standby power generators, motor back-EMF voltages, power sources that inadvertently remain energized and/or connected to the circuit through human error or mechanical failure, or the like. These electrical energy potentials may exist between the lines L1, L2, L3 and/or between one or more of the lines L1, L2, L3 and the ground potential GRND. The electrical safety monitoring system 14 of this invention monitors the lines L1, L2, L3 and the ground potential GRND to detect hazardous energy potentials.
Referring to
A next step 59 for the initial verification and installation of the system 14 is to erect a flash barrier at the site surrounding the electrical enclosure 10. A four foot arc flash barrier is often recommended. Next steps include a service technician donning PPE 61 and then opening the enclosure and panel 63 mounted thereon. The service technician then verifies 65 the line voltage for each phase utilizing the volt meter 42 with direct contact to the associated lines L1, L2, L3. A service technician then verifies 67 the voltage for each phase to ground in a similar manner. Presumably these steps result in the volt meter 42 reading a positive voltage active within the enclosure 10 for the associated lines. Once these steps are completed, the panel 12 on the enclosure 10 is closed 69 and then the service technician verifies 71 that all lights associated with lines L1, L2, L3 are illuminated on the voltage indicator 30 confirming active voltage in the lines and proper operation of the indicator 30.
A service technician then verifies 73 the line voltage for each phase to phase utilizing the probes 44 on the volt meter 42 and the ports 24 on the receptacle 16. Next, the technician verifies 75 the voltage for each phase to ground via the receptacle 16 in a similar manner. These readings will likewise indicate active electricity on the lines L1, L2, L3 and proper operation of the receptacle 16 and volt meter 42.
The technician then isolates and turns off the electrical power 76 to the enclosure 10 in preparation for servicing the system. A documented lockout/tagout procedure may be followed to de-energize the equipment. The power down or isolation step 76 may include disconnecting the main electrical power isolating or disconnecting the enclosure 10 and isolating or disconnecting any compression air valve to bring equipment to a zero stage associated within the electrical enclosure 10. The technician then verifies 78 that the equipment associated with the electrical enclosure 10 will not operate or start.
The service technician then may open 79 the panel 12 on the cabinet or enclosure 10 while donning the PPE for protection. The service technician then verifies 81 that line voltage L1, L2, L3 for each phase to phase has been shut off utilizing the volt meter 42.
The reading on the volt meter 42 at this step may show a nominal amount of voltage which is often referred to as a phantom voltage transmitted from adjacent electrical lines and is commonly a fraction of the line voltage measured prior to electrical power isolation. Next, voltage for each phase to ground is likewise checked 83 while the panel 12 is open. The panel 12 is then closed 85 and the technician verifies 86 that the indicator 30 is not illuminated and that each of the signals 32 is off. The technician then verifies 88 that the line voltage for each phase to phase is off utilizing the ports 24 on the receptacle 16 with the volt meter 42. Here again, the reading on the volt meter 42 may show a nominal amount which is the phantom voltage transmitted from adjacent electrical lines. The technician also verifies 90 the voltage for each phase to ground is isolated or off with the exception of any phantom voltage reading.
It is important to note that the probes 44 of the volt meter 42 are in direct contact with each line or phase associated with the various ports 24 of the receptacle 16 during steps 88 and 90 thereby providing for direct or contact voltage detection through the dead front of the panel 12 on the closure 10.
If the indicator 30 and the measurements from the receptacle ports 24 each indicate that the electrical system is isolated, a final step in the testing protocol according to one embodiment of this invention is to once again verify 92 that the volt meter 42 is operational at a known live source such as a nearby electrical outlet or the like.
The various methods and steps described herein and shown in
An alternative to the embodiment of this invention as presented in
From the above disclosure of the general principles of this invention and the preceding detailed description of at least one embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/845,027, filed on Jul. 11, 2013, and herein incorporated by reference in its entirety.
Number | Date | Country | |
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61845027 | Jul 2013 | US |