In House Arc Flash

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Arc Flash and NFPA 70E

MWU Shop Training

Arc Flash and NFPA 70E

• Developed for MarquipWardUnited Field Service Staff

• Installation and Troubleshooting in the fieldMWU FS d t k ith di t ib ti• MWU FS does not work with distribution or switchgear

• Voltages below 600VAC (nominal)

Arc Flash Training Outline1. Introduction

What is arc flashLock Out Tagout OSHA StyleWhy do we need to follow the NFPA 70E GUIDELINES?Arc Flash description

2 Boundary descriptions

4. Examples5. PPE

Head and FaceEyes2. Boundary descriptions

LimitedRestrictedProhibitedFlash Protection

3. Flash Hazard AnalysisNFPA ChartsUp to 240V PanelUp to 600V PanelMotor Control Center

BodyGlovesShoesTools

6. Application to FSPPESupervision

Times

• Arc Flash Movie (30 sec)• Guys that had it happen (26 min)• Clothing Video (1min 30 sec)• Gloves Video (9 min)• Live Accident Video (42 Sec)

Arc Flash Arc Flash – Something went wrong

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Screwdriver Slipped? It’s more than Electrical Safety!

Is it the Law?Is it the Law?

• OSHA IS THE SHALL &• NFPA 70E IS THE HOW

I d t t d d h NFPA 70EIndustry consensus standards, such as NFPA 70E, can be used by employers as guides to making the assessments and equipment selections required by the standard. Similarly, in OSHA enforcement actions, they can be used as evidence of whether the employer acted reasonably

Interpretation of 07/25/2003

NFPA 70E – 2009 Edition Standard

• Electrical Safety Requirements for Employee Workplaces

This req irement co ers all aspects of– This requirement covers all aspects of worker safety associated with electrical hazards in the workplace. Within this standard are recommendations for proper PPE (Personal Protective Equipment)

• http://www.nfpa.org

Why Now?• While the potential for these explosions to occur has

existed as long as industrial and commercial applications of electricity, two factors have pushed accident prevention to the forefront.

• The first is a greater understanding of hazards and the risks• The first is a greater understanding of hazards and the risks they pose to personnel. Research into blasts has been able to quantify the powerful forces they unleash.

• The second factor is increased vigilance on the part of OSHA.

• OSHA is using the requirements of NFPA 70E, the industry's consensus standard for electrical safety, to judge whether the employer "acted reasonably" in protecting its workers from hazards. In many cases, this has resulted in employers facing substantial fines after such accidents.

§§1910.333 1910.333 Selection and use of work practices Selection and use of work practices ----

electrical electrical “(a) General. 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 or circuits which are or may be energized. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards.”

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1910.333(a)(1) Deenergized parts.1910.333(a)(1) Deenergized parts.

“Live parts to which an employee may be exposed shall be deenergized before the employee works on or near them, unless the employer can demonstrate that deenergizing introduces additional or increased hazards or is infeasible due to equipment design or operational limitations.”

1910.333 (a)(1)1910.333 (a)(1)Note 1:Note 1:“Examples of increased or additional hazards include interruption of life support equipment, deactivation of emergency alarm systems, shutdown of hazardous location ventilation equipment.”

1910.333 (a)(1)1910.333 (a)(1) Note 2:Note 2: InfeasibilityInfeasibility“Examples of work that may be performed on or near energized circuit parts because of infeasibility due to equipment design or operational limitations include testing of electric circuits that can only be performed with thecircuits that can only be performed with the circuit energized and work on circuits that form an integral part of a continuous industrial process in a chemical plant that would otherwise need to be completely shut down in order to permit work on one circuit or piece of equipment.”

MWU Lock Out Procedures

• Click on product for LOTO Procedure

MWU Lock Out Procedures

Arc Flash Description Arc Flash Damage

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OSHA regulations make it clear that, with very few exceptions, equipment must be

deenergized before employees work on or near it.

• When employers must make exceptions to the above, the regulations also make it clear that it is the employer's responsibility to evaluate the workplaceemployer s responsibility to evaluate the workplace for hazards and protect workers from these hazards. This requires:– A hazard/risk assessment for the electrical

hazards associated with energized work – selection of appropriate personal protective

equipment (PPE)

(A) Safety Training(A)Training requirements apply to employees who face

a risk of electrical hazard that is not reduced to a safe level by the applicable electrical installation requirements.

(B)Such employees shall be trained to understand the ( ) p yspecific hazards associated with electrical energy

(C)They shall be trained in Safety related work practices and procedural requirements as necessary to provide protection from the electrical hazards associated with their job or task assignments

(D)Employees shall be trained to identify and understand the relationship between electrical hazards and possible injury.

(B) Type of Training

• The training required by this section shall be classroom or on-the-job type, or a combination of the two.

• The degree of training provided shall be• The degree of training provided shall be determined by the risk to the employee

(C) Emergency Procedures

• Employees exposed to shock hazards shall be trained in methods of release of victims from contact with exposed electrical conductors or circuit parts

• Employees shall be regularly instructed in methods of aid and emergency procedures, such as approved methods of resuscitation if their duties warrant such training.

• Training of employees in approved methods of resuscitation, including CPR, shall be certified by the employer annually

(D) Employee Training

• Qualified Person: A qualified person shall be trained and knowledgeable of the construction and operation of equipment or a specific work method and be trainedor a specific work method and be trained to recognize and avoid the electrical hazards that might be present with respect to that equipment or work method.

