bms tss – electrical safety programjohn gallagher february 11, 2009page 1 electrical safety...
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BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 1
Electrical Safety ProgramBaytown Site, Texas
Houston Business Round Table
Best Practice
OSHA
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 2
Electrical Safety Program
The program is designed for all personnel who work in an environment influenced by the presence of energized electrical equipment and empowers those personnel to work safely on the electrical equipment.
The focus of the program is directed toward the general features of a set of principles and controls that when practiced on a regular basis will lead people into the awareness and discipline to safely perform electrical work.
The program has been progressively implemented in three world scale Chemical facilities in both the USA and Canada and received a IEEE prize paper award at the 1986 PCIC Petroleum Industry Technical Conference.
The program recently recognized by OSHA as a best practice.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 3
Presentation Outline
•Electrical Safety Statistics
•OSHA requirements
•The development of Electrical Safety in North America
•The development of one users Electrical Safety Program
•The Electrical Safety Program Standard and Procedures
•Designing the potential electrical hazard out of the equipment.
•Empowerment
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Electrical Safety Program – NIOSH
108
296
192
2126230 6276
2458 2282
2458 2282
1068 1078
1012 5297
516795
2474 5547
0 2000 4000 6000 8000
Agriculture
Mining
Construction
Manufacturing
Transport
Wholesale
Retail
Finance, Insurance, Real Estate
Services
Electrical BurnsElectrical Shock
(N=18,360)(N=29,046)
Nonfatal Electrical Incidents, Industry Sector Versus Nature of Injury (U.S data) 1992-2002
[Source: Cawly and Homce, Trends in Electrical Injury, 1992-2002 PCIC-IEEE-2006-38]
Total=47,406
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Electrical Safety Program – NIOSH
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 6
Edison took electricity out of the lab with the first commercially practical light bulb.Patented 1880
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 7
1900 1920 1940 1960 1980
NEC - 1897
NESC - 1913
OSHA-1970
NIOSH-1970
NFPA 70E-1979
Burn Center-1980
Milestones in the First 100 Years
Development of Electrical Safe Work Practices
IEC - 1904
1879
First commercially practical incandescent light bulb.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 8
20001980 1990
Lee’s Paper - 1982
NFPA 70E-1988
Subpart S-1989
PCIC Safety Subcom.-1990
1st IEEE-IAS-ESW in Dallas 1992
NESF-1994
NFPA 70E-1995
Arc-Resistant Swgr. - 1997
ASTM F-1506 - 1998
Workshop. SE Asia - 1998
Yellow Book - 1998
Incident energy consensus - 2000
Milestones in the Past 28 Years
DuPont Safety Workshop, Chantilly -1991
Elect Hot Work Safety Program by JMG/LBMc - 1987
Development of Electrical Safe Work Practices
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 9
20082000 2004
NFPA 70E - 2000 NFPA 70E-2004
IEEE 1584-2002
Milestones in the Past 8 Years
IEEE/NFPA Collaborative Effort on AFH Issues
$3.2MM Contributions Rec’d for AFH Testing
15th Annual IEEE-IAS-ESW in Dallas
Development of Electrical Safe Work Practices
OSHA VPPBEST PRACTICE
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February 11, 2009Page 10
Development in Electrical Safety OSHA & NFPA-70E
Occupational Safety & Health Administration
OSHA 29 CFR 1910.119 Process Safety ManagementOSHA 29 CFR 1910.137 Electrical Protective EquipmentOSHA 29 CFR 1910.145 Specification for Accident Prevention & TagsOSHA 29 CFR 1910.147 The Control of Hazardous Energy (LO/TO)OSHA 29 CFR 1910.254 Subpart Q – Welding, Cutting and BrazingOSHA 29 CFR 1910.269 Subpart R- Generation,& DistributionOSHA 29 CFR 1910.301 Subpart S thru 1910.399 - UtilizationOSHA 29 CFR 1926.400 Subpart K thru 1926.499 -OSHA 29 CFR 1926.950 Subpart V- Construction
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 11
OSHA Mandates for Electrical Safety
• Electrical equipment installed safe per recognized
installation and inspection is considered to be safe until:– Deterioration occurs– Unsafe acts are performed– Carelessness takes place
• OSHA directs that electrical equipment be de-energized before working on or near exposed electrical conductors or circuit parts
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 12
OSHA Mandates for Electrical Safety
• OSHA recognizes a few situations where it is infeasible to deenergize the electrical equipment while performing some tasks in proximity of “live” parts:– Performing diagnostics and testing (startup or troubleshooting)
