Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Safety and Your Data Center Martin Conroy, CPQ AFCOM.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. l This presentation is intended to serve as an explanation and introduction to electrical safety. It is not intended to substitute for expert analysis or professional consultation. Information presented is accurate to the best of our knowledge and is based on review of industry-accepted data and studies. l Tier4 Data Center Group assumes no liability or responsibility whatsoever in connection with any use of this information l Each site requires engineering study to determine risk and hazard levels. Disclaimer

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Questions l Do you have workers install power cables on energized panels? (example: running new circuit for server rack?) l Do you have work/modifications performed on energized electrical systems? (example: upgrading power, UPS, generator systems?) l Do you commission live electrical systems (example: UPS, batteries, generators, PDU’s) l Do your UPS vendors service equipment while energized? l Do your employees have unrestricted access to areas where energized electrical equipment is open or being worked on? l Is you data center designed to allow electrical equipment to be de- energized without shutting down the IT loads? l Do you understand the potential risks, hazards and liabilities associated with these questions?

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Observations l Compliance with existing safety laws may require you to change how you manage, operate and design your data center l Data centers require large amounts of power and this increases safety risks l Data centers do not like to shut down and this increases electrical safety risks l Many people choose to ignore, deny or dismiss their responsibilities when it comes to electrical safety and this increases risks and liabilities Request: Please do not shoot the messenger!

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Facts Electricity will take path of any resistance –including you!! Electric current will always return to the source (utility transformer or separately derived source) Electricity flows in complete paths, if you complete the path you will get shocked! The earth is a ground fault current path!  The earth can conduct enough electrical current to electrocute a person  The earth shall not be considered as an effective ground-fault path. (An earth ground could or could not cause overcurrent devices to open)

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Statistics l Approximately 30,000 workers receive electrical shocks each year l 3600+ disabling electrical shock injuries per year l 2000+ workers are sent to burn centers due to arc-flash injuries/year l 1000+ electrical workers die each year from workplace accidents l 97% of all electricians have been shocked or injured on the job. l Estimated 10 arc-flash incidents / day in USA l 60% of workplace deaths are due to burn injuries l Medical costs can exceed $4M/person for severe electrical burns, total costs per electrical incident can exceed $15 million *Source NFPA, National Safety Council, Bureau of Labor Statistics, Littlefuse

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Statistics l The National Safety Council estimates that between 600 and 1,000 people die each year from electrocution. Of those killed with voltages less than 600V, nearly half were working on “exposed” energized circuits at the time the fatal injury occurred. Electrocution continues to rank as the fourth highest cause of industrial fatalities (behind traffic, violence/homicide, and construction incidents). l In year 2002 work injuries cost Americans $ 146.6 Billion

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electricity Risk Areas l Electrical Shock Hazards »Existing standards and practices address many of these risks l Arc Flash/Burn Hazards »Existing Standards and practices address some these risks l Arc Blast Hazards »Existing standards and practices address very few of these risks

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Risk issues l Both employer and employee risks l Injury or death to personnel l Rehab / disabilities l OSHA fines and citations l Lost / damaged equipment l Unplanned outages and repairs l Increased insurance and worker compensation costs l Expensive lawsuits

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Shock Hazards Most personnel are aware that there is a danger of electrical shock, even electrocution. It’s the one electrical hazard around which most electrical safety standards have been built. However, few people really understand just how little current is required to cause injury, even death. Actually, the current drawn by a 7.5W, 120V lamp, passing across the chest, from hand-to-hand or hand-to-foot, is enough to cause death by electrocution.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Shock Hazards The human body will conduct electrical current! A circuit path can be through both arms, through an arm or leg to ground, or through any body surface to ground. There is a certain current level at which an individual cannot voluntarily release from the circuit. This is the "no let go current" from which burns and death by electrocution can result. Studies have shown that the perception of electrical shock begins when the current through the affected parts of the body is about 0.002 amperes. When the current increases to about 0.015 to 0.020 amperes, it becomes impossible to let go of the circuit. At higher values of current, e.g. above about 0.100 amperes, ventricular fibrillation and/or heart stoppage will cause certain death.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Arc-Flash Hazards l Arc-Flash is an unexpected sudden release of heat and light energy produced by electricity traveling through air. l This explosive condition includes a broad spectrum of electromagnetic energy, plasma, fragments and a spray of molten materials. l Temperatures at the arc terminals can exceed 35,000 deg F, (4 times hotter than the surface of the sun) l Air and gases surrounding the arc are instantly heated and the conductors are vaporized causing a pressure wave called an Arc Blast.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Arc-Flash Hazards l Burns from direct heat exposure or clothing ignition. At distances of more than 10 feet, arc flash is capable of causing serious burns requiring skin grafts. l Loss of eyesight from UV light emitted by vaporized metal l Death l Equipment damage/outages l Fire