(D)(1)(a)

• Such persons shall also be familiar with the proper use of the special precautionary techniques, PPE, including arc flash, insulating and shielding materials andinsulating and shielding materials, and insulated tools and test equipment.

• A person can be considered qualified with respect to certain equipment and methods but still be unqualified for others.

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(D)(1)(c) • Such persons permitted to work within the Limited Approach

Boundary of exposed live parts operating at 50 Volts or more, shall, at a minimum, be additionally trained in all of the following:

1) The Skills and techniques necessary to distinguish exposed energized parts from other parts of electrical equipment.

2) The skills and techniques necessary to determine the nominal ) q yvoltage of exposed live parts.

3) The approach distances specified in tables 130.2(c) and the corresponding voltages to which the qualified person will be exposed.

4) The decision-making process necessary to determine the degree and extent of the hazard and the PPE and job planning necessary to perform the task safely

Qualified Person• Trained and Knowledgeable of the construction and

operation of equipment• Trained to recognize and avoid the electrical hazards

that might be present• Trained in emergency release procedures and First

Aid/CPR (certified annually)Aid/CPR (certified annually)• You may be qualified for one task but not for another• To work within the Limited distance

– Distinguish exposed energized parts– Determine Nominal Voltage– Approach distances for corresponding voltages– Determine the degree and extent of the hazard and PPE

required and job planning to perform the task Safely

Qualified Vs Unqualified

1) Hot or not2) Nominal voltage3) Distances4) PPE needed

There are specific steps NFPA 70E dictates to ensure an electrically safe working condition

exists• Determine all possible sources of supply• Open disconnecting device(s) for each source (deenergize)• Where possible, visually verify device is open• Apply lockout/tagout devices• Test voltage on each conductor to verify that it is de-energized• Apply grounding devices where stored energy or induced voltage could• Apply grounding devices where stored energy or induced voltage could

exist or where de-energized conductors could contact live parts.• Establishing these safety procedures is part of the company safety plan

that must be in effect for each facility:– Employers must formalize procedures and practices such as the qualification

of employees to work in hazardous areas, tasks they may perform, steps needed to secure management approval for work to be done and audits.

– Employers must provide training for employees in the skills and techniques needed to work with electrical equipment, equipment details and emergency procedures.

– Employees must implement the practices according to the training.– Companies must perform a flash hazard analysis before work is done on any

energized equipment.

Warning Label for energized Equipment (Required)

Example 2

• Sign a customer placed on the Singlefacer Blower CircuitBlower Circuit Breaker box

• Note numbers and Category!

• (Very Nice)

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What is an ARC FLASH

• When insulation or isolation between electrified conductors is breached or can no longer withstand the applied voltage, an arc flash occursan arc flash occurs.

• As employees work on or near energized conductors or circuits, movement near or contact with the equipment, or a failure of the equipment, may cause a phase-to-ground and/or a phase-to-phase fault.

Sequence of events

• Power feeds through a circuit breaker or fuse• Something down stream of the protective

device shorts phase to phase or to groundTh t ti d i t k ti t• The protective device takes some time to react (CB typically 6 cycles or 0.1 sec)

• Between the time of the short and when the CB opens, how many Amps flow?

• Ohms Law V=IxR or V÷R=I

Play 480 Arc Flash Movie

• 480 VAC same as our plants480 VAC same as our plants• The actual fault current in the above

demonstration is not known, but is likely in the range of 10,000 amps which is similar to what our breakers may let through in a case of short circuit

• The photograph shows a side view of an equipment rack during an arc flash explosion.

Photograph provided by Square D / Schneider Electric

What happens• The temperature of an arc can reach more than

5000 F (some up to 35000F) as it creates a brilliant flash of light and a loud noise.

• Copper melts around 2000F and boils about 4600F• An enormous amount of concentrated radiant

energy explodes outward from the electrical equipment, spreading hot gases, melting metal,equipment, spreading hot gases, melting metal, causing death or severe radiation burns, and creating pressure waves that can damage hearing or brain function and a flash that can damage eyesight.

• The fast-moving pressure wave also can send loose material such as pieces of equipment, metal tools, and other objects flying, injuring anyone standing nearby.

< 740 mph

Visible

IR

165 db15000 °C

50 cal/cm22000 psf

1000 °CUV

165 db15000 C

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How they measure Arc Flash• Incident energy is expressed in calories per centimeter squared

(cal/cm²).• The flash protection boundary is the point at which the energy

number is 1.2 cal/cm², equating to a second-degree burn.

• As workers get closer to the energized equipment, that energy figure rises.

• This boundary is different for different types of equipment and depends in part on the voltages involved.

• Typically, the higher the voltages, the larger the danger zone.• A 10,000 A arc at 480 V is equivalent to 8 MW or

approximately eight sticks of dynamite, noted John Lane, electrical safety engineer at AVO Training Institute, Dallas, TX.

• If this happens when you are in the panel the Arc Flash is in your face, arms/hands, chest, and possibly legs


and possibly legs.

Arc Flash and Electrical Safety

• Electrical safety is to keep you and the electrons separated. Shock Hazard

• Arc Flash is to protect you from the fire ball caused by a catastrophic faultball caused by a catastrophic fault.

