Jackie McAlhaney Vice Chairman, Senior Electrical Review Board Savannah River Site Phone: (803) Lloyd Gordon Vice Chairman, Electrical Safety Committee Los Alamos National Laboratory ESIP Project Area 5 Awareness/ Continuation Training Briefing to EFCOG ISM Working Group Electrical Safety Improvement Idaho Falls, Idaho October 11, 2006

FSS-ESH Project Area 5 Awareness/Continuation Training SCOPE I. Provide recommendation for a standardized approach for initial Electrical Safety Awareness and continuation training for non- electrical workers - Jackie McAlhaney II. Provide recommendations and materials for standardized approach for R&D Worker Electrical Safety Training - Lloyd Gordon

FSS-ESH I. Nonelectrical Worker Training Jackie McAlhaney Savannah River Site

FSS-ESH Project Area 5 Awareness/Continuation Training  Milestones : 1.Develop Recommended Approach for Initial and Continuation Electrical Hazards Awareness Training for Non-Electrical Workers - COMPLETE 2.Complete review of other industries approaches- COMPLETE 3.Develop and issue training materials and summary of good practices- COMPLETE 4.Issue implementation recommendations

FSS-ESH Project Area 5 Awareness/Continuation Training  Team Members: DOE: Ray Blowitski, EH-32 - LEAD Richard Lasky, EH-32 EFCOG: Jackie McAlhaney, WSRC – LEAD Lloyd Gordon, LANL – Co-LEAD David Mills, WSRCBill Reed, INL Paul Case, FHJim Bird, INL Bobby Gray, FHAbby Crumpler, BWXP Dennis Wiatrak, FHT. Carrona, LBNL INPO: George Mortensen

FSS-ESH Project Area 5 Awareness/Continuation Training  Recommended Approach: 1.Develop a General Training Module: Basic Electrical Safety for Non-Electrical Workers 2.Develop Targeted Training Modules for specific Non-Electrical Worker Groups 3.Identify and recommend other available training sources

FSS-ESH Project Area 5 Awareness/Continuation Training Specific Non-Electrical Worker Groups Targeted: Welders Painters Crafts (e.g., carpenters, pipefitters, construction workers, and including D&D workers) Laboratory Researchers and Engineers Excavation Workers Heavy Equipment Operators Radiological Workers Office and Administrative Personnel – Basic Module & Electrical Cord Safety

FSS-ESH Project Area 5 Awareness/Continuation Training Specific Modules Completed: General Electrical Safety Awareness Electrical Cord Safety Electrical Safety for Arc Welding and Plasma Cutting Laboratory Researchers and Engineers Electrical Safety for Excavation and Trenching Excavation for Skilled Worker Electrical Safety Working Near Overhead Power Lines Electrical Safety Awareness Study Guide (Instructors and Students)

FSS-ESH Project Area 5 Awareness/Continuation Training Supplementary Training Sources Available: NIOSH Electrical Safety Student Manual Construction Safety Council Booklet “Managing Power Line Hazards” Video “Boom Truck Contact with Overhead Power Line” Links to electrical safety information: – – –

FSS-ESH Project Area 5 Awareness/Continuation Training Team Recommendation: Post all training modules and resources on EFCOG Electrical Safety WEB site Communicate availability of training modules to all DOE facilities and stress use for non-electrical worker

FSS-ESH Project Area 5 Awareness/Continuation Training Module 1: General Electrical Safety Awareness: Introduces electrical terminology and how an electric shock can be received Emphasizes hazard potential with 120 Vac and low currents Provides graphic images of electrical burns Several electrical hazard scenarios for discussion Stresses importance of GFCI’s Stresses proper electrical cord control Stresses proper inspections prior to resetting breakers Response during electrical emergency Response to downed power lines

FSS-ESH Project Area 5 Awareness/Continuation Training Module 2: Electrical Cord Control: Short review of electric shock theory Emphasizes cord inspection prior to use Provides examples of cord hazards for discussion Proper plug installation and removal Stresses importance of GFCI’s and GFCI testing Multi outlet adaptors Stresses role of electrical safety officer for guidance

FSS-ESH Project Area 5 Awareness/Continuation Training Module 3: Electrical Safety for Arc Welder and Plasma Cutter: Discusses recent arc welding fatality Introduces touch potential and open circuit voltage Emphasizes safe practices for grounding with illustrations Emphasizes safe practices using welding cables Stresses importance of environmental conditions Stresses importance to protect others in area Stresses proper maintenance and modification control of equipment