of electric circuits that can only be performed with the circuit energized
– Work on circuits that form an integral part of a continuous process that would otherwise have to be completely shut down in order to permit work on one circuit or piece of equipment
– If deenergizing the electrical power could present a greater hazard than the potential hazard of working on or near exposed energized electrical conductors or circuit parts.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 13
OSHA Recognition of NFPA 70E
• OSHA is revising the general industry electrical installation standard found in Subpart S of 29 CFR Part 1910. In the Wednesday, February 14, 2007 OSHA Final Rule, “The agency has determined that electrical hazards in the workplace pose a significant risk of injury or death to employees and that the requirements in the revised standard, which draw heavily from the 2000 Edition of NFPA 70E and the 2002 Edition of the NFPA 70 are reasonably necessary to provide protection from these hazards.” This final rule became effective August 13, 2007.
• “OSHA is responding to requests from stakeholders that the agency revise Subpart S so that it reflects the most recent editions of NFPA 70E and NFPA 70.”
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 14
NFPA 70E Standard for Electrical Safety
• National Standard for Electrical Safety• Consensus document and presents basis for OSHA CFR Subpart S
1910.331-335• Strategies
– Electrical Safe Work Condition– Training– Planning the work– Protective Equipment– Preventative Maintenance
• NEC• Fundamental principles of protection against
– Electric shock– Thermal effects – Overcurrent– Fault currents– Overvoltage
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 15
Development of Electrical Safety Program
•The development spans 22 years•Electrical Safety Standard
–Electrical Safety Principles–Controls–Responsibilities–Shock Hazard–Arc Flash Hazard–Definitions–Limits of Approach
•General and Specific Electrical Work Procedures•Electrical Safety Working Group
–Manage the Program–Select the electrical tools–Selects the electrical PPE–Develop general and specific Electrical Work Procedures
Training leading to Qualification
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 16
1986 1991
19851994
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 17
1995 2000
BMS TSS – Electrical Safety ProgramJohn Gallagher
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•
2004
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Electrical Safety Program – Baytown Site
•One Electrical Safety Program for the Site (multi business site)
•Principles
•Controls
•Training to provide the awareness and discipline
•Simple Program that empowers people to work safely through awareness and discipline
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 20
Electrical Safety Program – Baytown Site
The Electrical Safety Program is not designed for hands on live line work. It is designed for an integrated electrical system in a 24 hour continuous Petro-Chemical facility where every alternative is investigated before electrical energized work is authorized.
The majority of work performed in Baytown is:
– Troubleshooting an energized circuit
– Checking and testing for Isolation
– Applying temporary grounds
– Opening and closing Circuit breakers
– Resetting Overload relays
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February 11, 2009Page 21
Electrical Safety Program - Principles
Principles of the programThe Electrical Safety Working Group uses the following principles to
implement the Electrical Safety Program.
Identify the Hazard
Each job must identify and focus on the Electrical Shock and Electrical Arc Flash Hazard.
Eliminate the Hazard (whenever possible)
The energized electrical work and potentially hazardous switching will be reviewed to determine if the hazard can be removed by design or by
establishing an electrically safe work condition.
Control the Hazard
When the electrical hazard cannot be eliminated by design or by establishing an electrically safe work condition, it will be controlled by qualified personnel using a well defined electrically safe work or electrical switching procedure.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 22
Electrical Safety Program - Principles
Minimize the Severity of Potential Injuries
The severity of injuries when a potential hazard gets out of control during the execution of energized electrical work or potentially hazardous switching will be minimized by:
Wearing the correct personnel protective equipment
Minimizing the number of personal potentially exposed to the hazard within the arc flash hazard boundary to only those persons necessary to perform the work.