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Burn Hazard l First-degree burns are limited to the top layer of skin: »Signs and symptoms: These burns produce redness, pain, and minor swelling. The skin is dry without blisters. »Healing time: Healing time is about 3 to 6 days; the superficial skin layer over the burn may peel off in 1 or 2 days. l Second-degree burns are more serious and involve the skin layers beneath the top layer: »Signs and symptoms: These burns produce blisters, severe pain, and redness. The blisters sometimes break open and the area is wet looking with a bright pink to cherry red color. »Healing time: Healing time varies depending on the severity of the burn

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Burn Hazard l Third-degree burns are the most serious type of burn and involve all the layers of the skin and underlying tissue: »Signs and symptoms: The surface appears dry and can look waxy white, leathery, brown, or charred. There may be little or no pain or the area may feel numb at first because of nerve damage. »Healing time: Healing time depends on the severity of the burn. Deep second- and third-degree burns (called full-thickness burns) will likely need to be treated with skin grafts, in which healthy skin is taken from another part of the body and surgically placed over the burn wound to help the area heal. l Internal burns – muscle, organs, veins, »Could continue to burn after shock event due to internal heating

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Arc-Flash Metrics l The amount of instantaneous heat energy released by an Arc-Flash is called incident energy. l Expressed in calories per square centimeter (cal/cm²) l Five Hazard Risk categories (HRC 0 to 4) l Calculations are based on working distance of 18” from arc terminals

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Incident Energy Result 0.0033Amount of energy sun produces in 0.1 sec at the earth surface at the equator 1Finger tip exposed to cigarette lighter flame for one second 1.2Energy that will instantly cause 2 nd degree burn to bare skin 4Energy that will instantly ignite a cotton shirt 8Energy that will cause incurable 3 rd degree burn to bare skin

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. HRC - Hazardous Risk Categories Incident Energy cal/cm² Hazard Risk Category 0 to 1.20 1.21 to 41 4.1 to 82 8.1 to 253 25.1 to 404

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Arc-Blast Hazards l High energy arc-flash heats and expands air l Vaporized copper expands 67,000 times its mass when it changes from solid to vapor l Blast pressure can exceed 2000 pounds per square foot. l Blast speed can exceed 700 MPH l Injuries from falls or collision with equipment. An arc fault of 50 kA can accelerate a nearby worker at speeds of up to 110 mph.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Arc Blast Hazards l Hearing damage or total hearing loss from ruptured eardrums. The sound of a blast can exceed 160 dB. (Sounds above 140 dB cause hearing loss even with protective equipment.) l Lung collapse or scarring from the shock wave and inhalation of vaporized metal l Memory loss and other neurological damage from concussion l Injuries from flying shrapnel l Death l Equipment damage

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Safety Compliance Law, rules, regulation OSHA Installation codes, safe products, safe installation, inspections and enforcement Policies, procedures, training, risk analysis, qualified workers, PPE Scheduled maintenance, testing and replacement per manufacture and industry best practices

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. OSHA l Occupational Safety and Health Administration l OSHA Standard 29 CFR Part 1910, Subpart S addresses electrical safety work practices and maintenance requirements. l OSHA is the “Shall” with regards to electrical safety l OSHA is the law!

