OSHA Electrical Safe Work Practices ESWP NFPA 70

OSHA Electrical Safe Work Practices (ESWP) & NFPA 70 E 2009 Updates Mark A. Hernandez, CHST

ESWP Outline • • Statistical information Definitions OSHA requirements Qualified / Unqualified NFPA 2009 updates Safety References Interpretations

ESWP Statistics • Average of 4, 000 non-disabling and 3, 600 disabling electrical contact injuries annually in the United States • One person is electrocuted in the workplace every day. • Electrocutions were the fourth leading cause of traumatic occupational fatalities. • 10 -15 employees are sent to the hospital every day with electrical burns. • Over 4 workers every day go to the burn unit due to arc flash.

Electrical Safety Program – NIOSH 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

Electrical Definitions • Electrical Hazard: A dangerous condition such that contact or equipment failure can result in electric shock, arc-flash burn, thermal burn, or blast. • Shock Hazard: A dangerous condition associated with the possible release of energy caused by contact or approach to live parts. • Electrical shock: Occurs when current flows through the body from contact with two energized conductors or from contact with one energized conductor and earth. • Electrocution: Death through shock. • Flash Hazard: A dangerous condition associated with the release of energy caused by an electric arc.

OSHA requirements When working on or near electricity or electrical equipment you must be trained in & use Electrical Safety Related Work Practices 1910. 331 -. 335 NFPA 70 E 2009

Qualified workers 1910. 331 -. 335 All Qualified Workers shall cover the following information: • (2)(a) Safety-related work practices (SOP, LOTO) • (3) (i) skills and techniques necessary to distinguish exposed live parts • (3)(ii) skills & techniques necessary to determine nominal voltage • (3)(iii) The clearance distances Applies to both Qualified / Unqualified workers

Unqualified workers Unqualified Workers • Are normally protected by the installation requirements by Subpart K or S (covers on no exposed live parts). • Are responsible to conduct activities outside the limit of approach. • Are responsible to follow instructions from electrical However: • If their work exposes them to electrical hazards which would otherwise be protected -- they must be trained to recognize and avoid hazards encountered or likely to encounter while working.

NFPA 70 E training updates • • Article 110. 6 (C) requires that employees be trained in CPR and recertified annually Article 110. 6(D)(1)(d) requires that employees be retrained before performing any tasks that are performed less often than once per year Article 100. 6 (D)(3) requires that an employee must be retrained or receive additional training under any of the following circumstances: If the supervisor observes, or annual inspections reveal, that the employee is not following the rules and regulations. If new technology, new types of equipment or changes in procedures necessitate the use of safety-related work practices that are different from those the employee would normally use. If the employee must use safety related work practices that are not normally used during his or her regular job duties. 110. 6(E), requires that all training must be documented and employees must show proficiency, and that the documentation must be maintained for the duration of the employee's employment.

NFPA 70 E PPE updates v Section 130. 7(A): Use PPE that is designed and constructed for the body to be protected. v HRC 1: Worker must wear long pants having a rating of 4 calories or more. (Manufacturing Ind. ) v Headgear: face shield rated for 4 cal/cm 2 v Hearing protection & leather gloves for all HRC. v Going into a 277/480 V to test – Table 130. 7©(9) assigns HRC 2. v The flash suit hood may be replaced by a balaclava (sock hood) in combination w/ a face shield rated for 8 calories. . OSHA PPE requirements: • 1910. 335: Safeguards for personnel protection • . 335(a)(1(i): requires employer to provide electrical PPE. • . 335(a)(1)(v): requires employees to wear PPE where electric arc or flashes hazards are present. • . 132(d) PPE Assessment (certified)

PPE Warning PPE will help to protect the worker from thermal effects of electrical arc flash hazards; however, it may not protect against shrapnel and pressure waves. Also, the incident energy calculation and resulting PPE level is based upon a specific working distance from the potential arc fault source; typically 18” is selected. The incident energy within this 18” will be higher and thus protection may not be assured or additional personal protective equipment may be necessary. • Arc Flash. wmv

NFPA 70 E “Establishing an Electrically Safe Work Condition • • Determine all possible sources of electrical supply Properly interrupt load current Open disconnecting devices for each source Visually verify all blades of disconnecting devices are open, or draw out devices are withdrawn Apply lockout/tag-out devices Test for voltage Where possibility of induced voltage, stored electrical energy exists, or where it could be anticipated that conductors or circuit parts being de-energized could contact other exposed energized conductors or circuit parts, ground phase conductors before touching them Article 130 provisions, such as the justification for work through the use of an energized electrical work authorization permit.