Maximize the ability to recover from an injury.
The ability to recover from an injury is maximized by:– The use of a second qualified person for Class A and a standby person
for class B, W, X and Y energized electrical work and electrical switching. Refer to S-056 Appendix “B”.
– The use of radios to communicate the status of the work.– Standby personnel qualified in the use of CPR.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 23
Electrical Safety Program - Controls
•Electrical Safety Program (S-056 Site Procedure)•Electrical Safety Working Group
–Authority for electrical safety at the site.–Selection of PPE–Selection of Live Line Tool’s
•Electrical Work Procedures (EWP’s)•Electrical Switching Procedures (EWP’s)•Training leading to qualification•Restricting access of personnel into the Limited Approach Boundary•Arc Flash Hazard Analysis and Label’s
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 24
Electrical Safety Program - Training
•Classroom training–Two day class room. Training included “skits” performed by electrical supervisors and technicians on how and how not to perform electrical work. Actual equipment or equipment “mock ups” used.
•Computer based training –Automatic system that requires reader sign off and test.
–Records updated automatically
•Contractor training –Minimum requirement for contractors is the Electrical Safety Program.
–Procedures identified on ISTC WEB page.
• Training address qualified and unqualified workers
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 25
OSHA
• At OSHA’s hearing in 12/05, Dr. Heinz Ahlers of NIOSH, spoke about the effect of training on accidents. “In a majority of those instances the fatality involved the worker who had been appropriately trained for the exposure that he subsequently came in contact with and just was not following the training and the company policy involved”.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 26
Electrical Safety Program – Baytown Site
AWARENESS
DISCIPLINE
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 27
Electrical Safety Program – Overview
S-056 Electrical Safety ProgramAppendix A Limit of Approach
Appendix B Energized Electrical Work and Switching Classification
Appendix C Energized Electrical Work Permit
Appendix D Job Briefing
EWP-1 Electrical Safety Working Group
EWP-2 Arc Flash Hazard
EWP-3 Hazard Flash Analysis label
EWP-4 Personal Protective Equipment for Electrical Shock Hazards
EWP-5 Personal Protective Equipment for Electrical Arc/Flash Hazards
EWP-6 Electrical Emergency Release Procedure
EWP-7 Training and Qualification
EWP-8 Testing and Inspection of Temporary Wiring, Portable Electrical Equipment, Extension Cords, and Portable GFCI’s.
EWP-9 Electrical Documentation
EWP-10 Contractor Electrical Safety
EWP-11 Electrical W, X, Y Switching
EWP-12 High-Direct-Voltage (DC Hi-pot) Test on Power Cables
EWP-13 Demolition of Isolated Electrical Cables
EWP-14 Temporary Personnel Protective Grounds
EWP-15 Voltage-rated Test Equipment and Tools
EWP-16 Electrolysis
EWP-17 Basic Electrical Safety
EWP-18 Energized Electrical Work
EWP-19 Normal Electrical Switching S-56 Class Z
EWP-20 Inspection and Troubleshooting Inside a 480-volt MCC Bucket
EWP-21 Removing and Inserting a a 480-volt MCC Bucket
EWP-22 Removing or Replacing a bolted Non Hinged Cover to expose an energized component 301 to 150,000 volts
EWP-23 Testing for Absence of Voltage
EWP-24 Qualification Requirements to Enter Electrical Rooms
EWP-25 Repair Work 51-300 Volts
EWP-27 Operation of Equipment Near Power Lines
EWP-28 Ground Assurance Programs
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 28
S-056 “Electrical Safety Program”
Purpose: The Electrical Safety Program sets the minimum requirements to safeguard against electrical shock and electrical arc flash while installing, commissioning, maintaining and operating electrical equipment at the Bayer Baytown Industrial Park.
Scope: The electrical safety program applies to all Bayer employees and contractors whose job requires them to install, commission, operate, service, inspect or maintain electrical equipment including electrical power distribution equipment.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 29
S-056 “Electrical Safety Program”
Procedures for all electrical work, energized electrical work, emergency work and electrical switching shall comply with this program.
