Showing posts with label connector failures. Show all posts
Showing posts with label connector failures. Show all posts

Monday, January 21, 2013

Have we learned nothing?

The festival season starts early in the south, and Mardi Gras is one of the first events we see set-up for numerous stages and shows.  Outdoor festival stage canopies have proven to present opportunities for accidents because they have large surfaces that can be caught by side winds and uplifting plow winds.  To counter-act the forces developed by gale-force winds, event riggers rely heavily on large ballast weights to tie-off canopy structures in an attempt to anchor the framework to the ground.


These ballast weights work well if they are massive enough for the predicted winds and effective 'sail area' presented by the canopy roof and side walls.  If they are too light, the ballast weights will just be dragged across the ground and bulldoze a path of their own.  Slippery grass, or dirt that turns to mud, just act as a lubricant to free the ballast weights up for sliding in the event of a downpour, so anchoring or pinning the ballast weights to keep them from moving is also part of a good rigging plan.  (The ballast weights shown above were not pinned or anchored to prevent sliding)

Wind is not a steady-state event.  You know that.  It gusts.  It starts and stops.  It changes direction.  It generally whips everything around a bit as it works it mayhem.  For this reason, we need to use secure connections on the guy wires for the ballast weights and stabilizing X's that are used to stiffen the structures against parallelogram movements.  If you don't, a gust of wind can slack the line, unhook the conenction(s), and you loose all anchoring in the blink of an eye.


As you can see above, the anchor ties used in the blocks in the first picture are common ratcheting tie-downs in the trucking industry, and they only have a open hook at the load securing end.  This may be de rigueur for the transport industry, but it's a no-go for event safety.  If the wind gets to blowin' and this bad boy comes loose, it could rip the flesh right off of someone unlucky enough to get in it's flailing path.

So, it was bad enough to see the above tie-down terminations at almost every corner of the stage, but then I looked further up the anchor line and found this:


Each anchor line had two possible points of failure.  Three stages and a major cable bridge over the street, all in close proximity, four to eight anchor blocks secured in this manner for each one, and two possible failure points per securement.  All of this within a city block of a major open waterway (read: obstruction-free wind-path).  Personally, I don't like those odds.

The City is relying on the Event Producers to Employ Staging Subcontractors that will erect facilities that will be safe for the (possibly highly intoxicated) general public to hang-out around and potentially be leaning-on, climbing on, or even messing with.  Plan for the worst, and you may have a chance of having an incident-free event, but if you leave opportunities for failures in the system like are shown above, be ready to pay the piper (or at least the plaintiffs).

Follow-up to commenter:
If you are going to use ratchet-straps to secure anything (subject to load rating), then utilizing products that have a self-closing clip is highly recommended.  Here is a picture of that type of ratchet and clip:


It is also recommended to have a wire rope safety cable that runs in parallel with this, preferably one that is only slightly longer than the final tensioned length of the ratchet strap.  This can prevent a total release of the system should the ratchet strap fail.  Fabric based straps and slings are subject to weakening due to abrasion, minor cuts, and rot.  Straps exposed to sunlight have shortened lifespans due to the exposure to UV light which weakens the fibers.

Saturday, March 31, 2012

Outlets, inlets, receptacles, plugs, jacks, whatever you call them, they oughta be correctly mounted

Alex, I'll go for $1,000 for "Places you shouldn't stick your finger.  Ever."


Note the missing cover plate and the uninsulated wiring sticking out.
Should not have an ungrounded outlet in a commercial building - or any building for that matter.


Note the extension box pulled off the wall.


Note the box and ground conductor completely missing.

Wednesday, June 3, 2009

Cover me !

Aside from the missing cover on this electrical box there are other interesting installation 'features':
  • The installer elected to screw into the box from the adjacent panelboard (I sure hope he killed power before he went in there!) so that there were two sharp pointed sheet metal screws protruding into the handibox about an inch or so (if you hadn't noticed, the screws that are intended to protrude into an electrical box are always blunt ended), and
  • There is no bushing through the holes connecting the two boxes, thus leaving sharp metal edges to nick the wire insulation where the knock-out was removed.
  • The source power comes into the box as a white (presumably neutral) conductor and a green (presumably line voltage) conductor, and then depart to the load as a non-standard RED (presumably neutral) conductor and a standard black line voltage conductor. Well, at least they got the NEC color coding scheme half right . . .
  • There is no dedicated ground conductor, as the conduit connections are relied upon for ground continuity. See: http://theatresafetyblog.blogspot.com/2009/04/whats-wrong-with-this-picture.html, and http://theatresafetyblog.blogspot.com/2009/04/electrical-safety-grounding-continuity.html for more discussion of this topic.

Thursday, April 30, 2009

Electrical Safety - Grounding continuity

When you think that your lighting batten is inherently grounded, you may want to check that it really is grounded. Modern rigging systems use Nylatron (plastic) pulleys and the counterweight carraige arbor shoes may be Nylon, leaving the only electrical path back to the safety ground as the ground wire in the SO power cable or flexible conduit that feeds your plugstrip or plugbox. If the fixed conduit or flex conduit body is the only ground path you have, then the ground is broked (open circuit) if the conduit becomes separated.

The same is true if your ground lead on a lighting instrument becomes disconnected. This can happen several ways:
  • A two wire connector (an old style two-pin 2P&G stage plug or a two-bladed Edison plug) is installed on a three-wire cable
  • A ground-lift adapter is installed on the end of a normally grounded NEMA 5-15P connector
  • The wire breaks internally
  • The wire gets yanked-out of the connector body
  • The wire gets yanked out of the lighting instrument body

In any case, you are in a situation that would let the fault current of an internal problem in a lighting instrument look for another path back to the source, and that path may be you!

Wednesday, April 29, 2009

Electrical Safety - Equipment Maintenance

Most stage equipment that uses electricity has a power cord with a (male) plug or (female) receptacle on one or both ends of it. Maintaining those connections is vital to both the operation of the device and the safety of those using it. Below is the back-end of a stage lighting instrument that has the cable strain relief missing, which in-turn allowed the inner wiring to become frayed and short-out to the casing. Here is a cable end plug that was hurredly assembled to get it working for a show, but the cable clamp (strain relief) was never tightened-down to take the stress off of the inner conductors.
Here is a 2P&G cable end that was not properly secured to the outher sheathing of the stage lighting instrument cable, and over time it frayed apart.
The same thing can happen to extension cords, twofers, and just about any other cable connection. When you find these types of equipment damage, the best thing to do is red-tag the equipment as non-usable, and submit it to your repair shop for correction

An ounce of prevention
In general, the root cause of these types of connector failures is due to people yanking on the cable instead of grasping the plug body when they remove them from their mating device. Take care of your equipment and it may not seek revenge by failing at five minutes to eight, or worse yet, shocking you to get your attention.