• Remember this when we refer to the PPE requirements, PPE is for the fire ball more than for the shock hazard. – (Exception - gloves and tools)

• Because of electrical safety and the released energy during an arc flash explosion, boundary areas are defined.


• Limited Approach• Restricted Approach• Prohibited Approach• Flash Protection

Boundary DescriptionFlash Protection Boundary

• For systems that are 650V or less, the Flash Protection Boundary shall be 4 feet unless a Flash Analysis is performed.

• There must be a barricade to prevent entry to• There must be a barricade to prevent entry to the Flash protection Boundary.

• This is for the Flash, Flames and Fireball.

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Limited Approach Boundary• Limited Approach Boundary is the closest

distance an UNQUALIFIED person can approach an energized conductor or circuit part.For our equipment the Limited Approach• For our equipment the Limited Approach Boundary is set at 3 feet 6 inches – 1.07 meters or 42”

Exposed (Live Parts)

• NFPA 70E Definition• Exposed – Capable of being inadvertently

touched or approached nearer than a safe distance by a person. It is applied to parts that are not suitably guarded, isolated or insulated.

Restricted Approach Boundary• Restricted Approach Boundary is the closest

distance to exposed live parts a QUALIFIEDperson can approach WITHOUT proper PPE and tools. (PPE for Shock i.e. gloves!)

• Inside this boundary, accidental movement can put a part of your body or conductive tools in contact with live parts or inside the prohibited approach boundary.

Restricted Approach BoundaryTo cross the restricted approach boundary, the qualified

person must:• Have a documented plan that is approved by the

manager responsible for the safety plan.• Use PPE suitable for working near exposed liveUse PPE suitable for working near exposed live

parts and rated for the voltage and energy level involved.

• Be certain that no part of the body enters the prohibited space.

• Minimize the risk from unintended movement, by keeping as much of the body as possible out of the restricted space; body parts in the restricted space should be protected.

Prohibited Approach Boundary

• Prohibited Approach Boundary is the minimum approach distance to exposed live parts to prevent flashover or arcing.

• Approaching any closer is comparable to• Approaching any closer is comparable to making direct contact with a live part.

Prohibited Approach BoundaryTo cross the prohibited approach boundary, the qualified

person must:a. Have specified training to work on exposed live

parts.b. Have a documented plan with proper written work

d d j tif i th d t kprocedures and justifying the need to work energized. This is a work permit.

c. Do a written risk analysis. Document this.d. Have (b) and (c) approved and signed by

management.e. Use PPE appropriate for working near exposed live

parts and rated for the voltage and energy level involved.

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Safety• Strange as it may seem, most fatal

electrical shocks happen to people who should know better.

• It's not the voltage but theIt s not the voltage but the current that kills.

• People have been killed by 100 volts AC in the home and with as little as 42 volts DC.

The Effects of Shock

• Immediate– Muscle contraction– Vital organs (Heart,

• Long term– Memory Loss– Nervous disordersg ( ,

Lungs, etc.)– Tingling– Pain– Breathing– Disorientation– Dizziness

– Chemical imbalances– Damage to vital

organs– Sometimes Fatal

Effects of Current on the BodyMen• Perception Threshold

– 0.001 Amps (1 mA)• Painful Shock

– 0.009 Amps (9 mA)

Women• Perception Threshold

– 0.0007 Amps (0.7 mA)• Painful Shock

– 0.0012 Amps (1.2 mA)

• Cannot Let-Go Level0.010 Amps (10 mA)

• Ventricular Fibrillation0.100 Amps (100 mA) 3 Seconds

0.200 Amps (200 mA) 1 Second• Heart Failure

0.5 Amps (500 mA) • Organ Burn and Cell Breakdown

1.5 Amps (1500 mA)

Why 50 volts?• Ohm’s Law for Electric current (amps), voltage and

Body Resistance• The typical body has a contact resistance of 500

ohms at the point of contact with the electrical source.

• The body has an internal resistance of approximatelyThe body has an internal resistance of approximately 100 ohms.

• There is another point of contact to ground of maybe 5000 ohms. – 120v / (500Ω+ 100Ω+ 5000Ω) = 21mA– 50v / (500Ω+ 100Ω+ 5000Ω) = 8.9mA

• It is around 10mA that the “cannot let go” level is reached

• Once lock up occurs, exposure time is increased and the possibility of electrocution may occur.

Question!

Does Electricity take the path of least resistance?

130.1 (3) Exemptions to Work Permits

• Work Performed on or near live parts by qualified persons related to tasks such as:– Testing– Troubleshootingg– Voltage Measuring (etc.)

• Shall be permitted to be performed without an energized electrical work permit provided appropriate safe work practices and PPE (IAW Chapter 1) are provided and used.

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Electrical and Arc Flash

• Boundary areas for Electrical safety– Limited Approach– Restricted Approach

Prohibited Approach– Prohibited Approach• Boundary area for Arc Flash protection

– Flash Protection• For us, the Flash Protection Boundary is

more limiting than the Limited or Restricted area Boundaries

Table 130.2(C) Approach Boundaries to Live Parts for Shock Protection

Boundary Distances• Boundary area for Arc Flash protection

– Flash Protection 4 Feet• Boundary areas for Electrical safety

– Limited Approach 3’-6”Restricted A h

Prohibited A hApproach Approach

<50V Not Specified Not Specified

<300V Avoid Contact Avoid Contact

<750 One foot One inch

Performing a Flash Hazard Analysis

• NFPA 70E requires facility owners to perform a flash hazard analysis prior to allowing a worker to work on energized equipment.

