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Repair of extension cord

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Toolbox Talk: Repair of Extension Cords

Date: [DATE] Duration: [DURATION] minutes Presenter: [PRESENTER NAME] Location: [LOCATION]

Objective

To educate participants on the safe practices for inspecting, repairing, and using extension cords to prevent electrical hazards and ensure workplace safety.

Introduction

Extension cords are commonly used in various work environments to provide power to tools and equipment. However, improper use or damaged cords can lead to electrical hazards, including shocks, burns, or even fires. Understanding how to properly inspect and repair extension cords is crucial for maintaining a safe workplace.

Presenter Note: Engage the audience by asking if anyone has personal experience with extension cord hazards.

Key Points

  • Inspection Before Use: Always visually inspect extension cords for external defects such as loose parts, deformed or missing pins, or damage to the outer jacket or insulation before use on any shift [1].
  • Handling and Storage: Handle cords carefully to avoid damage. Do not use cords for raising or lowering equipment, and avoid fastening them with staples or hanging them in a way that could damage the insulation [1].
  • Grounding: Ensure that cords used with grounding-type equipment contain an equipment grounding conductor and are not altered in a way that interrupts the grounding connection [1].
  • Repair and Testing: Remove damaged cords from service until they are repaired and tested to ensure safety. Conduct tests before first use, after repairs, and at regular intervals [2].
  • Proper Use: Use cords only for their intended purpose and ensure they are suitable for the conditions of use and location [3].

Hazard Identification

  • Electrical Shock: Damaged cords can expose live wires, leading to electrical shock.
  • Fire Hazard: Overloaded or damaged cords can overheat and cause fires.
  • Trip Hazard: Improperly placed cords can create tripping hazards in the workplace.

Presenter Note: Encourage participants to share any additional hazards they've encountered.

Control Measures

  • Elimination: Use permanent wiring instead of extension cords whenever possible.
  • Engineering Controls: Use ground-fault circuit interrupters (GFCIs) to protect against electrical shock [4].
  • Administrative Controls: Implement a regular inspection and maintenance program for all extension cords [2].
  • PPE: Use appropriate personal protective equipment when handling or repairing cords.

Safe Work Procedures

  1. Inspect the cord for damage before use.
  2. Ensure the cord is rated for the intended use and environment.
  3. Use GFCIs when working in wet or conductive environments.
  4. Remove damaged cords from service immediately.
  5. Repair and test cords before returning them to service.

Presenter Note: If possible, demonstrate the safe work procedure or use visual aids.

Personal Protective Equipment (PPE) Requirements

  • Insulated Gloves: Use when handling cords in wet conditions.
  • Safety Glasses: Protect eyes from potential sparks during repairs.
  • Non-conductive Footwear: Prevent electrical shock in conductive environments.

Real-World Example or Case Study

A worker was electrocuted when using a damaged extension cord that had exposed wires. The incident could have been prevented with proper inspection and use of a GFCI.

Presenter Note: Ask participants if they can relate this example to their own experiences.

Group Discussion

Discuss the following questions:

  1. What are the common causes of extension cord damage?
  2. How can we improve our current inspection procedures?
  3. What additional safety measures can we implement?

Presenter Note: Encourage active participation and facilitate the discussion.

Emergency Procedures

  1. Disconnect power immediately if a cord is damaged.
  2. Report the incident to a supervisor.
  3. Do not attempt repairs unless qualified.
  4. Follow lockout/tagout procedures if necessary.

Questions and Answers

Encourage participants to ask questions and provide answers to common questions related to the topic.

  • Q: What should I do if I find a damaged cord?

A: Remove it from service immediately and report it for repair.

  • Q: How often should cords be tested?

A: Before first use, after repairs, and at intervals not exceeding three months [2].

  • Q: Can I use an extension cord in wet conditions?

A: Only if it is rated for wet conditions and used with a GFCI.

Summary

  • Always inspect cords before use.
  • Handle and store cords properly to prevent damage.
  • Use GFCIs to protect against electrical shock.
  • Remove and repair damaged cords immediately.

Action Items

  1. Review and update the extension cord inspection checklist.
  2. Schedule regular training on electrical safety.
  3. Implement a GFCI testing program.

Remember: Safety is everyone's responsibility. Report all hazards, near-misses, and incidents to your supervisor immediately.

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4 source record(s)

Sources used for this answer

[1] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)

Page 467

Open source document

Source excerpt

## WIRING METHODS, COMPONENTS, & EQUIPMENT FOR GENERAL USE - (C) Receptacles shall be of the grounding type. Unless installed in a complete metallic raceway, each branch circuit shall contain a separate equipment grounding conductor, and all receptacles shall be electrically connected to the grounding conductor. Receptacles for uses other than temporary lighting shall not be installed on branch circuits which supply temporary lighting. Receptacles shall not be connected to the same ungrounded conductor of multiwire circuits which supply temporary lighting. - (D) Disconnecting switches or plug connectors shall be installed to permit the disconnection of all ungrounded conductors of each temporary circuit. - (E) All lamps for general illumination shall be protected from accidental contact or breakage. Metal-case sockets shall be grounded. - (F) Temporary lights shall not be suspended by their electric cords unless cords and lights are designed for this means of suspension. - (G) Portable electric lighting used in wet and/or other conductive locations, as for example, drums, tanks, and vessels, shall be operated at 12 volts or less. However, 120-volt lights may be used if protected by a ground-fault circuit interrupter. - (H) A box shall be used wherever a change is made to a raceway system or a cable system which is metal clad or metal sheathed. - (I) Flexible cords and cables shall be protected from damage. Sharp corners and projections shall be avoided. Flexible cords and cables may pass through doorways or other pinch points, if protection is provided to avoid damage. - (J) Extension cord sets used with portable electric tools and appliances shall be of three-wire type and shall be designed for hard or extra-hard usage. Flexible cords used with temporary and portable lights shall be designed for hard or extrahard usage. - Note: The National Electrical Code, ANSI/NFPA 70, in Article 400, Table 400-4, lists various types of flexible cords, some of which …

