Electrical Safety Program Baytown Site, Texas Houston Business Round Table

BMS TSS – Electrical Safety ProgramJohn Gallagher

February 11, 2009

Electrical Safety ProgramBaytown Site, Texas

Houston Business Round Table

Best Practice

OSHA


February 11, 2009

Electrical Safety Program

The program is designed for all personnel who work in an environment influenced by the presence of energized electrical equipment and empowers those personnel to work safely on the electrical equipment.

The focus of the program is directed toward the general features of a set of principles and controls that when practiced on a regular basis will lead people into the awareness and discipline to safely perform electrical work.

The program has been progressively implemented in three world scale Chemical facilities in both the USA and Canada and received a IEEE prize paper award at the 1986 PCIC Petroleum Industry Technical Conference.

The program recently recognized by OSHA as a best practice.


February 11, 2009

Presentation Outline

•Electrical Safety Statistics

•OSHA requirements

•The development of Electrical Safety in North America

•The development of one users Electrical Safety Program

•The Electrical Safety Program Standard and Procedures

•Designing the potential electrical hazard out of the equipment.

•Empowerment


February 11, 2009

Electrical Safety Program – NIOSH

108

296

192

2126230 6276

2458 2282

2458 2282

1068 1078

1012 5297

516795

2474 5547

0 2000 4000 6000 8000

Agriculture

Mining

Construction

Manufacturing

Transport

Wholesale

Retail

Finance, Insurance, Real Estate

Services

Electrical BurnsElectrical Shock

(N=18,360)(N=29,046)

Nonfatal Electrical Incidents, Industry Sector Versus Nature of Injury (U.S data) 1992-2002

[Source: Cawly and Homce, Trends in Electrical Injury, 1992-2002 PCIC-IEEE-2006-38]

Total=47,406


February 11, 2009

Electrical Safety Program – NIOSH


February 11, 2009

Edison took electricity out of the lab with the first commercially practical light bulb.Patented 1880


February 11, 2009

1900 1920 1940 1960 1980

NEC - 1897

NESC - 1913

OSHA-1970

NIOSH-1970

NFPA 70E-1979

Burn Center-1980

Milestones in the First 100 Years

Development of Electrical Safe Work Practices

IEC - 1904

1879

First commercially practical incandescent light bulb.


February 11, 2009

20001980 1990

Lee’s Paper - 1982

NFPA 70E-1988

Subpart S-1989

PCIC Safety Subcom.-1990

1st IEEE-IAS-ESW in Dallas 1992

NESF-1994

NFPA 70E-1995

Arc-Resistant Swgr. - 1997

ASTM F-1506 - 1998

Workshop. SE Asia - 1998

Yellow Book - 1998

Incident energy consensus - 2000

Milestones in the Past 28 Years

DuPont Safety Workshop, Chantilly -1991

Elect Hot Work Safety Program by JMG/LBMc - 1987



February 11, 2009

20082000 2004

NFPA 70E - 2000 NFPA 70E-2004

IEEE 1584-2002

Milestones in the Past 8 Years

IEEE/NFPA Collaborative Effort on AFH Issues

$3.2MM Contributions Rec’d for AFH Testing

15th Annual IEEE-IAS-ESW in Dallas


OSHA VPPBEST PRACTICE


February 11, 2009

Development in Electrical Safety OSHA & NFPA-70E

Occupational Safety & Health Administration

OSHA 29 CFR 1910.119 Process Safety ManagementOSHA 29 CFR 1910.137 Electrical Protective EquipmentOSHA 29 CFR 1910.145 Specification for Accident Prevention & TagsOSHA 29 CFR 1910.147 The Control of Hazardous Energy (LO/TO)OSHA 29 CFR 1910.254 Subpart Q – Welding, Cutting and BrazingOSHA 29 CFR 1910.269 Subpart R- Generation,& DistributionOSHA 29 CFR 1910.301 Subpart S thru 1910.399 - UtilizationOSHA 29 CFR 1926.400 Subpart K thru 1926.499 -OSHA 29 CFR 1926.950 Subpart V- Construction


February 11, 2009

OSHA Mandates for Electrical Safety

• Electrical equipment installed safe per recognized

installation and inspection is considered to be safe until:– Deterioration occurs– Unsafe acts are performed– Carelessness takes place

• OSHA directs that electrical equipment be de-energized before working on or near exposed electrical conductors or circuit parts


February 11, 2009

OSHA Mandates for Electrical Safety

• OSHA recognizes a few situations where it is infeasible to deenergize the electrical equipment while performing some tasks in proximity of “live” parts:– Performing diagnostics and testing (startup or troubleshooting)

of electric circuits that can only be performed with the circuit energized

– Work on circuits that form an integral part of a continuous process that would otherwise have to be completely shut down in order to permit work on one circuit or piece of equipment

– If deenergizing the electrical power could present a greater hazard than the potential hazard of working on or near exposed energized electrical conductors or circuit parts.