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. OSHA General Duty Clause 29 U.S.C. § 654, 5(a)1: Each employer shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees." Each employee shall comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this Act which are applicable to his own actions and conduct.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. OSHA General Duty Clause l 29 U.S.C. § 654, 5(a)2: Each employer shall comply with occupational safety and health standards promulgated under this act. l 29 U.S.C. § 654, 5(b): Each employee shall comply with occupational safety and health standards, and all rules, regulations, and orders issued pursuant to this Act which are applicable which are applicable to his own actions and conduct.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. NFPA 70 – 2008 National Electrical Code 90.1 Purpose » (A) Practical Safeguarding. The purpose of this Code is the practical safeguarding of persons and property from hazards arising from the use of electricity. » (B) Adequacy. This Code contains provisions that are considered necessary for safety. Compliance therewith and proper maintenance results in an installation that is essentially free from hazard but not necessarily efficient, convenient, or adequate for good service or future expansion of electrical use. » (C) Intention. This Code is not intended as a design specification or an instruction manual for untrained persons.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. NEC and Standards NEC 110.2 Approval - Equipment must be approved NEC 110.3 – Covers listing of equipment (UL, ETL, CSA, etc) NRTL – Nationally Recognized Testing Laboratory - UL, ETL, CSA

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. NFPA 70 – 2008 National Electrical Code l Article 110.16 Flash Protection. Electrical equipment, such as switchboards, panelboards, industrial control panels, meter sockets enclosures, and motor control centers that are in other than dwelling occupancies and are likely to require examination, adjustment, service, or maintenance while energized shall be field marked to warn qualified persons of potential electrical arc flash hazards. The marking shall be located so as to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment. FPN No. 1 - NFPA 70E-2009 Safety standard FPN No. 2 - ANSI Z535.4-1998 Product safety signs

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. NFPA 70E-2009 l Standard for Electrical Safety in the Workplace, provides assistance in determining severity of potential exposure, planning safe work practices, and selecting personal protective equipment. l Requires all information on labels including boundaries and PPE requirements. l Concentrates on safety requirements to protect employees. l This covers the “how” of electrical safety

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. NFPA 70B 2006 – Recommended Practice for Electrical Equipment Maintenance This recommended practice applies to preventive maintenance for electrical, electronic, and communication systems and equipment and is not intended to duplicate or supersede instructions that manufacturers normally provide. Systems and equipment covered are typical of those installed in industrial plants, institutional and commercial buildings, and large multifamily residential complexes.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. OSHA and NFPA requirements l Electrical Hazard Analysis »Analysis shall address all potential electrical hazards including shock, Arc-Flash, Arc-Blast, and burns. »NFPA 70E Article 110.8(B)(1) requires electrical hazard analysis within all areas of the electrical system that operate at 50 volts or greater. »The analysis will determine work practices, protection boundaries, exposure levels, personal protective equipment and other procedures. »The analysis provides the required information necessary for equipment labeling.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. IEEE Std 1584-2002 ( Guide for Performing Arc-Flash Hazard Calculations ) IEEE 1584-2002 was developed to help protect people from arc-flash hazard dangers. The predicted arc current and incident energy are used in selecting appropriate overcurrent protective devices and personal protective equipment, as well as defining safe working distance. Since the magnitude of the arc current is inherently linked with the degree of arc hazard, the arc is examined as a circuit parameter. Furthermore, since estimation are often useful, simple equations for predicting ballpark arc current, arc power, and incident energy values and probable ranges are presented in this work

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Four Protection Boundaries Flash Protection Boundary (FPB) Safe approach distance from energized parts <1.2 cal/cm² Three shock approach boundaries 1. Limited Approach Boundary Unqualified persons must be accompanied by a qualified person and use PPE 2. Restricted Approach Boundary Only qualified persons are allowed in this area and must use PPE 3. Prohibited Approach Boundary Work in this area considered the same as making direct contact with energized parts. Only qualified persons are allowed in this area and must use PPE

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. IEEE 1584 Level of PPE l This is the minimum level of Personal Protective Equipment in calories per centimeter squared, as evaluated in IEEE Standard 1584, with the intent to protect the worker from the thermal effects of the arc flash at 18 inches from the source of the arc l Note: Does not address the arc blast hazards

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Sample Table Min Incident Energy, cal/cm^2 Max Incident Energy, cal/cm^2 Risk Category Required Min Rating of PPE, cal/cm^2 01.20 1.2001414 4.001828 8.001253 25.001404 40.001and aboveNot Available

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. PPE l Personal Protective Equipment l Provides shock and arc flash burn protection l Suits are rated in cal/cm² l Electrically rated shoes, gloves l Resistant to flame and self-extinguishing l Thermal insulation from heat radiation l Over 40 cal = arc flash/blast that you cannot be protected from, you could be killed!

