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

Advancing Electrical Safety Through Engineering

Electrical Safety for the 21st Century

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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

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Electrical Safety for the 21st 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

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Electrical Safety for the 21st 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

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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

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Risk Control Hierarchy –ANSI Z10

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Electrical Safety for the 21st 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.

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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 21st 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)

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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

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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

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Racking Breaker-Which Method?

Conventional Remote

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Remote Racking Video Demo

( Watch video to demonstrate a remote racking solution applicable to existing switchgear)

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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

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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

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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

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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

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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

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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

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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

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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

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Fluorescent Light Tester

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Troubleshoot fluorescent fixtures without dismantling

Tests lamp, ballast and pins Cost effective and enhance

safety Available Feb. 2012 ($200)

Moving Forward in the 21st Century

Prevention technology is available and should be our 1st choice when evaluating the electrical hazard

Our challenge in the 21st 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

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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

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Partial List of Resources

WWW.EFCOG.ORG/WG/ESH_ES WWW.CHICKENSWITCH.COM WWW.INOLECT.COM WWW.CBARCSAFE.COM WWW.BUSSMAN.COM WWW.MILWAUKEETOOL.COM WWW.UESYSTEMS.COM WWW.MELTRIC.COM WWW.FLUKE.COM WWW.GRACEPORT.COM WWW.HAWK-IR.COM WWW.IRISS.COM

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