February 11, 2009

OSHA Recognition of NFPA 70E

• OSHA is revising the general industry electrical installation standard found in Subpart S of 29 CFR Part 1910. In the Wednesday, February 14, 2007 OSHA Final Rule, “The agency has determined that electrical hazards in the workplace pose a significant risk of injury or death to employees and that the requirements in the revised standard, which draw heavily from the 2000 Edition of NFPA 70E and the 2002 Edition of the NFPA 70 are reasonably necessary to provide protection from these hazards.” This final rule became effective August 13, 2007.

• “OSHA is responding to requests from stakeholders that the agency revise Subpart S so that it reflects the most recent editions of NFPA 70E and NFPA 70.”


February 11, 2009

NFPA 70E Standard for Electrical Safety

• National Standard for Electrical Safety• Consensus document and presents basis for OSHA CFR Subpart S

1910.331-335• Strategies

– Electrical Safe Work Condition– Training– Planning the work– Protective Equipment– Preventative Maintenance

• NEC• Fundamental principles of protection against

– Electric shock– Thermal effects – Overcurrent– Fault currents– Overvoltage


February 11, 2009

Development of Electrical Safety Program

•The development spans 22 years•Electrical Safety Standard

–Electrical Safety Principles–Controls–Responsibilities–Shock Hazard–Arc Flash Hazard–Definitions–Limits of Approach

•General and Specific Electrical Work Procedures•Electrical Safety Working Group

–Manage the Program–Select the electrical tools–Selects the electrical PPE–Develop general and specific Electrical Work Procedures

Training leading to Qualification


February 11, 2009

1986 1991

19851994


February 11, 2009

1995 2000


February 11, 2009

•

2004


February 11, 2009

Electrical Safety Program – Baytown Site

•One Electrical Safety Program for the Site (multi business site)

•Principles

•Controls

•Training to provide the awareness and discipline

•Simple Program that empowers people to work safely through awareness and discipline


February 11, 2009


The Electrical Safety Program is not designed for hands on live line work. It is designed for an integrated electrical system in a 24 hour continuous Petro-Chemical facility where every alternative is investigated before electrical energized work is authorized.

The majority of work performed in Baytown is:

– Troubleshooting an energized circuit

– Checking and testing for Isolation

– Applying temporary grounds

– Opening and closing Circuit breakers

– Resetting Overload relays


February 11, 2009

Electrical Safety Program - Principles

Principles of the programThe Electrical Safety Working Group uses the following principles to

implement the Electrical Safety Program.

Identify the Hazard

Each job must identify and focus on the Electrical Shock and Electrical Arc Flash Hazard.

Eliminate the Hazard (whenever possible)

The energized electrical work and potentially hazardous switching will be reviewed to determine if the hazard can be removed by design or by

establishing an electrically safe work condition.

Control the Hazard

When the electrical hazard cannot be eliminated by design or by establishing an electrically safe work condition, it will be controlled by qualified personnel using a well defined electrically safe work or electrical switching procedure.


February 11, 2009


Minimize the Severity of Potential Injuries

The severity of injuries when a potential hazard gets out of control during the execution of energized electrical work or potentially hazardous switching will be minimized by:

Wearing the correct personnel protective equipment

Minimizing the number of personal potentially exposed to the hazard within the arc flash hazard boundary to only those persons necessary to perform the work.

Maximize the ability to recover from an injury.

The ability to recover from an injury is maximized by:– The use of a second qualified person for Class A and a standby person

for class B, W, X and Y energized electrical work and electrical switching. Refer to S-056 Appendix “B”.

– The use of radios to communicate the status of the work.– Standby personnel qualified in the use of CPR.