This program does not cover: –Electrical work from 0-50 volts –Telephone company equipment owned and maintained by the telephone company –Utility electrical equipment owned and maintained by the utility company –Electrical equipment owned, maintained and operated by 3rd party operations
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February 11, 2009Page 30
S-056 “Electrical Safety Program”
This procedure has four appendices:
Appendix A Limits of Approach
Appendix B Energized Electrical Work and Electrical Switching Classifications
Appendix C Energized Electrical Work Permit
Appendix D Energized Electrical Work Job Briefing
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February 11, 2009Page 31
S-056 “Electrical Safety Program”Appendix A Limits of Approach
NOMINAL SYSTEM VOLTAGE/EQUIP. RANGE
LIMITED APPROACH BOUNDARY RESTRICTED APPROACH BOUNDARY
PROHIBITED APPROACH BOUNDRY
PHASE TO PHASE EXPOSED MOVABLE
CONDUCTOR
EXPOSED FIXED CIRCUIT PART
INCLUDES STANDARD INADVERTENT MOVEMENT ADDER
(NOTE #1)
Energized Part to Personnel – Distance in feet & inches
0 to 50V Not Specified Not Specified Not Specified
51V to 300V 10 ft. 0 in. 3 ft. 6 in. Avoid contact Avoid contact
301V to 750V (MCCs and Panel boards)
10 ft. 0 in 3 ft. 6 in. 1 ft. 6 in. 0 ft. 1 in.
301V to 750V (Low-voltage Switchgear)
10 ft. 0 in. 5 ft. 0 in. 2 ft. 0 in. 0 ft. 1 in.
751V to 15.0 kV 10 ft. 0 in. 5 ft. 0 in. 2 ft. 2 in. 0 ft. 7 in.
15.1 kV to 40 kV 10 ft. 0 in. 6 ft. 0 in. 3 ft. 0 in. 0 ft. 10 in.
40.1 kV to 145 kV 11 ft. 0 in. 10 ft. 0 in. 6 ft. 0 in. 3 ft.1 in.
NOTE #1: The restricted approach distance is the working distance used to calculate the incident energy. If closer work distances are required on specific equipment, a deviation is required that is authorized by the Baytown PCT Head. The deviation shall include new incident energy calculations and a written procedure for the specific task to be completed.
Limit Approach Boundary
Arc Flash Hazard Boundary
Restricted Space
Prohibited SpaceExposed
Energized Component
Prohibited Approach Boundary
Restricted Approach Boundaries
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 32
S-056 “Electrical Safety Program”Appendix B: Energized Electrical Work and Electrical Switching Classifications
Microsoft Excel Worksheet
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 33
S-056 “Electrical Safety Program”
Appendix C Energized Electrical Work Permit
{click on to view}
Microsoft Word Document
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 34
S-056 “Electrical Safety Program”
Appendix D ENERGIZED ELECTRICAL WORK JOB BRIEFING
{click on to view}
Microsoft Word Document
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 35
EWP-1 “Electrical Working Group”2.1 This Electrical Safety Working Group will manage and develop the
electrical safety program for the Baytown site to meet the S‑056 “Electrical Safety Program”. Contractors and third party personnel working at the Baytown BMS site will comply with the requirements of the Baytown BMS Electrical Safety Program.
4.0 The “Electrical Safety Working Group” will use the following principles to implement the Electrical Safety Program.
– Identify the hazard– Eliminate the hazard (whenever possible)– Control the hazard– Minimize the severity of potential injuries– Maximize the ability to recover from an injury
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 36
EWP-1 “Electrical Working Group”
RESPONSIBILITIES
The Electrical Safety Working group is responsible to develop and manage the following:
The Baytown BMS S‑056 “Electrical Safety Program”
Electrical Work Procedures (EWP)
Electrical Safety Training
Qualifications of personnel to perform electrical energized work and electrical switching
Selection of live line tools and temporary safety grounds
Selection of personnel protective equipment for energized electrical work and electrical switching
Electrical Arc Flash Hazard analysis
Label Electrical Equipment with an Arc Flash Hazard label
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 37
Electrical ShockElectrical Shock
• Over 30,000 non-fatal electrical shock accidents occur each year.
