jackie mcalhaney vice chairman, senior electrical review board savannah river site phone: (803)...

Jackie McAlhaneyVice Chairman, Senior Electrical Review BoardSavannah River Site Phone: (803) 208-3389 E-Mail: [email protected]

Lloyd GordonVice Chairman, Electrical Safety CommitteeLos Alamos National Laboratory

ESIP Project Area 5

Awareness/

Continuation Training

Briefing to EFCOG ISM Working GroupElectrical Safety ImprovementIdaho Falls, IdahoOctober 11, 2006

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Project Area 5 Awareness/Continuation Training

SCOPEI. 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

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I. Nonelectrical Worker Training

Jackie McAlhaneySavannah River Site

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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

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Team Members:DOE: Ray Blowitski, EH-32 - LEAD

Richard Lasky, EH-32

EFCOG: Jackie McAlhaney, WSRC – LEAD

Lloyd Gordon, LANL – Co-LEAD

David Mills, WSRC Bill Reed, INL

Paul Case, FH Jim Bird, INL

Bobby Gray, FH Abby Crumpler, BWXP

Dennis Wiatrak, FH T. Carrona, LBNL

INPO: George Mortensen

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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

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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

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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)

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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:

– http://www.electrical-safety.org/– http://www.cdc.gov/elcosh/docs/hazard/safety_electricity.htm

l– http://www.osha-slc.gov/SLTC/electrical/index.html

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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

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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

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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

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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

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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

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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

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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

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II. R&D Worker Training

Lloyd GordonLos Alamos National Laboratory

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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.

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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

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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?

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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)

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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

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1. 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)

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1. 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.

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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

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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

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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”

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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

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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

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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

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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.

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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.

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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

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Module 9: The Control of Hazardous Energy in the R&D Lab :• Covers the principles of OSHA 1910.147, 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

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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

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3. 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

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QUESTIONS?

jackie mcalhaney vice chairman, senior electrical review board savannah river site phone: (803)...

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