February 11, 2009

Electrical Safety Program - Controls

•Electrical Safety Program (S-056 Site Procedure)•Electrical Safety Working Group

–Authority for electrical safety at the site.–Selection of PPE–Selection of Live Line Tool’s

•Electrical Work Procedures (EWP’s)•Electrical Switching Procedures (EWP’s)•Training leading to qualification•Restricting access of personnel into the Limited Approach Boundary•Arc Flash Hazard Analysis and Label’s


February 11, 2009

Electrical Safety Program - Training

•Classroom training–Two day class room. Training included “skits” performed by electrical supervisors and technicians on how and how not to perform electrical work. Actual equipment or equipment “mock ups” used.

•Computer based training –Automatic system that requires reader sign off and test.

–Records updated automatically

•Contractor training –Minimum requirement for contractors is the Electrical Safety Program.

–Procedures identified on ISTC WEB page.

• Training address qualified and unqualified workers


February 11, 2009

OSHA

• At OSHA’s hearing in 12/05, Dr. Heinz Ahlers of NIOSH, spoke about the effect of training on accidents. “In a majority of those instances the fatality involved the worker who had been appropriately trained for the exposure that he subsequently came in contact with and just was not following the training and the company policy involved”.


February 11, 2009


AWARENESS

DISCIPLINE


February 11, 2009

Electrical Safety Program – Overview

S-056 Electrical Safety ProgramAppendix A Limit of Approach

Appendix B Energized Electrical Work and Switching Classification

Appendix C Energized Electrical Work Permit

Appendix D Job Briefing

EWP-1 Electrical Safety Working Group

EWP-2 Arc Flash Hazard

EWP-3 Hazard Flash Analysis label

EWP-4 Personal Protective Equipment for Electrical Shock Hazards

EWP-5 Personal Protective Equipment for Electrical Arc/Flash Hazards

EWP-6 Electrical Emergency Release Procedure

EWP-7 Training and Qualification

EWP-8 Testing and Inspection of Temporary Wiring, Portable Electrical Equipment, Extension Cords, and Portable GFCI’s.

EWP-9 Electrical Documentation

EWP-10 Contractor Electrical Safety

EWP-11 Electrical W, X, Y Switching

EWP-12 High-Direct-Voltage (DC Hi-pot) Test on Power Cables

EWP-13 Demolition of Isolated Electrical Cables

EWP-14 Temporary Personnel Protective Grounds

EWP-15 Voltage-rated Test Equipment and Tools

EWP-16 Electrolysis

EWP-17 Basic Electrical Safety

EWP-18 Energized Electrical Work

EWP-19 Normal Electrical Switching S-56 Class Z

EWP-20 Inspection and Troubleshooting Inside a 480-volt MCC Bucket

EWP-21 Removing and Inserting a a 480-volt MCC Bucket

EWP-22 Removing or Replacing a bolted Non Hinged Cover to expose an energized component 301 to 150,000 volts

EWP-23 Testing for Absence of Voltage

EWP-24 Qualification Requirements to Enter Electrical Rooms

EWP-25 Repair Work 51-300 Volts

EWP-27 Operation of Equipment Near Power Lines

EWP-28 Ground Assurance Programs


February 11, 2009

S-056 “Electrical Safety Program”

Purpose: The Electrical Safety Program sets the minimum requirements to safeguard against electrical shock and electrical arc flash while installing, commissioning, maintaining and operating electrical equipment at the Bayer Baytown Industrial Park.

Scope: The electrical safety program applies to all Bayer employees and contractors whose job requires them to install, commission, operate, service, inspect or maintain electrical equipment including electrical power distribution equipment.


February 11, 2009


Procedures for all electrical work, energized electrical work, emergency work and electrical switching shall comply with this program.

This program does not cover: –Electrical work from 0-50 volts –Telephone company equipment owned and maintained by the telephone company –Utility electrical equipment owned and maintained by the utility company –Electrical equipment owned, maintained and operated by 3rd party operations


February 11, 2009


This procedure has four appendices:

Appendix A Limits of Approach

Appendix B Energized Electrical Work and Electrical Switching Classifications


Appendix D Energized Electrical Work Job Briefing


February 11, 2009

S-056 “Electrical Safety Program”Appendix A Limits of Approach

NOMINAL SYSTEM VOLTAGE/EQUIP. RANGE

LIMITED APPROACH BOUNDARY RESTRICTED APPROACH BOUNDARY

PROHIBITED APPROACH BOUNDRY

PHASE TO PHASE EXPOSED MOVABLE

CONDUCTOR

EXPOSED FIXED CIRCUIT PART

INCLUDES STANDARD INADVERTENT MOVEMENT ADDER

(NOTE #1)

Energized Part to Personnel – Distance in feet & inches

0 to 50V Not Specified Not Specified Not Specified

51V to 300V 10 ft. 0 in. 3 ft. 6 in. Avoid contact Avoid contact

301V to 750V (MCCs and Panel boards)

10 ft. 0 in 3 ft. 6 in. 1 ft. 6 in. 0 ft. 1 in.

