HESNI ANNUAL CONFERENCE May 3, 2012 Aramark Conference Center, Downers Grove Jim Dungar, P.E. Principal Engineer Schneider Electric Engineering Services Jim.dungar@schneider-electric.com (920-766-8012) office (920-540-4075) cell
6 Steps for Compliance to OSHA Safe Work Practices Requirements 1. Electrical Safe Work Practices Policy 2. Arc Flash Hazard Analysis and Equipment Labeling 3. Personal Protective Equipment (PPE) and Tools 4. Safety Training 5. Maintenance and Testing 6. Mitigate and Control Arc Flash Hazards Carla to add graphic 2
Step 1: Develop and Audit an ESWP 3
What is ESWP? Company s OH&S Policy Statement OH&S Processes Program #1 Program #2 ESWP Program 4
Hierarchy of Controls Most Effective Elimination Substitution Engineering Controls Arc Flash Mitigation Warnings Administrative Controls Typical ESWP Range Least Effective PPE Disaster Recovery References: NFPA 70E - 2012 Annex and ANSI Z10-2005 5
ESWP is a Live Document The Electrical Safety Program shall be audited to verify the principles and procedures are in compliance with this standard. The frequency of audit shall no exceed 3 years. Reference: NFPA 70E 2012, Article 110.3(H) Introduces the continual improvement circle from ANSI Z10 6
Guiding Standards for ESWP OSHA, 29 CFR, Part 1910, Subpart S 1910.137 Electrical Protective Devices 1910.331 to 335 Electrical safe work practices NFPA 70E Per NFPA 70E 2012 edition the electrical safe work practices policy needs to be audited at a minimum: Every 3 Years 7
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Step 2: Arc Flash Hazard Analysis Methods 9
Arc Flash Analysis 1. Incident Energy Method (IEEE 1584) Requires a model of the electrical power system to calculate short circuit currents and protective device clearing time Calculates the incident energy and flash protection boundary Utilizes empirical formulas 2. NFPA 70E tables 130.7(C)(15)(a) Developed based on some assumptions of short circuit currents and protective device clearing time 10
Frequently asked questions Q: Can I use the NFPA 70E tables instead of performing the arc flash calculations? A: You can, but you have to do short circuit and overcurrent device trip calculations. The recommended PPE in NFPA 70E tables are based on certain assumptions about the available short circuit current and the overcurrent protective device characteristics. The tables may recommend too much or too little PPE. 11
NFPA 70E Table 12
Arc Flash Labels Required by NFPA 70E since the 2009 revision Must show the voltage and arc flash boundary and at least one of the following Incident energy Hazard risk category PPE 13
Frequently asked questions Q: We shut things down before we work on them. So we don t need PPE. Is that right? A: No! Until the circuit is verified dead, it is considered energized. In order to approach the circuit to test it, you must have full PPE, as you would with an energized circuit. 14
Power System Studies Process System Data Collection System Modeling Report Implementation Cycle Analytical Tools and Methods 15
Performing the Analysis - Key Questions Are there existing single-lines? Are the single lines accurate, complete? Who s doing onsite verification, data collection? Is there an existing model, analysis? Keys to success Data collection can be hazardous and should be completed by qualified workers. Precise data is critical for an accurate study 16
Once the Hazard Analysis is complete... Workers are required to wear Personal Protective Equipment (PPE) What workers wear depends upon the exposure level 17
Step 3: PPE 18
Protective Equipment 19
Protective Equipment Fabric rating 25Cal/cm2 Category 3 Fabric rating 40Cal/cm 2 Category 4 Fabric rating 100Cal/cm 2 No Category 20
Proper Tools PPE is the last line of defense PPE only works when worn PPE will NOT prevent injury during an Arc Flash incident 21
PPE and Proper Tools PPE must be provided by the employer Insulated tools are required Meters must be rated for the system (typically this means Category III) Inspect, calibrate, maintain your tools and equipment Gloves tested every 6 months Meters calibrated every 12 months PPE is the last line of defense PPE only works when worn PPE will NOT prevent injury during an Arc Flash incident 22
Step 4: Training 23
Qualified Person NFPA 70E and the National Electrical Code (NEC) define a qualified person as One who has skills and knowledge e related to the construction and operation of the electrical equipment and installations and has received safety training on the hazards involved. Training on the hazards is required by definition. Incorporate into your specification document requirements for any vendor to provide their company safety ratings and safety program information! NFPA 70E and OSHA hold the end-user employer fully responsible for all contractors hired, to insure that these contractors follow safe electrical work practices. The contractor s assurance of having met this safety standard is not sufficient; the end-user must validate ESWP compliance independently. 24
Safety training for employees The workers understand the importance of a safe work environment Must adhere to policy and program requirements Awareness that hazards exist Definitions within NFPA 70E How to minimize the risk of injury Information on the new labels What PPE to wear and why Update every 3 years Maintain training records. 25
Step 5: Maintenance and Testing 26
Maintenance and Testing 27
Maintenance and testing Over current protective devices need to perform as designed to ensure the results from the arc flash analysis remain accurate for worker safety NFPA 70E - 205.5 & 210.5 The most controllable factor in reducing the arc flash incident energy is time 28
Step 6: Mitigation of Problem Areas 29
Arc Flash Mitigation Solutions Reducing Arc Flash Energy The importance of maintenance and equipment operability Lowering device settings Changing the device that controls arcing time Specialized protective relaying Separating the worker from the arc IR window Remote control of breakers Schneider Electric Engineering Services May 3, 2013 Arc Resistant Switchgear Virtual Main LV Direct Replacement Arc Terminator IR Windows Remote Racking 30
Summary ESWP Arc Flash Hazard Analysis PPE Training Maintenance Mitigation 31
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Questions.
