Advancing Electrical Safety Through Engineering Electrical Safety for the 21 st Century 1

Purpose Stimulate cultural shift in our thinking from “how to protect worker from hazard” to “how to prevent or reduce the hazard” To raise awareness of engineered controls and technology available to eliminate or reduce the electrical hazard as well as minimize facility impact/cost 2

Electrical Safety for the 21 st Century As awareness of electrical arc flash emerged in the 80’s and 90”s, electrical safety programs have expanded to comply with standards NFPA 70E, Standard for Electrical Safety in Workplace, NFPA 70 National Electrical Code and OSHA regulations serve as the basis for electrical safety programs within the DOE complex 3

Electrical Safety for the 21 st Century Current standards regarding workplace electrical safety focuses more on personal protective equipment as opposed to engineering solutions We generally invest in safety warning signs, safety training, and PPE to protect workers However, engineered solutions are generally recognized as the most effective measure in safeguarding worker safety – Eliminate the hazard through engineering and design 4

How Can We Advance Electrical Safety? Focus more on prevention and risk reduction through technical excellence along with safety management practices, i.e. safety by design and engineering The risk control hierarchy in ANSI-Z10 standard provides a roadmap for setting these safety objectives 5

Risk Control Hierarchy –ANSI Z10 6

Electrical Safety for the 21 st Century Apply the risk control hierarchy to determine most effective feasible method to reduce or eliminate the hazard – First consider methods to eliminate the hazard or substitute a less hazardous method or process Continue down hierarchy until highest level feasible control is found Often, a combination of controls is most effective Integrating “safety by design” is generally easier and costs are generally less during the design. Engineered controls can be feasible for retrofits too. 7

Why Engineered Solutions? Benefits (+) + Reduces worker exposure to hazard + Reduces PPE requirements for operators and electrical workers + Reduces planning time and costs associated with electrical troubleshooting, testing, and inspections + Reduces Operations and Maintenance costs Barrier/Challenges (-) - Modification cost, particularly for safety related systems - Difficulties making minor modifications in operating systems - Not a “crisis” so not urgent - Not knowing what new technology exists

Electrical Safety for the 21 st Century Engineered Solutions The next several slides provides examples of technology and engineered controls that may be effective in “preventing” or reducing electrical hazards Design engineers, facility system engineers, facility operators, safety professionals and others should consider these solutions for applications in their facility Engineered solutions should not be limited to just those in this presentation. New technology and electrical safety solutions continue to emerge every week. Continue to search manufacturers websites. (See last slide for resources) 9

Voltage/Current Test Portals Provides current and voltage test portal to safely test on energized motors and equipment Portals install in panel door or separate enclosure Precludes need for L/T Data collection time significantly reduced Cost ~$500 Applicable to new designs and retrofits 10

Remote Breaker Racking Operator can stand outside the arc flash protection boundary – Over 40 cals – Under 40 cals Compatible with multiple type breakers and programmable Some units equipped with remote operator Cost $35k Applicable to existing switchgear equipment 11

Racking Breaker-Which Method? ConventionalRemote 12

Remote Racking Video Demo ( Watch video to demonstrate a remote racking solution applicable to existing switchgear) 13

Arc Resistant Switchgear and MCC’s Stronger door hinges, latches and gaskets Redirects blast and arc flash energy to plenum on top Reduced operator PPE Some provide “through the door” racking capability adding additional protection Generally for new designs only Cost about 25% more than standard switchgear and MCC’s 14

Finger Safe Terminals Finger safe terminals available as IP20 rating for fuse holders, terminal blocks, non-conductive covers Reduce chance of worker coming in contact with live conductor Reduce risk of conductive part falling across bare exposed parts and creating an arc fault 15

Remote Breaker Operation Portable device to operate pistol grip style handles Operator can stand outside arc flash boundary Cost $2K Applicable to existing electrical installations 16

Infrared Viewing Panes Viewing pane allows non- invasive thermography inspection without opening doors or removing panels Eliminates shock/arc flash exposure PPE reduction Allow thermography on equipment exceeding 40 cals Cost $200 typical Applicable to new designs and retrofits for existing equipment 17

Arc Flash Maintenance Reduction Switch Provides temporary change for overcurrent protection to faster tripping time Reduce arc flash energy – Locations over 40 cals – Locations under 40 cals Switch must be controlled Cost $2k typical Applicable to new designs and retrofits 18

Switch Rated Motor Plug Safe make/break plug – Enclosed arc chamber – No exposure live parts Plug and play simplicity Eliminate voltage testing Easy motor change out $350 for 60A, 3 phase Applicable to new designs and retrofits 19

Ultrasonic Test Probe Detect frequencies associated with electrical discharges (arcing, tracking and corona) Medium and low voltage applications Non-invasive and cost effective (Scan at door seams and vents) Equipment outage or L/T not required for testing Also useful to locate steam and compressed air leaks 20

Remote Display Multi-Meter Detachable display Place meter and probes on electrical device being checked – Read remotely Eliminate exposure to a second worker holding meter Cost $350 21

Fluorescent Light Tester 22 Troubleshoot fluorescent fixtures without dismantling Tests lamp, ballast and pins Cost effective and enhance safety Available Feb ($200)

Moving Forward in the 21 st Century Prevention technology is available and should be our 1 st choice when evaluating the electrical hazard Our challenge in the 21 st Century is to advance electrical safety by changing our approach from protection to prevention – Educate others (operators, electrical workers, etc.) – Look for opportunities to apply engineered solutions in workplace Retrofits and new designs and projects New consensus standards and programs will emphasize prevention IEEE 1814 Electrical Safety Through Design (Draft) IEEE 1683 Enhanced Motor Control Center Safety (Draft) NIOSH Prevention through Design (PtD) initiative 23

Conclusion People will make mistakes PPE can fail Engineered solutions will provide the safest foolproof protection And, engineered solutions will generally be most cost effective 24

Partial List of Resources