301V to 750V (Low-voltage Switchgear)

10 ft. 0 in. 5 ft. 0 in. 2 ft. 0 in. 0 ft. 1 in.

751V to 15.0 kV 10 ft. 0 in. 5 ft. 0 in. 2 ft. 2 in. 0 ft. 7 in.

15.1 kV to 40 kV 10 ft. 0 in. 6 ft. 0 in. 3 ft. 0 in. 0 ft. 10 in.

40.1 kV to 145 kV 11 ft. 0 in. 10 ft. 0 in. 6 ft. 0 in. 3 ft.1 in.

NOTE #1: The restricted approach distance is the working distance used to calculate the incident energy. If closer work distances are required on specific equipment, a deviation is required that is authorized by the Baytown PCT Head. The deviation shall include new incident energy calculations and a written procedure for the specific task to be completed.

Limit Approach Boundary

Arc Flash Hazard Boundary

Restricted Space

Prohibited SpaceExposed

Energized Component

Prohibited Approach Boundary

Restricted Approach Boundaries


February 11, 2009

S-056 “Electrical Safety Program”Appendix B: Energized Electrical Work and Electrical Switching Classifications

Microsoft Excel Worksheet


February 11, 2009



{click on to view}

Microsoft Word Document


February 11, 2009


Appendix D ENERGIZED ELECTRICAL WORK JOB BRIEFING

{click on to view}



February 11, 2009

EWP-1 “Electrical Working Group”2.1 This Electrical Safety Working Group will manage and develop the

electrical safety program for the Baytown site to meet the S‑056 “Electrical Safety Program”. Contractors and third party personnel working at the Baytown BMS site will comply with the requirements of the Baytown BMS Electrical Safety Program.

4.0 The “Electrical Safety Working Group” will use the following principles to implement the Electrical Safety Program.

– Identify the hazard– Eliminate the hazard (whenever possible)– Control the hazard– Minimize the severity of potential injuries– Maximize the ability to recover from an injury


February 11, 2009

EWP-1 “Electrical Working Group”

RESPONSIBILITIES

The Electrical Safety Working group is responsible to develop and manage the following:

The Baytown BMS S‑056 “Electrical Safety Program”

Electrical Work Procedures (EWP)

Electrical Safety Training

Qualifications of personnel to perform electrical energized work and electrical switching

Selection of live line tools and temporary safety grounds

Selection of personnel protective equipment for energized electrical work and electrical switching

Electrical Arc Flash Hazard analysis

Label Electrical Equipment with an Arc Flash Hazard label


February 11, 2009

Electrical ShockElectrical Shock

• Over 30,000 non-fatal electrical shock accidents occur each year.

• Over 350 people die from electrocution each year.

• Electrocution remains the fourth (4th) highest cause of industrial fatalities.

• Most injuries and deaths could be avoided


February 11, 2009

EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”

This procedure identifies the use, field care, testing and inspection of electrical PPE required when performing energized electrical work and electrical switching.


February 11, 2009

EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”The Restricted Approach Boundary has two conditions, based on the

voltage system as follows:

Less than 750 volts

The qualified person must keep face and body trunk, including legs, outside of the Restricted Approach Boundary. The Restricted Approach Boundary can be penetrated by qualified persons with the persons arm and hand if wearing PPE and rubber insulating gloves approved for the voltage class and identified by procedure.

EXCEPTION: It is permissible to use the Class 00 or Class 0 rubber insulating gloves without the leather protectors, only if high finger dexterity is needed for the handling of small parts, and there is no potential for small parts to puncture, cut or tear the rubber glove; thereby permitting the energized part to contact the employee’s bare hand.


February 11, 2009

EWP-4 “Personal Protective Equipment for Electrical Shock Hazards”

Greater than 750 volts

The qualified person must keep all body parts outside the Restricted Approach Boundary.

The Restricted Approach Boundary can only be penetrated by qualified persons with live line tools or test equipment approved to the voltage class of the system being work on and operated to the manufacturer’s instructions.

The live line tools or test equipment must be operated by the qualified person wearing full PPE, including rubber insulating gloves approved for the voltage class with all body parts outside of the Restricted Approach Boundary.