• The analysis is necessary for determiningThe analysis is necessary for determining the flash protection boundary distance and type of PPE required.

• To establish this information, an incident energy calculation is generally necessary.

15 A 480V CB

• What does 15 Amp mean?

240 AC 18K• 240 AC 18K• 480 AC 14K• 250 DC 10K• Interrupting capacity

Hazard Analysis

• Power Limits• Transformers• Transformers• Wire lengths• CB’s or Fuses• Line Layout

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Hazard/Risk Category Classifications

• The best method of assigning the Hazard/Risk Classifications is an Incident energy analysis of 130.3 (B) (1)

• In Lieu of the analysis this table must be used.y• The Notes section lists assumptions that must

be met.• For tasks not listed or for systems with greater

than the assumed max currents or clearing times, an analysis must be done.

Hazard/Risk Category Classifications

• Each Hazard/Risk has increasing danger and increased PPE requirements

• Hazard Risk 0 (<4 cal/cm²)H d Ri k 1 (4 l/ ²)• Hazard Risk 1 (4 cal/cm²)

• Hazard Risk 2 (8 cal/cm²)• Hazard Risk 3 (25 cal/cm²)• Hazard Risk 4 (40 cal/cm²)

NFPA 70E – Hazard Risk 1(4 cal/cm²)

• This hazard risk category poses some risk. Some examples of tasks in this category are tasks that involve:– Circuit breaker or fused

switch operation with covers off when working with Panel boards rated 240 V and below.

– Opening hinged covers (to expose bare, energized parts) when working with "Other 600 V Class (277 V through 600 V, nominal) Equipment.

Panel boards Rated 240V and BelowTasks Performed on Energized Equipment

Panelboards or Other Equipment Rated 240 V and Below –Note 1

Hazard/Risk Category

Rubber Insulating

Gloves

Insulated and Insulating Hand

Tools

Perform infrared Thermography and other non-contact inspections outside the restricted approach area

0 N N

Circuit breaker (CB) or fused switch operation with covers on 0 N NCB or fused switch with covers off 0 N NWork on energized electrical conductors and circuit parts, including voltage testing

1 Y Y

R /i t ll CB f d it h 1 Y Y

• (a) Rubber insulating gloves are gloves rated for the maximum line-to-line voltage which work will be done.• (b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line voltage upon

which work will be done, and are manufactured and tested in accordance with ASTM F 1505, Standard Specification for Insulated and Insulating Hand Tools.

• (f) For equipment protected by upstream current limiting fuses with arcing fault current in their current limiting range (1/2 cycle fault clearing time or less), the hazard/risk category required may be reduced by one number.

• Note1. Maximum of 25 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing time.

Remove/install CBs or fused switches 1 Y YRemoval of bolted covers (to expose bare, energized electrical conductors and circuit parts)

1 N N

Opening hinged covers (to expose bare, energized electrical conductors and circuit parts)

0 N N

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the panelboard

1 Y Y

Table 130.7(C) (9) Notes• General Notes (applicable to the entire table):• (a) Rubber insulating gloves are gloves rated for the maximum line-to-line voltage which work will

be done.• (b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line

voltage upon which work will be done, and are manufactured and tested in accordance with ASTM F 1505, Standard Specification for Insulated and Insulating Hand Tools.

• (c) Y=yes (required), N=no (not required).• (d) For systems raged less than 100 volts, the fault currents and upstream protective device

clearing times are based on an 18 in. working distance.( ) F t t d 1 KV d t th H d/Ri k C t i b d 36 i• (e) For systems rated 1 KV and greater, the Hazard/Risk Categories are based on a 36 in. working distance.

• (f) For equipment protected by upstream current limiting fuses with arcing fault current in their current limiting range (1/2 cycle fault clearing time or less), the hazard/risk category required may be reduced by one number.

• Specific Notes (as referenced in the table):• 1. Maximum of 25 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing

time.• 2. Maximum of 65 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing

time.• 3. Maximum of 42 kA short circuit current available; maximum of 0.33 sec (20 cycle) fault clearing

time.• 4. Maximum of 35 kA short circuit current available; maximum of up to 0.5 sec (30 cycle) fault

clearing time.

You do need gloves for 120V

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NFPA 70E – Hazard Risk 2 (8 cal/cm²)

• This hazard risk category involves tasks that pose a moderate risk. Some examples of tasks in this category are tasks that involve:

Circuit breaker or fused switch– Circuit breaker or fused switch operation with enclosure doors closed when working with 600 V Class Motor Control Centers (MCCs).