• Over 350 people die from electrocution each year.
• Electrocution remains the fourth (4th) highest cause of industrial fatalities.
• Most injuries and deaths could be avoided
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 38
EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”
This procedure identifies the use, field care, testing and inspection of electrical PPE required when performing energized electrical work and electrical switching.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 39
EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”The Restricted Approach Boundary has two conditions, based on the
voltage system as follows:
Less than 750 volts
The qualified person must keep face and body trunk, including legs, outside of the Restricted Approach Boundary. The Restricted Approach Boundary can be penetrated by qualified persons with the persons arm and hand if wearing PPE and rubber insulating gloves approved for the voltage class and identified by procedure.
EXCEPTION: It is permissible to use the Class 00 or Class 0 rubber insulating gloves without the leather protectors, only if high finger dexterity is needed for the handling of small parts, and there is no potential for small parts to puncture, cut or tear the rubber glove; thereby permitting the energized part to contact the employee’s bare hand.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 40
EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”
Greater than 750 volts
The qualified person must keep all body parts outside the Restricted Approach Boundary.
The Restricted Approach Boundary can only be penetrated by qualified persons with live line tools or test equipment approved to the voltage class of the system being work on and operated to the manufacturer’s instructions.
The live line tools or test equipment must be operated by the qualified person wearing full PPE, including rubber insulating gloves approved for the voltage class with all body parts outside of the Restricted Approach Boundary.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 41
Class 2 (17 kV) Insulating Rubber Gloves, with Leather Protectors
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 42
Arc-Flash
• As much as 80% of all electrical injuries are burns resulting from an arc-flash and ignition of flammable clothing
• Arc temperature can reach 35,000°F - this is four times hotter than the surface of the sun
• Fatal burns can occur at distances over 10 ft.• Over 2000 people are admitted into burn centers
each year with severe electrical burns• An Arc-flash also contains molten metal
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 43
EWP-2 “Arc Flash Hazard Analysis”
The purpose of the procedure is to document the custody, care, and use of the Bayer Baytown Power Distribution System Model (“Model”).
The Model is the electronic software representation of the entire Bayer Power Distribution System and is capable of providing short circuit calculations, arc flash boundaries, relay settings, circuit breaker settings, arc flash label information and other technical data.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 44
EWP-3 “Hazard Flash Analysis Label”
The purpose of the label is to communicate in a consistent way, the electrical shock and arc flash hazards and limits of approach to energized components. This allows persons engaged in electrical work or switching to select the correct PPE.
– Breaker panels, MCC and Switchgear above 300 volts will be marked with the Arc Flash Hazard Analysis label.
– Electrical panels 50 volts to 300 volts will be marked with a label indicating the maximum voltage inside the panel. An Arc Flash Hazard Analysis label is not required on electrical panels 50 volts to 300 volts unless the circuit includes at least one 125KVA or larger transformer.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 45
EWP-3 “Hazard Flash Analysis Label”
ARC FLASH HAZARD ANALYSIS LABEL
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 46
EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”
This procedure identifies the use, field care, testing and inspection of arc flash PPE that must be worn by BMS qualified personnel when they work inside the Arc Flash Protection Boundary. This procedure also applies to personnel who are not performing energized electrical work or switching, but are within the Arc Flash Protection Boundary.