February 11, 2009

Class 2 (17 kV) Insulating Rubber Gloves, with Leather Protectors


February 11, 2009

Arc-Flash

• As much as 80% of all electrical injuries are burns resulting from an arc-flash and ignition of flammable clothing

• Arc temperature can reach 35,000°F - this is four times hotter than the surface of the sun

• Fatal burns can occur at distances over 10 ft.• Over 2000 people are admitted into burn centers

each year with severe electrical burns• An Arc-flash also contains molten metal


February 11, 2009

EWP-2 “Arc Flash Hazard Analysis”

The purpose of the procedure is to document the custody, care, and use of the Bayer Baytown Power Distribution System Model (“Model”).

The Model is the electronic software representation of the entire Bayer Power Distribution System and is capable of providing short circuit calculations, arc flash boundaries, relay settings, circuit breaker settings, arc flash label information and other technical data.


February 11, 2009

EWP-3 “Hazard Flash Analysis Label”

The purpose of the label is to communicate in a consistent way, the electrical shock and arc flash hazards and limits of approach to energized components. This allows persons engaged in electrical work or switching to select the correct PPE.

– Breaker panels, MCC and Switchgear above 300 volts will be marked with the Arc Flash Hazard Analysis label.

– Electrical panels 50 volts to 300 volts will be marked with a label indicating the maximum voltage inside the panel. An Arc Flash Hazard Analysis label is not required on electrical panels 50 volts to 300 volts unless the circuit includes at least one 125KVA or larger transformer.


February 11, 2009

EWP-3 “Hazard Flash Analysis Label”

ARC FLASH HAZARD ANALYSIS LABEL


February 11, 2009

EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”

This procedure identifies the use, field care, testing and inspection of arc flash PPE that must be worn by BMS qualified personnel when they work inside the Arc Flash Protection Boundary. This procedure also applies to personnel who are not performing energized electrical work or switching, but are within the Arc Flash Protection Boundary.

Personnel who perform electrical switching directly on non arc-resistant switchgear are considered to be in the arc-flash protection boundary and have to wear arc flash PPE.


February 11, 2009

EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”Range of Calculated Incident Energy Cal/cm2

Personal Protective Clothing for Electrical Arc Flash Hazard

< 1.2Long sleeve shirt and pants, minimum 4.2 oz/yd2 Natural fiber (100% cotton)

Safety glasses

Hard hat

Voltage rated gloves rated for the circuit being worked on (EWP-4)

< 6.8 Energized Electrical Work

Flame-Resistant coveralls 5.9 oz/yd2 PBI@ 6.8 ATPV

Safety Glasses

Hard HatHood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)

< 40Electrical Switching only

Flame-Resistant Lab Coat 50” long - Stores part # (M) 40667850, (XL) 40667821, (3XL) 40891241 Safety Glasses Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183 Ear protection Gloves – Arc Flash Gloves – Stores part # (L) 80166940


February 11, 2009

EWP-5 “Personal Protective Equipment for Electrical Arc Flash Hazards”Range of Calculated Incident Energy Cal/cm2

Personal Protective Clothing for Electrical Arc Flash Hazard

< 40 Energized Electrical Work

Flame-Resistant pants - Stores part # (M) 80169680, (XL)80169702) (2XL) 80169737. Flame-Resistant flash jacket – Stores part # (M) 80167181 (XL) 80167629 (2XL) 80169435. Safety Glasses. Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling fan - Stores part # 40892183. Ear protection. Voltage rated gloves rated for the circuit being worked on plus glove leather protectors (EWP- 4)


Flame-Resistant pants- Stores part #(M) 81214825, (L) 81214892, (XXL) 81214965 Flame-Resistant flash jacket –Stores part # (M) 81214469, (L) 81214523, (XXL) 81214620. Safety Glasses. Hood complete with hard hat and polycarbonate insert complete with integral fresh air cooling fan - Stores part # 80167165. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)<


Flame-Resistant pants- Stores part # (M) 80169761, (XL) 80169605, (3XL) 80169664. Flame-Resistant flash jacket - Stores part # (M) 80169575, (XL) 80169494 (3XL) 80169532. Safety Glasses. Hood complete with hard hat and polycarbonate insert and complete with integral fresh air cooling air fan.- Stores part # 80167122. Ear protection. Voltage rated gloves rated for the circuit being worked on plus Glove leather protectors (EWP- 4)


February 11, 2009

Flash Suit Hood


February 11, 2009

ATPV in cal/cm2 – Level of Protection


February 11, 2009

BMS TSS PCT John Gallagher June 14, 2006

Electrical Hazard Analysis


February 11, 2009

Electrical Hazard Analysis - Purpose

To determine the minimum Personal Protective Equipment (PPE) when performing the following tasks on a 480 volt MCC:– Operating a circuit breaker with the door closed.