– Work on control circuits with energized parts 120 V or below, exposed when working on Metal Clad Switchgear, 1 kV and above

Panel boards or Switchboards Rated Between 240V and 600V

Panelboards Or Switchboards Rated >240 V and up to 600 V (with Molded case or insulated case circuit breakers) – Note 1


Rubber Insulating

Gloves


Tools


1 N N

CB or fused switch operation with covers on 0 N NCB or fused switch with covers off 1 Y NWork on energized electrical conductors and circuit parts, 2* Y Y

Legend:• Voltage-rated gloves are gloves rated and tested for the maximum line-to-line voltage upon which work will be done.• Voltage-rated tools are tools rated and tested for the maximum line-to-line voltage upon which work will be done.• 2* A double-layer switching hood and hearing protection are required for this task in addition to the other hazard/risk

category requirements. Notes:• 1. 25 kA short-circuit current available, 0.03 second (2-cycle) fault-clearing time.• 2. 65 kA short-circuit current available, 0.03 second (2-cycle) fault-clearing time.• 3. For less than 10 kA short-circuit current available, the hazard/risk category required may be reduced by one number

Work on energized electrical conductors and circuit parts, including voltage testing

2 Y Y

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the panelboard

2* Y Y

600 V Class Motor Control Centers

600 V Class Motor Control Centers (MCCs) – Note 2 (except as indicated)


Rubber Insulating

Gloves


Tools


1 N N

CB or fused switch or started operation with enclosure doors closed

0 N N

Reading a panel meter while operating a meter switch 0 N NCB or fused switch or started operation with enclosure doors 1 N NCB or fused switch or started operation with enclosure doors open

1 N N


2* Y Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

0 Y Y

Work on control circuits with energized electrical conductors and circuit parts >120 V , exposed

2* Y Y

Insertion or removal of individual starter “buckets” from MCC – note 3

4 Y N

Application of safety grounds, after voltage test 2* Y NRemoval of bolted covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

4 N N

Opening hinged covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

1 N N

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the motor control center

2* Y Y

600 V Class Switchgear

600 V Class Switchgear (with power circuit breakers or fused switches) – Note 4


Rubber Insulating

Gloves


Tools


2 N N

CB or fused switch operation with enclosure doors closed 0 N NReading a panel meter while operating a meter switch 0 N NCB f d i h i i h l dCB or fused switch operation with enclosure doors open 1 N NWork on energized electrical conductors and circuit parts, including voltage testing

2* Y Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

0 Y Y

Work on control circuits with energized electrical conductors and circuit parts >120 V , exposed

2* Y Y

Insertion or removal (racking) of CBs from cubicles doors open or closed

4 N N

Application of safety grounds, after voltage test 2* Y NRemoval of bolted covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

4 N N

Opening hinged covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

2 N N

Other 600 V Class Equipment

Other 600 V Class (277 V through 600V, nominal) Equipment – Note 2 (except as indicated)


Rubber Insulating

Gloves


Tools

Lighting or small power transformers (600 V, nominal)

Removal of bolted covers (to expose bare, energized electrical conductors and circuit parts)

2* N N

Opening hinged covers (to expose bare energized electrical 1 N NOpening hinged covers (to expose bare, energized electrical conductors and circuit parts)

1 N N


2* Y Y

Application of safety grounds, after voltage test 2* Y NRevenue meters (KW-hour, at primary voltage and current) Insertion or Removal

2* Y N

Cable trough or tray cover removal or installation 1 N NMiscellaneous equipment cover removal or installation 1 N NWork on energized electrical conductors and circuit parts, including voltage testing

2* Y Y

Application of safety grounds, after voltage test 2* Y NInsertion or removal of plug-in devices into or from busways 2* Y N

Equipment over 600 VTasks Performed on Energized Equipment Hazard/Risk

CategoryRubber

Insulating Gloves


Tools

Charts for voltages over 600 V exist but have not been included

Up to 4 See Chart See Chart

• From my understanding our facilities are 460 V (575V for Canadian machines)

• Maintenance may deal with some switchgear at higher voltages, in which case they need to look at the tables or have an analysis performed

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• This hazard risk category involves tasks that pose a high risk. Some examples of tasks in this category are tasks that involve:– Insertion or removal of circuit breakers

from cubicles doors open whenfrom cubicles, doors open, when working with 600 V Class Switchgear (with power circuit breakers or fused switches).

– Opening hinged covers (to expose bare, energized parts) when working with "Metal Clad Switchgear, 1 kV and above.


• This hazard risk category represents tasks that pose the greatest risk. Some examples of tasks in this category are tasks that involve:– Removal of bolted covers (to

expose bare, energized parts) when working with NEMA E2 (fused contactor) Motor Starters, 2.3 kV through 7.2 kV.

– Opening voltage transformer or control power transformer compartments when working with Metal Clad Switchgear, 1kV and above.

Panel board and Switch board• Panel Board

– A single panel or group of units designed for assembly in the form of a single panel, including buses and automatic overcurrent devices and equipped with or without switches for the control of light, heat or power circuits: designed to be placed in a cabinet or cutout box placed in or against a wall, partition or other support: and g , p ppaccessible only from the front.

• Switch Board– A large single panel, frame or assembly of panels on

which are mounted on the face, back, or both, switches, overcurrent and other protective devices, buses, and usually instruments. Switchboards are generally accessible from the rear as well as from the front and are not intended to be installed in cabinets.

Motor Control Center

• An assembly of one or more enclosed sections having a common power bus and principally containing motor control units

Guys that had it happen

NIOSH video

!!!!WARNING!!!!