Personnel who perform electrical switching directly on non arc-resistant switchgear are considered to be in the arc-flash protection boundary and have to wear arc flash PPE.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 47
EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”Range of Calculated Incident Energy Cal/cm2
Personal Protective Clothing for Electrical Arc Flash Hazard
< 1.2Long sleeve shirt and pants, minimum 4.2 oz/yd2 Natural fiber (100% cotton)
Safety glasses
Hard hat
Voltage rated gloves rated for the circuit being worked on (EWP-4)
< 6.8 Energized Electrical Work
Flame-Resistant coveralls 5.9 oz/yd2 PBI@ 6.8 ATPV
Safety Glasses
Hard HatHood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)
< 40Electrical Switching only
Flame-Resistant Lab Coat 50” long - Stores part # (M) 40667850, (XL) 40667821, (3XL) 40891241 Safety Glasses Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183 Ear protection Gloves – Arc Flash Gloves – Stores part # (L) 80166940
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 48
EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”Range of Calculated Incident Energy Cal/cm2
Personal Protective Clothing for Electrical Arc Flash Hazard
< 40 Energized Electrical Work
Flame-Resistant pants - Stores part # (M) 80169680, (XL)80169702) (2XL) 80169737. Flame-Resistant flash jacket – Stores part # (M) 80167181 (XL) 80167629 (2XL) 80169435. Safety Glasses. Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183. Ear protection. Voltage rated gloves rated for the circuit being worked on plus glove leather protectors (EWP- 4)
< 65 Energized Electrical Work
Flame-Resistant pants- Stores part #(M) 81214825, (L) 81214892, (XXL) 81214965 Flame-Resistant flash jacket –Stores part # (M) 81214469, (L) 81214523, (XXL) 81214620. Safety Glasses. Hood complete with hard hat and polycarbonate insert complete with integral fresh air cooling fan - Stores part # 80167165. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)<
< 100 Energized Electrical Work
Flame-Resistant pants- Stores part # (M) 80169761, (XL) 80169605, (3XL) 80169664. Flame-Resistant flash jacket - Stores part # (M) 80169575, (XL) 80169494 (3XL) 80169532. Safety Glasses. Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling air fan.- Stores part # 80167122. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 49
Flash Suit Hood
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 50
ATPV in cal/cm2 – Level of Protection
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 51
BMS TSS PCT John Gallagher June 14, 2006
Electrical Hazard Analysis
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 52
Electrical Hazard Analysis - Purpose
To determine the minimum Personal Protective Equipment (PPE) when performing the following tasks on a 480 volt MCC:– Operating a circuit breaker with the door closed.
– Operating a circuit breaker with the door open.
– Work on energized parts inside a 480 volt MCC “bucket”.
– Inserting / Removing a 480 volt MCC “bucket”
– Removal of covers to expose bare exposed component.
– Resetting a O/L relay.
BMS TSS PCT John Gallagher June 14, 2006
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 53
Flash Hazard Analysis – Principles Used
The following Principles from the Electrical Safety Program were used to perform the Electrical Hazard Analysis:
– Identify the electrical hazard.
– Eliminate the hazard wherever possible.
– Control the hazard if the hazard cannot be eliminated.
– Minimize the severity of the potential injuries.
– Minimize the severity of injury after the injury has occurred.
BMS TSS PCT John Gallagher June 14, 2006
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 54
NFPA-70E (Ref NFPA-70E Handbook pg. 69-100)
NFPA-70E allows two methods to determine the required PPE.
1) Tables 130.7(c)(9)(A) in NFPA-70E.
2) Calculate the incident energy levels under Engineering supervision.
Programs must define the method and be consistent with the method that is used when conducting a Arc Flash Hazard Analysis.
BMS TSS PCT John Gallagher June 14, 2006
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 55
Electrical Hazard Analysis - Conclusion
NFPA-70E tables can not be used on the Baytown electrical system.
The Baytown Electrical Safety Program will continue to calculate the Arc Energy / Flash hazard boundary under engineering supervision.
Non-Arc resistant gear is not designed / tested/listed to keep the door closed under arc fault conditions.
BMS TSS PCT John Gallagher June 14, 2006
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 56
480 MCC
•Opening Door
•Circuit breaker on
• PPE Required - YES
•Inspection/Observation only
•Circuit Breaker on
•PCT Technician stood in front of open bucket within arc flash hazard zone.
• PPE Required - YES
•Testing and troubleshooting. Repair < 120 volt circuit.
•Circuit breaker on
•PCT technician stood in front of open bucket within arc flash hazard zone.
• PPE Required - YES
•Testing and troubleshooting. Repair < 120 volt circuit.
•Circuit breakers off
• PPE Required – NO after
establishing a safe working condition.
•Inspection/observation/amp probe reading/troubleshooting inside a vertical wire way.
•Circuit breaker on
•PCT Technician stood in front of open wire way within arc flash hazard boundary.
