Electrical Events Involving Look-Alike Equipment within the DOE Complex

Introduction Design and placement of electrical equipment for utilization purposes may require multiple sections of the same design to be installed. Multiple sections are typically the same size, color, shape, and configuration making them difficult to distinguish from one another. Multiple installations of similar equipment such as variable frequency drive cabinets, motors, disconnects all in close proximity has caused errors to occur in industry and the DOE complex. Errors involving similar or look-alike equipment have led to equipment damage and personal injury.

Idaho National Laboratory Electrician in support of an air compressor upgrade accesses an energized potential transformer cabinet resulting in a severe shock and minor equipment damage. Unlike the picture - the back of the switchgear was not labeled.

East Tennessee Technology Park Electrician enters wrong cabinet to disconnect transformer links using an open end wrench. Nearing the energized bus the worker realizes the equipment is energized and drops the wrench initiating an arc flash. Worker receives minor injuries and equipment is damaged.

Hanford Site Electricians locked and tagged pump #4 but electrically disconnect pump #1. Pump #1 circuit breaker was open but not locked and tagged.

Idaho National Laboratory Electrician disconnects wrong 480 Vac motor. Several motors of the same type and design located in same area. Classified as a near miss because the motor could have started automatically if conditions for start existed. Example only, not actual area of incident

Thomas Jefferson National Accelerator Laboratory Subcontractor incorrectly identifies and cuts energized 15 kV cable. The cable was remotely cut and no personnel were exposed to hazardous energy.

Los Alamos National Laboratory Electrician enters 13.8 kV switchgear to perform cleaning activities and initiates an arc flash. The worker entered a cubicle that was no longer controlled by the clearance. The arc flash injures the worker and damages equipment.

Summary Poor verification practices and flawed assumptions when working with look-alike equipment has lead to numerous errors resulting in personal injuries and equipment damage at DOE complex facilities. NFPA 70E addresses look alike equipment but does not describe how to eliminate or minimize errors involving look-alike equipment. It is up to the DOE complex facilities to implement policies, and procedures to mitigate the hazards of look-alike equipment. The Energy Facility Contractor Operating Group (EFCOG) electrical safety task group has been tasked to develop a best practice to guide facilities in their efforts to develop controls for look-alike equipment.