Next slides show photos after• Next slides show photos after an arc flash or electrocution

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IF CLOTHING IGNITES CLOTHED

AREAS CAN BE BURNED MORE

SEVERELY THAN

EXPOSED SKIN

EXTENSIVE 3RD DEGREE

BURNS RESULT

15

P i

Protective Clothing and PPE

Hazard/Risk Category 0Protective clothing, Non-melting (according to ASTM F 1506-00) or Untreated Natural FiberFR Protective Equipment

Shirt (long sleeve)Pants (long)Safety glasses or safety goggles (SR)Hearing protection (ear canal inserts)Leather gloves (AN) (Note 2 )

Hazard/Risk Category 1FR clothing, Minimum Arc Rating of 4 (Note 1)FR Protective Equipment

Arc-rated long-sleeve shirt (Note 3)Arc-rated pants (Note 3)Arc-rated coverall (Note 4)Arc-rated face shield or arc flash suit hood (Note 7)Arc-rated jacket, parka, or rainwear (AN)Hard HatSafety glasses or safety goggles (SR)Hearing protection (ear canal inserts)Leather gloves (Note 2 )Leather work shoes (AN)

Protective Clothing and

Personal Protective Equipment PPE Table

130.7(C)(10)

Hazard/Risk Category 2FR clothing, Minimum Arc Rating of 8 (Note 1)FR Protective Equipment

Arc-rated long-sleeve shirt (Note 5)Arc-rated pants (Note 5)Arc-rated coverall (Note 6)Arc-rated face shield or arc flash suit hood (Note 7)Arc-rated jacket, parka, or rainwear (AN)Hard HatSafety glasses or safety goggles (SR)Hearing protection (ear canal inserts)Leather gloves (Note 2 )Leather work shoes

Hazard/Risk Category 2*FR clothing, Minimum Arc Rating of 8 (Note 1)FR Protective Equipment

Arc-rated long-sleeve shirt (Note 5)Arc-rated pants (Note 5)Arc-rated coverall (Note 6)Arc-rated arc flash suit hood (Note 10)Arc-rated jacket, parka, or rainwear (AN)Hard HatSafety glasses or safety goggles (SR)Hearing protection (ear canal inserts)Leather gloves (Note 2 )Leather work shoes

Personal Protective Equipment• (1) General. When an employee is working

within the Flash Protection Boundary he/she shall wear protective clothing and other personal protective equipment in accordance with 130.3.OSHA/NFPA 70E t t “F i d• OSHA/NFPA 70E states: “For energized circuits over 50 volts or more, safety tools and personal protective equipment must be used.”

Protective Equipment

• (A) General. Employees working in areas where electrical hazards are present shall be provided with, and shall use, protective equipment that is designed and constructed for the specific part of the body to be protected and for the work to be performedprotected and for the work to be performed.

• PPE is described in two areas, – 130.7 (C) PPE equipment– 130.7 (C) (13) Arc Flash Equipment

• 130.7 (C) (9) are the Hazard/Risk Charts on the previous slides

(B) Care of Equipment

• Protective equipment shall be maintained in a safe, reliable condition.

• The protective equipment shall be visually inspected before each useinspected before each use.

• FPN: Specific requirements for periodic testing of electrical protective equipment are given in 130.7(C)(8) and 130.7(F).

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Head and Face Protection

• 2* Hazard level requires a Switching Hood

• The Balaclava and hardhat + face shieldhardhat + face shield provides equivalent protection

• Face shield must supply UV and IR protection (tinted)

(C)(3) Head, Face, Neck, and Chin Protection

• Employees shall wear nonconductive head protection wherever there is a danger of head injury from electric shock or burns due to contact with live parts or from flying objects resulting from electrical explosion.

• Employees shall wear nonconductive protective equipment for the face, neck, and chin whenever there is a danger of injury from exposure to electric arcs or flashes or from flying objects resulting from electrical explosion.

130.7(C)(13)(b) Face Protection• Face shields shall have an arc rating suitable for the arc

flash exposure.• Face shields without an arc rating shall not be used.• Eye protection (safety glasses or goggles) shall always

be worn under face shields or hoods along with hearing g gprotection.

• FPN: Face shields made with energy-absorbing formulations that can provide higher levels of protection from the radiant energy of an arc flash are available, but these shields are tinted and can reduce visual acuity. Additional illumination of the task area might be necessary when these types of arc protective face shields are used.

Clothing• Different energy levels available• Can be treated fiber (Indura) or

synthetic (Nomex) or a blend of both (Cool Touch)

(C)(5) Body Protection

• Employees shall wear FR clothing wherever there is possible exposure to an electric arc flash above the threshold incident-energy level for a second degree burn, 5 J/cm² (1.2 cal/cm2).

• Exception: For incident-energy exposures 8.36 J/cm² (2 cal/cm2) and below, employees may wear non-melting clothing described in Hazard/Risk Category 0 in Table 130.7(C)(ll)

• Arm protection shall be accomplished by apparel described in 130.7(C)(5). Long Sleeves!