FSS-ESH Project Area 5 Awareness/Continuation Training Module 4: Electrical Safety working near Overhead Power Lines: Discusses specific fatalities from contact with power lines Provides general planning for safe work Discusses importance of two barrier control system Emphasizes power line clearances Provides specific practices for operating cranes, dump trucks, material handling and use of ladders Emergency actions

FSS-ESH Project Area 5 Awareness/Continuation Training Module 5: Electrical Safety during excavation and trenching Discusses serious injuries from jackhammer event Identifies at-risk groups of workers Emphasizes practices to identify underground hazards Stresses proper field investigation and hand excavation where interferences known Stresses PPE

FSS-ESH Project Area 5 Awareness/Continuation Training Module 6: Electrical Safety for Skilled Worker: Introduces worker to 70E requirements and boundaries Stresses Lockout program Stresses safe practices using portable electrical tools Extension cord safe practices Discusses electrical intrusion events and specific examples Emphasizes importance to obey signs and barriers

FSS-ESH II. R&D Worker Training Lloyd Gordon Los Alamos National Laboratory

FSS-ESH Project Area 5 Awareness/Focused Training - R&D SCOPE  Provide recommendation for a standardized approach for Electrical Safety Modules on specific topics for workers in the R&D laboratory environment.  Provide recommendation for a standardized approach for training for contractor Electrical Safety Officers.

FSS-ESH What is an R&D Worker?  Scientists, engineers, technicians, and others who: – work in an R&D laboratory environment performing research and development, often with custom built, or state-of-the-art equipment.  The degree of electrical work can vary from: – the operation of custom built equipment, largely protected by engineering controls, to – the design, fabrication, and maintenance of custom built R&D equipment, to – working inside of R&D equipment as a part of the research process

FSS-ESH Electrical or Non-electrical Worker?  The difference between a facility electrical worker (e.g., electrician) and a facility non-electrical worker (e.g., welder, carpenter, heavy equipment operator) is clear. – An electrician/lineman has a formal licensing process. – An electrician/lineman’s job is electricity.  Experimental R&D workers learn some elements of electrical technologies in their academic education, especially in their specific fields. – There is no specific formal record of this electrical training. – They may know their specific equipment very well. – Working with electricity may only be a small part of their job.  Is the R&D worker a casual electrical worker?

FSS-ESH Some Statistics  R&D electrical workers may account for 90% of the DOE complex electrical workers, BUT  R&D workers account for less than 30% of the electrical events in the complex.  R&D electrical incidents tend to be shocks or near shocks (NOT LOTO, arc flash, or penetration/excavation)

FSS-ESH Project Area 5 Awareness/Focused Training - R&D  Recommended Approach: 1.Develop a General Training Module: Basic Electrical Safety for R&D Workers Most sites have a variation of this. 2.Develop Targeted Training Modules for specific R&D Worker Groups Few sites have these, need to be available. 3.Develop a Targeted Training Module for Electrical Safety Officers A few sites have this, need to be available. 4.Identify and recommend other available training sources

FSS-ESH Core Training for R&D Electrical Workers  All R&D sites have some form of basic training for R&D workers.  There is considerable variation in: – method of delivery (live class, self study, web-based) – length – retraining requirements (none to 3 years) – material (a function of a site’s electrical safety program requirements)  Problem! – No site accepts the electrical safety training from other sites. Some roving scientists have to take basic R&D electrical safety multiple times (example, accelerator scientists working at LANL, SLAC, BNL)

FSS-ESH Core Training for R&D Electrical Workers - cont.  As electrical safety programs become more consistent across the complex, some components of the core training for R&D electrical workers can be identical  Common elements of training can be available for use by any site: – electrical hazard classification – unlisted electrical equipment approval – PPE for R&D workers – ISM for electrical work  The ONLY unique aspect of R&D electrical safety training at a site are the site’s unique features of their program requirements.