OSHA Electrical Requirements Understand: Key concepts What are the hazards? What are the regulations? OSHA requirements A six step process to compliance 34
What are the Hazards? Shock and electrocution Arc flash Arc blast 35
Electrical Shock Hazard 20 15 10 4.050.030.015.010.005.001 4 AMPERES AND OVER Heart Paralysis, Serious Tissue and Organ Burning.050 AMPS TO 4 AMPS.1 -.2 Certain Ventricular Fibrillation.05 -.1 Possible Ventricular Fibrillation 30 ma - Breathing Difficult, Asphyxiation, Fibrillation in small children 15 ma - Muscles freeze in 50% of the population >10 ma - Let-Go Threshold 5 ma - GFCI Trip Level 1 ma - Perception Level 36
Arc Flash Hazard 37
Arc Flash Injuries Five to ten arc flash explosions occur in electrical equipment every day in the United States (Source: Cap- Schell, Inc.) Injuries range from minor injuries to third degree burns and potential death due to the energy released. Other injuries include blindness, hearing loss, nerve damage, and cardiac arrest. The average cost of medical treatment for survivors of serious arc flash injuries is $ 1,500,000 Total costs including litigation can be $8M - $10M 38
Non-human Results of Arc Flash Downtime Lost revenue Loss of product Equipment damage Regulatory impact OSHA citation and fines 39
Arc Blast Hazard 40
What s Changing in the Industry? Awareness of arc flash hazard (Ralph Lee papers in early 1980 s) Impact to manufacturers human costs and downtime Recognition of unsafe work practices: energized work Changes to NEC & NFPA 70E New IEEE 1584 Standard for Arc Flash Hazard Calculations (2002) Enforcement by OSHA 41
What are the Regulations OSHA 29 CFR Part 1910 NFPA70E-2012 NFPA70 (NEC) NESC IEEE C2-2012 OSHA Standards (Iowa Shown) Governs Employee Workplace Safety Governs Electrical Installations Applies to Utility Industry 42
Safety System for Work on or Near Electrical Equipment NEC (Installation) OSHA (Workplace Safety) Employer (Facility) Electrical Safety Program Equipment Practices Training Analysis (Product Standards) OSHA Standards NFPA 70E IEEE 1584 Calculations Enforcement by inspectors Design for Safety Employee (Work, PPE) Enforcement by OSHA Electrical Safety Program 43
Frequently asked question Q: What happens when a contractor enters a facility? Who is responsible? A: Safety Design Standards: OSHA 1901.301 to 308. If you comply with NEC you are generally fine. Electrical Safe Work Practices: Notify the contractor of known hazards and provide information about the electrical installation. Report observed contract employee violations of the safety standards to the contract employer. (NFPA 70E 2012) 44
Frequently asked questions Q: Who signs the energized electrical work permit when a contractor is doing the work? A: Establish the rule and the contractor must comply. Best for both parties to sign the work permit. 45
OSHA Design Safety Standards 1910.303 - General What is APPROVED? Acceptable to Assistant Secretary of Labor. Suitability for installation and use Suitability may be evidenced by Listing or Labeling Listed = recognized by a National Recognized Testing Laboratory (NRTL) Wire bending Short circuit interrupting rating Mechanical execution of work Other 46
Short Circuit Analysis (1910.303) Purpose: To verify the adequacy of Interrupting ratings of protective devices Withstand ratings of components 47
OSHA Design Safety Standards 1910.304 Wiring Design and Protection Follows NEC A well-executed coordination study catches wiring protection issues on main electrical equipment 48
Coordination Study Purpose: To establish the Optimal time/current protection settings of relays and breakers Also evaluates wiring and protection for major electrical equipment 49
Electrical Safe Work Practices ESWP (1910.333) Safety related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts when work is performed near or on equipment of circuits which are or may be energized OSHA plants the see for an electrical safe work practices program OSHA cites NFPA 70E for compliance requirements 50
Frequently asked questions Q: Where is OSHA citing NFPA 70E? A: Many OSHA agents are now carrying NFPA 70E. Extensive training is now being done throughout the USA. Significant citations have been written in a number of localities for both large and smaller facilities. 51