Clothing Video

NFPA 70E HRC 2

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Table 130.7(C)(11) Protective Clothing Characteristics


Clothing Description Required Minimum Arc Rating of PPE[J/cm² (cal/cm²)]

0 Non-melting, flammable materials (i.e., untreated cotton, wool, rayon or silk or blends of these materials) with a fabric weight of at least 4.5 oz/yd²

N/A

1 Arc-rated FR shirt and FR pants or FR coveralls

16.74 (4)

2 Arc-rated FR shirt and FR pants or FR coveralls

33.47 (8)

3 Arc-rated FR shirt and FR pants or FR coveralls and arc flash suit selected for that the system arc rating meets the required minimum

104.6 (25)

4 Arc-rated FR shirt and FR pants or FR coveralls and arc flash suit selected for that the system arc rating meets the required minimum

167.36 (40)

FR Kits

• Packages are available for users• Multiple calorie levels available

– 4,8, 25, 40 for level 1,2,3 and 4 hazards– Other levels are available including higher

Gloves… most commonGloves… most common

Class 0 Class 2

• Class 00 for 500V Class 0 for 1000V• Leathers are matched for the rubbers

Gloves… Gloves… are your first line of defenseare your first line of defense

• Insulated Rubber Gloves, ASTM Spec.• Leather Protectors, ASTM Spec.• Tested / Certified, OSHA 1910.137

““Electrical Protective Devices”• Gloves must be tested for leaks and

general condition EVERY time.• Must be recertified every 6 Months

(C)(6) Hand and Arm Protection

• Employees shall wear rubber insulating gloves where there is danger of hand and arm injury from electric shock due to contact with live parts.

• Hand and arm protection shall be worn where pthere is possible exposure to arc flash burn.

• The apparel described in 130.7(C)(13) shall be required for protection of hands from burns.

• Arm protection shall be accomplished by apparel described in 130.7(C)(5). Body Protection

Gloves Video

W H Salisbury

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Insulated Hand ToolsInsulated Hand Tools1000 Volt Rated / V-Rated

Th i l ti V t d t l i i t

WARNING

The insulation on Vrated tools is impact resistant and flame retardant. Each tool

should be inspected prior to use for cuts, cracks or other damage. If the yellow

insulation becomes visible through the outer orange layer, the tool should be removed

from service immediately.

ToolsInsulated Hand Tools

Insulated tools are to be used as SECONDARY protection from

SHOCK….They are NOT to be use as a replacement for proper

personal protective equipment

WARNING

Whenever possible, DE-ENERGIZE lines, and equipment prior to working on or around them.

– shall be rated for the voltage on which they are used

Voltage rated tools

– shall be double insulated• built to ATSM F1505 standards (double triangle

marking)• many tool are available in composite construction • rated at 1000 volts, tested to 10,000 volts

» 3M 33+ wrapped tool is not an insulated tool

• tool must be inspected before each use

Certified symbol for 1000V

If you don’t see this symbol . . .yIt’s NOT truly insulated

Meters• Meters need to be CAT III

– Three-phase distribution, including single-phase commercial lighting

• Leads must also be rated Cat III or with double Diamond

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Overvoltage Installation Categories Do I need all this stuff?

• No, You do not want to!!!• You've done it a thousand times.• It comes naturally to you. • You know what you're doing, its what

you've been trained to do your whole life.• Nothing could possibly go wrong, right ?

Think Again.

Accident Live Video

MarquipWardUnited• What affects MWU Service is:

– Work on energized parts, including voltage testing• For a 240V panel PPE is category 1

– FR (4) pants and long-sleeved FR (4) shirt

– or FR (4) Coveralls

• For a 600V (480V) PPE is Category 2 or 2*( ) g y– FR (8) long-sleeved shirt & pants over natural fiber short-

sleeved T-shirt and pants– FR (8) coveralls over natural fiber short-sleeved T-shirt and

pants– FR (8) long-sleeved shirt & pants

– * Adds the hood or face shield requirement to protect the face, forehead, ears and neck.

• Plus Gloves for each case

Why do we need this PPE

• Remember: This PPE is for the fire ball more than for the shock hazard.

• Gloves are for the Shock HazardWith th fi f t h• With the finger safe components we have very few “exposed” parts.

• Our history is very good on not getting Zapped but it does happen.

• Our equipment does not tend to explode but some parts, like drives, can.

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PPE – You and Plants

• You should know the PPE requirements for the Hazard/Risk category where you are working.

• Plants can set the required PPE higher• Plants can set the required PPE higher than NFPA for a greater margin of safety.

• As a vendor or contractor we need to follow the requirements set by the plant.

• Or NFPA 70E if none have been stated or posted.

Example• Note numbers and

Category!• This plant had

done a Hazard Analysis toAnalysis to achieve this rating

• Flash Boundary of 7.6”

• This is not by the charts.

Lockout Tagout

• With a Locked out machine there is no Arc Flash PPE required!!!

• Power Down and Lock it outVERIFY N P M !!• VERIFY No Power – Measure!!

• Now the PPE may be removed– Personal PPE– Boundary Markers

Remember• Power Down and Lock out all power!• With a ZES machine, the PPE is the

standard Eyes, Ears and Toes.• Any voltage testing, troubleshooting, CB

operation on a powered cabinet requires ope at o o a po e ed cab et equ esthe Hazard/Risk PPE to be worn!

• Our policies require the machine to be Locked out when working on the equipment unless you are troubleshooting or voltage testing.

Supervising the Troubleshooting

• If you are not able to meet the plant requirements, you cannot go into the Flash Protection Boundary area.

• You can still supervise the troubleshooting, p g,voltage testing or other operations from outside the Flash Protection area.

• This will allow continued repair and service of the equipment without your donning of the PPE.

Questions

• If you have any questions or comments, please send or reply to me or your manager.