Arch-Flash requirements • NFPA 70 E describes arc flash analysis as a study that investigates a worker's potential exposure to arc flash energy, conducted for the purpose of injury prevention and the determination of safe work practices and the appropriate levels of PPE. A flash hazard analysis determines two important things: the flash protection boundary distance and the possible arc flash incident energy. Source: Arc Advisor Min. Rtg. of PPE Max Rating of PPE Risk Category 0 1. 2001 5 1 5. 001 8 2 8. 001 25 3 25. 001 40 4 40. 001 and above Not Available

Arch Blast / Flash Definitions • Limited approach boundary distance: the “restricted approach boundary” and the “prohibited approach boundary” apply to protecting against shock. • Flash Protection Boundary Distance: “Flash protection boundary: An approach limit at a distance from exposed live parts within which a person could receive a second-degree burn if an electrical arc flash were to occur. ” (per NFPA 70 E) Flame resistant personal protection equipment (PPE) must be worn by anyone within the flash protection boundary. • The “working distance” is the space between the potential arc source(s) and the face/chest of the worker involved in the assigned task. (min 18”) Arc Thermal Performance Value (ATPV): is the performance specification of flame resistant apparel worn by personnel who could be exposed to momentary electrical arc and related thermal hazards. The units of measure are calories per centimeter squared (Cal/cm 2) • • Incident Energy: The amount of energy impressed on a surface, a certain distance from the source, generated during an electrical arc event. ” (per NFPA 70 E). This energy is generally expressed in calories/cm 2. The ‘surface’ of concern ‘impressed on’ is the worker’s body, particularly the head and trunk. Incident energy is calculated using variables such as available fault current, system voltage, expected arcing fault duration and the worker’s distance from the arc. The data obtained from the calculations is used to select the appropriate flame resistant (FR) PPE, just as voltage level is used to select a class of rubber gloves.

Arc Flash Update / Exemption Update: • Article 130. 3 now says that the analysis must be reviewed at least every 5 years or whenever a major modification occurs. This means that the label should include a date and the date must be documented. The analysis must be reviewed when major changes occur or, at a minimum, every 5 years. Exemption: • Not required if the circuit is rated 240 volts or less and is supplied by a single transformer rated less than 125 k. VA. • A shock hazard analysis must be performed if workers could be exposed to energized circuit parts. The shock hazard analysis determines the voltage of the live parts, shock protection boundaries (limited, restricted and prohibited) and proper shock protection PPE to be used.

Arch Blast • Temperatures may reach 35, 000 F and typically lasts less than one second. • Estimated cost as to the cost of major >50% burn averages to be between 1. 0 & 4 million dollars. • 80% of all electrical injuries are burns resulting from an arcflash and ignition of flammable clothing • Fatal burns can occur at distances over 10 ft. § Over 2000 people admitted to burn centers yearly with severe arc flash burns Source: Workplace Safety Awareness Council 2000 psf 165 db 740 mph

Article 130. 3 (c) Label Update ! WARNING Arc Flash and Shock Hazard Appropriate PPE Required Requires arc flash warning labels to include, at a minimum, the arc flash incident energy or required level of PPE.

Limited Approach Boundary For shock protection only Prohibited Restricted Limited The closest distance an “unqualified” person can approach, unless escorted by a “qualified” person. Energized panel (<750 V) 3 feet 6 inches for 480 V

Limited Approach Boundary For shock protection only Energized part 12 inches for 480 volts The closest distance to exposed live parts a “qualified” person can approach w/out proper PPE and tools. To cross this boundary, the qualified person must wear PPE and have proper tools.