[2] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 431

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ from the ground-fault circuit-interrupter-type receptacle to any outlet supplied from the ground-fault circuit-interrupter receptacle; or - (III) A nongrounding-type receptacle may be replaced with a groundingtype receptacle where supplied through a ground-fault circuitinterrupter; you must mark the replacement receptacle 'GFCI Protected' and 'No Equipment Ground;' an equipment grounding conductor may not be connected to such grounding-type receptacles. - (v) Receptacles connected to circuits having different voltages, frequencies, or types of current (AC or DC) on the same premises must be of such design that the attachment plugs used on these circuits are not interchangeable. ## (c) Ground-fault circuit interrupter protection for personnel . - (i) All 125-volt, single-phase, 15- and 20-ampere receptacles installed in bathrooms or on rooftops must have ground-fault circuit-interrupter protection for personnel. - (ii) The following requirements apply to temporary wiring installations that are used during construction-like activities, including certain maintenance, remodeling, or repair activities, involving buildings, structures or equipment. - (A) All 125-volt, single-phase, 15-, 20-, and 30-ampere receptacle outlets that are not part of the permanent wiring of the building or structure and that are in use by personnel shall have ground-fault circuit-interrupter protection for personnel. Note 1: Note 2: A cord connector on an extension cord set is considered to be a receptacle outlet if the cord set is used for temporary electric power. Cord sets and devices incorporating the required ground-fault circuit-interrupter that are connected to the receptacle closest to the source of power are acceptable forms of protection. - (B) Receptacles other than 1…

[3] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)

Page 455

Open source document

Source excerpt

## BRANCH CIRCUITS / WIRING DESIGN & PROTECTION - (c) Before each day's use, visually inspect each extension cord, or other device, and any equipment connected by cord and plug, for external defects, such as deformed or missing pins or insulation damage, and for signs of possible internal damage. Extension cords, devices and receptacles not exposed to damage are exempt from this inspection. Do not use damaged or defective equipment. - (d) Do these tests on all extension cords, other devices and receptacles that are not part of the permanent wiring of the building or structure, and cord- and plug-connected equipment required to be grounded: - (A) Test all equipment grounding conductors for continuity. - (B) Test each receptacle or plug to assure the equipment grounding conductor is connected to its proper terminal. - (e) Do all required tests: - (A) Before first use; - (B) Before first use after repair; - (C) Before use after any incident that reasonably could cause damage (for example, when a cord set is run over); and - (D) At intervals not longer than 3 months. Inspect fixed extension cords, other devices and receptacles not exposed to damage at least every 6 months. - (f) Record all tests required in this paragraph. This test record must identify each receptacle, cord set, and cord- and plug-connected equipment that passed the test and indicate the last date of testing or the test interval. Keep this record by means of logs, color coding, or other effective means. Keep the record until replaced by a newer record. The record must be available on the job site for inspection by the Administrator and any affected employee. - (2) Outlet devices. Outlet devices shall have an ampere rating not less than the load to be served and shall comply with the following: - (i) Single receptacles. A single receptacle installed on an individual branch circuit shall have an ampere rating of not less than that of the branch circuit. - (ii) Two or more receptacles. Where con…

[4] Safety Standards for General Safety and Health Standards (Chaper 296-24 WAC)

Page 497

Open source document

Source excerpt

\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ effective 09/01/01. Statutory Authority: Chapter 49.17 RCW. 91-24-017 (Order 91-07), 296-24-980, filed 11/22/91, effective 12/24/91.] ## WAC 296-24-985 Use of equipment. - (1) Portable electric equipment . This section applies to the use of cord- and plug-connected equipment, including flexible cord sets (extension cords). - (a) Handling . You must handle handling portable equipment in a manner which will not cause damage. You must not use flexible electric cords connected to equipment for raising or lowering the equipment. You must not fasten flexible cords with staples or otherwise hung in such a fashion as could damage the outer jacket or insulation. ## (b) Visual inspection . - (i) You must visually inspect portable cord- and plug-connected equipment and flexible cord sets (extension cords) before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket). Cord- and plug-connected equipment and flexible cord sets (extension cords) which remain connected once they are put in place and are not exposed to damage need not be visually inspected until they are relocated. - (ii) If there is a defect or evidence of damage that might expose an employee to injury, you must remove the defective or damaged item from service, and employees must no use it until repairs and tests necessary to render the equipment safe have been made. - (iii) When an attachment plug is to be connected to a receptacle (including any on a cord set), you must first check the relationship of the plug and receptacle contacts to ensure they are of proper mating configurations. ## (c) Grounding-type equipment . - (i) A flexib…

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