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Typical PPE Examples CategoryEnergy Level Typical PPE 0N/ANatural fiber ( cotton / wool ) long sleeve shirt & pants, safety glasses, hard hat, V-rated gloves 15 calFR shirt and pants, safety glasses, hard hat, V- rated gloves 28 calFR shirt and pants, face shield, hard hat, ear canal inserts, V-rated and leather gloves, leather work shoes, cotton underwear 325 calFR coverall over FR shirt and pants, flash suit hood, ear canal inserts, V-rated and leather gloves, leather work shoes, cotton underwear 440 calFlash suit over FR coverall over FR shirt and pants, flash suit hood, ear canal inserts, V-rated and leather gloves, leather work shoes, cotton underwear

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Steps to compliance l Understand and follow NFPA and OSHA guidelines »Allow only qualified individuals to perform work or be in vicinity of work »Establish a Safe Work Condition and work on system components de-energized whenever possible »Develop an Electrical Safety Policy and Program »Perform shock hazard and flash hazard analysis, available fault currents, hazard risks, shock and flash protection boundaries »Develop formal training for equipment operators, service technicians, vendors and any other employee that might come in contact with the identified hazard »Label equipment with required information »Use appropriate PPE, insulated tools, barriers, etc. »Use live work permits

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Live Work Permits l OSHA Standards require all work to be done with equipment de-energized except for two conditions l What qualifies for “live work”? »Testing (power must be on to take measurements) »If the risk involves MORE than one life, then you probably have the justification to work on live equipment. »Need valid justification for live work. »Financial and convenience reasons are not valid justifications for live work ! * l If the equipment must be worked on while energized, then you need a live work permit. * per OSHA interpretation letter

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Qualified Individuals l Qualified workers must be knowledgeable on the equipment and the hazards that exist and receive documented training.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Employee Training l An essential element in an effective electrical safety program is training. From both a legal and effective point of view, training records are important. Training should be based on the program and procedures in place within an organization. The training should focus first on increasing knowledge and understanding of electrical hazards and second on how to avoid exposure to these hazards. As a person completes a specific segment of training, a record should be established and maintained. An electrical safety program should accomplish the following objectives: Make personnel aware of the rules, responsibilities and procedures for working safely in an electrical environment;

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Documentation l Demonstrate the employer’s intention to fully comply with federal law; l Document general requirements and guidelines to provide workplace facilities free from unauthorized exposure to electrical hazards; l Document general requirements and guidelines to direct the activities of personnel, who could be either deliberately, or accidentally, exposed to electrical hazards; l Encourage, and make it easier for each employee to be responsible for his or her own electrical safety self- discipline.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Data Center Compliance Issues Major issue: Is “Live Work” justifiable ? l Option 1: »Shut down data center when doing electrical work and maintenance l Option 2: »Design data center so that majority of electrical system can be bypassed and de-energized without having to shut down IT equipment »Have well documented MOP’s – Methods of Procedures to perform bypass and shut down procedures. l Option 3: IF “Live Work” can be justified »Will have to limit size of electrical systems to HRC of 4 or less »Must follow all applicable electrical safety requirements »Must have “Live Work” permit, PPE, qualified workers, safety policies & program, MOP’s, Arc-Flash study, proper labeling, etc.

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Summary l Employers/owners have requirements including providing appropriate PPE l Employees have requirements l Contractors have requirements l Cannot transfer liabilities and responsibilities l Get trained! l Perform Electrical Hazard Analysis l Use appropriate PPE l Keep unqualified persons out of hazard areas

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Conclusions l Data Center industry will learn to adjust and adapt to the rules, requirements and laws concerning electrical safety. l Compliance with existing regulations and standards will increase the reliability of your data center. l Compliance will increase the safety of your data center. l In the end, let me leave you with one thought: “Human life trumps everything else”

Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Safety and Your Data Center Martin Conroy, CPQ AFCOM.

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Y our D ata C enter P artner © 2009 Tier4 Data Center Group, Inc. All rights reserved. Electrical Safety and Your Data Center Martin Conroy, CPQ AFCOM.

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