FSS-ESH Project Area 5 Awareness/Focused Training - R&D 2. Specific R&D Topics Available: 1 - High Power (HV, HC, capacitor and inductor safety) 2 - RF and Microwave Safety 3 - Batteries and Battery Banks 4 - R&D Grounding and Shielding 5 - Computer Safety (CPU, monitors, ESD, and UPSs) 6 - Designing Safe R&D Equipment 7 - Basic Electrical Theory for R&D Workers 8 - Basic Facility Wiring Principles 9 - The Control of Hazardous Energy in the R&D Lab 10 - PPE for R&D Workers Based on NFPA 70E

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 1: High Power Electrical Safety : Covers the unique hazards encountered in the use of High Voltage, High Current, and High Power DC systems Includes capacitor and inductor stored energy hazards Includes electric and magnetic forces Includes unique hazards of Pulsed Power – Induced voltages and currents – Potential gradients – Generated EMI Covers capacitor hazard classification and proper PPE Includes material from DOE Electrical Safety Handbook

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 2: Radiofrequency and Microwave Safety: Presents the effects of rf shock and burn Covers the dangers of exposure to rf electromagnetic fields Provides tools for the identification of rf and microwave hazards Safe work practices are discussed Includes material from DOE Electrical Safety Handbook Covers the IEEE/ANSI C95 Standard, “Exposure to RF and Microwave Electromagnetic Radiation”

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 3: Batteries and Battery Banks: Covers the multitude of hazards associated with batteries and battery banks, including: – shock – burn – explosion – chemicals – environmental contamination Proper design and safe work practices are presented Covers battery hazard classification and PPE Covers the issues with UPS battery replacement including: – training requirements – procedures – proper disposal of batteries

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 4: R&D Grounding and Shielding : Covers the basics of electromagnetic interference (EMI), including conductive and radiative coupling. Basic techniques are presented for controlling EMI, inluding: – clean power (isolation transformers, isolated grounds, etc.) – grounding (single point grounds, ground loops, etc.) – shielding – filtering The focus of this module is finding solutions to EMI problems in data acquisition WITHOUT the violation of NEC requirements, especially in power delivery and grounding

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 5: Computer Safety : Hazard identification and safe work practices work working on computers are presented. Module is geared towards nonelectrical worker. Covers three main topics: – electrical hazards (shock) – ElectroStatic Discharge (ESD) – UPSs (maintenance, battery replacement, and disposal) Addresses the conflict between electrical safety and ESD safety

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module R&D 6: Designing Safe R&D Equipment : Covers guidelines to design and fabricate electrical equipment for laboratory use, that meets OSHA, NEC, and NRTL standards. Includes topics of overcurrent protection, enclosure, grounding, and protection of the operator. This course helps the designer builder meet requirements for the approval of unlisted electrical equipment.

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module 7: Basic Electrical Theory for R&D Workers : Covers the basics needed to understand and control electrical hazards in the R&D laboratory. Includes electrical parameters, electromagnetic fields, Ohm’s Law, impedance, induction, energy storage, resistive heating, conductors and dielectrics, and dielectric breakdown. It helps the worker understand principles that can be directly applied to laboratory electrical safety. Examples are chosen that are relevant, e.g., load calculations, daisy chaining, grounding, etc. This module is aimed towards the “nonelectrical” scientist, e.g., biologist, chemist, mechanical engineer, IH, etc.

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module 8: Basic Facility Wiring Principles : Addresses the basic principles, terminology, and requirements for facility wiring including: – overcurrent protection – types of outlets and plugs – single and three phase circuits – grounding This module is NOT for the electrician or NEC knowledgeable facility engineer. Explains common mysteries, such as – polarization – boot legging a ground – phase rotation

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module 9: The Control of Hazardous Energy in the R&D Lab : Covers the principles of OSHA , The control of hazardous energy Presents three methods of energy isolation: – plug control (material from DOE Electrical Safety Hnbk) – Lockout/Tagout – engineering controls (e.g., Kirk key systems) Discusses verification and zero energy checks Discusses the removal of capacitive stored energy

FSS-ESH Project Area 5 Awareness/Focused Training - R&D Module 10: PPE for R&D Workers Based on NFPA 70E : Discusses the principles from NFPA 70E for worker protection using PPE Discusses shock boundaries (limited, restricted, and prohibited) Adapts NFPA 70E shock boundaries for ac to dc Presents the principles of arc flash injury Presents methods of calculating arc flash boundaries for dc and capacitor systems Presents types and use of PPE for R&D work Discusses the hazards of facility work, and the need for additional training for facility workers

FSS-ESH Electrical Safety Officer Training  Two labs led the development of the training of Electrical Safety Officers (also know by other terms): – LANL (also used at BNL and ANL), beginning in 1998 – LLNL (also adapted by SLAC), beginning in 2000  Courses are 4 to 5 days  The most common element in this training is for the approval of unlisted electrical equipment: – basic codes and standards (NEC, OSHA, UL, etc.) – inspection and approval techniques – laboratory for equipment approval  Other training modules for ESOs include: – hazard classification – work control – lessons learned – managing a electrically safe work place

FSS-ESH QUESTIONS?