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Ward United Lockout

From Customer Manual

O.S.H.A. defines the following as:• “SERVICING and/or MAINTENANCE. Workplace activities such as

constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.”“LOCKOUT Th l t f l k t d i• “LOCKOUT. The placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed.”

• “LOCKOUT DEVICE. A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment.”

O.S.H.A. defines the following as:• “TAGOUT. The placement of a tagout device on an energy isolating

device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.”

• “TAGOUT DEVICE. A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device, to indicate that the energy isolating device

d th i t b i t ll d t b t d til thand the equipment being controlled may not be operated until the tagout device is removed.”

• “When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and is never to be bypassed, ignored, or otherwise defeated.”

LOCKOUT/TAGOUT PROCEDURE LOCKOUT/TAGOUT PROCEDURE

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LOCKOUT/TAGOUT PROCEDURE LOCKOUT/TAGOUT PROCEDURE

Marquip Lockout

SAFETY• To safely operate Marquip machinery, operators and maintenance personnel must

undergo training by Marquip. It is the customer's responsibility to provide training to new individuals. If you need assistance training new individuals, please contact Marquip Field Service.

• This Marquip equipment operates with minimal operator intervention. However, maintenance personnel are required to be in the area of potentially dangerous mechanical and electrical devices. Use EXTREME CAUTION while operating or servicing the machines.

• False external inputs may cause the equipment to operate in an abnormal sequence. When servicing machines, shut off all pneumatic, hydraulic, and electrical power and

li i ti d h d li t Pl th hi irelieve pressure in pneumatic and hydraulic systems. Place the machine in a zero energy state by following the Safety Lockout procedure in the Operation section.

• Obey all safety signs!• The safety precautions given in this manual are for operation and maintenance

personnel's protection. Observe all rules of safety and good judgment for coworkers' and your protection.

• Many safety agencies' regulations recommend the use of hearing protection when work place noise exceeds an 8-hour time weighted average sound level of 85 dBA. Furthermore, the use of hearing protection is required when work place noise exposures exceed 90 dBA over an 8-hour work day. Marquip strongly recommends that all operating personnel use adequate hearing protection to prevent possible PERMANENT HEARING LOSS.

• SAFETY INFORMATION This manual is an integral part of the machine and has to be stored in the immediate proximity of the machine.

Splicer SAFETY LOCKOUT (ZES)• Perform safety lockout before performing any maintenance. Follow the

Safety Lockout procedure to obtain a Zero Energy State (ZES).• DANGER! Failure to perform Safety Lockout procedure before

performing maintenance of jam clearing may result in severe injury or death.

1. Place the splicer controls in the Thread-Up Mode. (Turn keyswitch from run to thread-up or manually move run/thread valve to thread-up position.)

2 Turn off and lockout air at pneumatic lockout valve2. Turn off and lockout air at pneumatic lockout valve.3. Push Control Power button Off.4. Turn primary disconnect Off.5. Lock out primary disconnect.6. Sever web at forward end of Splicer.7. Loosen the airline on both ends (home & thread-up) of either cable cylinder

to allow any trapped air to escape from the dancer system.8. Lockout pneumatic valve.• WARNING! Potential energy exists in the Dancer system when the web

is tensioned. Relieve tension on web before entering machine. Failure to do so could result in severe injury or death.

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Slitter SAFETY LOCKOUT (ZES)• Perform safety lockout before performing any maintenance. Follow the Safety Lockout

procedure to obtain a Zero Energy State (ZES).• DANGER! Failure to perform Safety Lockout procedure before performing

maintenance may result in severe injury or death.• DANGER! If the Slitter/Scorer is equipped with a Manual Auxiliary Section, the

section must be locked out before entering. Lock out the Manual Auxiliary Section by attaching the safety hold-up bolt assembly.

1. Lock out the Manual Auxiliary Section according to Specific Safety Instructions in Safety sectionsection.

2. Place the machine in an Intermediate Energy State (IES) according to Turning Control Power Off (IES) procedure in Operation section.

3. Turn the primary disconnect Off.a. Shout "Power off."b. Pause, look, and listen.c. Turn off the primary disconnect.

4. Lock out the primary disconnect.5. Turn the air Off at pneumatic lockout valve.

a. Shout "Air off."b. Pause, look and listen.c. Turn air off by rotating the air disconnect valve handle.

6. Lock out pneumatic lockout valve.

Stacker Safety Lockout (ZES)• Perform safety lockout before performing any maintenance. Follow the Safety

Lockout procedure to obtain a Zero Energy State (ZES).• DANGER! Failure to perform Safety Lockout procedure before performing

maintenance may result in severe injury or death.1. Lower all lifts and other devices to their lowest possible position (if applicable).• DANGER! Support lifts and other devices by their locking pins or bottom stops.

Do not rely on normal stopping mechanisms only. Failure to do so may result in severe injury or death.

2 P h C t l P b tt Off2. Push Control Power button Off.3. Turn Control Power Lockout keyswitch to 0 (if applicable).4. Remove key (if applicable).5. Turn primary disconnect Off.6. Lock out primary disconnect.7. Turn air Off at pneumatic lockout valve.8. Lock out pneumatic valve.• * NOTE: If maintenance requires that personnel be positioned under the lift, follow

the Lift Lock procedure in Maintenance section before continuing this lockout procedure.

Arc Flash

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In House Arc Flash

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