Limited Approach Boundary For shock protection only Energized part 1 inch for 480 volts Crossed ONLY by a “qualified” person, which when crossed by body part or object, requires the same protection as if direct contact was made with the live part.

JHA for PPE Assessment 1. Determine the Arc Flash Protection Boundary & the appropriate PPE for use within this boundary or 2. Select PPE based on Hazard/Risk of Specific Task

Arc Flash Boundary Protection Prohibited Energized part Restricted Limited Calculated distance Flash Protection Boundary The distance from exposed live parts within which a person could, at a minimum, receive a second degree burn if an arc flash were to occur. Arc flash PPE is required within this boundary. Note: Distance may be less than or greater than the shock protection boundaries.

Electrical Safety Program Skit SKIT # 3 is presented to demonstrate the safe way under the Electrical Safety Program work on a 480 volt MCC: • Opening door with breaker on • Making an observation without touching • Trouble shooting with breaker on • Trouble shooting with breaker off • Opening door with breaker on Source: Bayer Facility – VPP Best Practice

Bayer Facility: VPP Best Practice skit 480 MCC 1. Opening Door 2. Circuit breaker on PPE Required YES … 1. Observation only 2. Circuit Breaker on 3. Qualified Worker stood in front of open bucket within arc flash hazard zone. PPE Required YES … 1. Testing and troubleshooting. Repair < 120 volt circuit. 2. Circuit breakers off PPE Required – NO after establishing a safe working condition Always Test Before you touch

Source: American Burn Association (1991 -1993 Study)

References OSHA: • • • 1910. 132(d) – PPE Assessment. 137 Electrical Protective Equipment. 147: LOTO. 269: Power Generation & Distribution. 331 -. 335 - ESWP. 334 Use of equipment - Portable Fixed - Test • . 335 PPE & warning

References cont. NFPA 70 E: • • Sections 130. 7(C)(9) and (C)(10): HRC Matrix Table Article 130 provisions: Electrical Work Permit NFPA 70 E Section 1303(B): Requires an arc-flash hazard analysis NFPA 70 E Sections 130. 7(C)(9)&(C): Hazard/Risk Category Classifications and Protective Clothing and Personal Protective equipment (PPE) Matrix tables IEEE: • IEEE 1584 Guide for Performing Arc. Flash Hazard Calculations NESC / ANSI: • NESC / ANSI C 2 -2007 Section 410. A. 3: Requires employers to perform an Arc Flash Assessment by 1 -1 -09

ESWP Interpretations OSHA interpretations: • http: //www. osha. gov/pls/oshaweb/owasrch. search_form? p_doc_type=INTERPRETATIONS&p_to c_level=0&p_keyvalue= • 11 -14 -06: http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 25557 A few arc Flash ESWP interpretation Links: • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 25559 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 25438 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 21350 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 25557 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 21066 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 24383 • http: //www. osha. gov/pls/oshaweb/owadisp. show_document? p_table=INTERPRETATIONS&p_id= 24009

“Safety has priority over service continuity, equipment damage or economics. ” Institute of Electrical and Electronic Engineers “Buff Book”

Where is OSHA Located? Houston North Area Office: 507 N. Sam Houston Pkwy E. Ste. 400 Houston, TX 77060 281 -591 -2438 Houston South Area Office: 17625 El Camino Real #400 Houston, TX 77058 281 -286 -0583 *241

Disclaimer • This information has been developed by an OSHA Compliance Assistance Specialist and is intended to assist employers, workers, and others as they strive to improve workplace health and safety. While we attempt to thoroughly address specific topics [or hazards], it is not possible to include discussion of everything necessary to ensure a healthy and safe working environment in a presentation of this nature. Thus, this information must be understood as a tool for addressing workplace hazards, rather than an exhaustive statement of an employer’s legal obligations, which are defined by statute, regulations, and standards. Likewise, to the extent that this information references practices or procedures that may enhance health or safety, but which are not required by a statute, regulation, or standard, it cannot, and does not, create additional legal obligations. Finally, over time, OSHA may modify rules and interpretations in light of new technology, information, or circumstances; to keep apprised of such developments, or to review information on a wide range of occupational safety and health topics, you can visit OSHA’s website at www. osha. gov.