•PPE Required - YES
… … …
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 57
EWP-7 “Training and Qualification”
This procedure identifies the training and recertification requirements to meet the requirements of S-056 “Electrical Safety Program”.
Microsoft Word Document
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 58
EWP-10 “PCT Contractor Electrical Safety”•The Baytown Electrical Safety Program applies to all Contractors who work at the Baytown BMS Site
–Maintenance, Project (expense and Capital), Service work.
Microsoft PowerPoint Presentation
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 59
EWP-13 “Demolition of Isolated Electrical Cables”This procedure provides the methods to safeguard personnel and maintain continuity of electrical supply in adjacent energized equipment and cables during the demolition of isolated cable. This is achieved by the continuous identification of the circuit being demolished.
ATTACHMENT #1
Field end of cable
Switchgearor MCC end
of cable
Location of next cut between cut end and PVC
sleeve
Cut cable end
PVC Sleeve with red and white striped hazard tape applied
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 60
EWP-13 “Demolition of Isolated Electrical Cables”ATTACHMENT #2
Cables passing through cable block installed in wall.Outside Building
Cut made here inside building
Cable to be demolishedCut made here outside building
WALLCable Block
WALL
Inside Room
Note:The above sketch illustrates an incident that occurred in the MDI/MR-3 unit. A cable being demolished was cut inside the building. The technician then went outside the building and counted off the cables making the assumption the cable went straight through the cable block. However, the cable being demolished made a bend inside the cable block and exited the building on the side opposite to the point of entry inside the building.
The result was the technician cut the wrong cable.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 61
Electrical Safety Program - Principles
Prior to any electrical work being started, the following principles will be reviewed and applied to the specific electrical job task to be completed:
Identify the electrical hazard.
Eliminate the hazard wherever possible.
Control the hazard if the hazard cannot be eliminated.
Minimize the severity of potential injuries.
Minimize the severity of injury after the injury has occurred.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 62
Eliminate/Reduce the Potential Hazard
• Arc Resistant Switchgear (Note: not “Arc proof”)
• SF6 gas Switchgear
• High resistance grounding
• Current limiting devices (molded case breakers and fuses)
• Arc Flash Calculations
– <40 cal/cm^2
– Protective device coordination (may have to sacrifice)
• Finger safe fuses
• See through rigid barriers
• Insulated terminal covers
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 63
Eliminate/Reduce the Potential Hazard
• Line side shutters
• Identify and label equipment that has more than one power source
• Removable insulated boots
• Grounding balls for temporary personnel protective grounds
• IR Windows
• Mimic panels
• Umbilical cords (Chicken Switch)
• Remote racking
• Control voltage <50V
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 64
Reduce/Eliminate the Potential Hazard
• Preventative and Predictive Maintenance:.– Partial Discharge Detection System: Installed at all
MV installations, Cable testing for partial Discharge activity is schedule for March 2008
– PM programs/software: the Power Distribution dept. developed details PM programs for substations and load centers, the programs include detailed work scopes as per NETA recommendations.
– Process Information: Use of DCS and Process Historian as enabling tools to facilitate data driven decisions verses making decisions on perceptions.
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 65
Reduce/Eliminate the Potential Hazard
• Use of remote CB control switches Chicken Switch
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 66
Eliminate/Reduce the Potential Hazard
• AF Resistant gear (Sub 31)
Through the specification and design of internal arc classified switchgear, where the energy and emissions resulting from and internal arc are suitably vented away from the operator and/or people in the vicinity, the ‘safe’ working distance (flash boundary) can be effectively managed without the need for excessive PPE
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 67
Electrical Safety Program - Summary• Electrical Safety Working Group
• Principles
• Controls
• Classification of work/voltage rating/work group/requirements
• Training Leading to Qualification Leading to Awareness and Discipline Leading to empowerment.
• Arc Flash Hazard Analysis Label/PPE ATPV
• Simple program that empowers personnel to be responsible for their own safety.
• Designing the potential electrical hazard out of the equipment
BMS TSS – Electrical Safety ProgramJohn Gallagher
February 11, 2009Page 68
Thank You