– Operating a circuit breaker with the door open.

– Work on energized parts inside a 480 volt MCC “bucket”.

– Inserting / Removing a 480 volt MCC “bucket”

– Removal of covers to expose bare exposed component.

– Resetting a O/L relay.



February 11, 2009

Flash Hazard Analysis – Principles Used

The following Principles from the Electrical Safety Program were used to perform the Electrical Hazard Analysis:

– Identify the electrical hazard.

– Eliminate the hazard wherever possible.

– Control the hazard if the hazard cannot be eliminated.

– Minimize the severity of the potential injuries.

– Minimize the severity of injury after the injury has occurred.



February 11, 2009

NFPA-70E (Ref NFPA-70E Handbook pg. 69-100)

NFPA-70E allows two methods to determine the required PPE.

1) Tables 130.7(c)(9)(A) in NFPA-70E.

2) Calculate the incident energy levels under Engineering supervision.

Programs must define the method and be consistent with the method that is used when conducting a Arc Flash Hazard Analysis.



February 11, 2009

Electrical Hazard Analysis - Conclusion

NFPA-70E tables can not be used on the Baytown electrical system.

The Baytown Electrical Safety Program will continue to calculate the Arc Energy / Flash hazard boundary under engineering supervision.

Non-Arc resistant gear is not designed / tested/listed to keep the door closed under arc fault conditions.



February 11, 2009

480 MCC

•Opening Door

•Circuit breaker on

• PPE Required - YES

•Inspection/Observation only

•Circuit Breaker on

•PCT Technician stood in front of open bucket within arc flash hazard zone.


•Testing and troubleshooting. Repair < 120 volt circuit.


•PCT technician stood in front of open bucket within arc flash hazard zone.


•Testing and troubleshooting. Repair < 120 volt circuit.

•Circuit breakers off

• PPE Required – NO after

establishing a safe working condition.

•Inspection/observation/amp probe reading/troubleshooting inside a vertical wire way.


•PCT Technician stood in front of open wire way within arc flash hazard boundary.

•PPE Required - YES

… … …


February 11, 2009

EWP-7 “Training and Qualification”

This procedure identifies the training and recertification requirements to meet the requirements of S-056 “Electrical Safety Program”.



February 11, 2009

EWP-10 “PCT Contractor Electrical Safety”•The Baytown Electrical Safety Program applies to all Contractors who work at the Baytown BMS Site

–Maintenance, Project (expense and Capital), Service work.

Microsoft PowerPoint Presentation


February 11, 2009

EWP-13 “Demolition of Isolated Electrical Cables”This procedure provides the methods to safeguard personnel and maintain continuity of electrical supply in adjacent energized equipment and cables during the demolition of isolated cable. This is achieved by the continuous identification of the circuit being demolished.

ATTACHMENT #1

Field end of cable

Switchgearor MCC end

of cable

Location of next cut between cut end and PVC

sleeve

Cut cable end

PVC Sleeve with red and white striped hazard tape applied


February 11, 2009

EWP-13 “Demolition of Isolated Electrical Cables”ATTACHMENT #2

Cables passing through cable block installed in wall.Outside Building

Cut made here inside building

Cable to be demolishedCut made here outside building

WALLCable Block

WALL

Inside Room

Note:The above sketch illustrates an incident that occurred in the MDI/MR-3 unit. A cable being demolished was cut inside the building. The technician then went outside the building and counted off the cables making the assumption the cable went straight through the cable block. However, the cable being demolished made a bend inside the cable block and exited the building on the side opposite to the point of entry inside the building.

The result was the technician cut the wrong cable.


February 11, 2009


Prior to any electrical work being started, the following principles will be reviewed and applied to the specific electrical job task to be completed:

Identify the electrical hazard.

Eliminate the hazard wherever possible.

Control the hazard if the hazard cannot be eliminated.

Minimize the severity of potential injuries.

Minimize the severity of injury after the injury has occurred.


February 11, 2009

Eliminate/Reduce the Potential Hazard

• Arc Resistant Switchgear (Note: not “Arc proof”)

• SF6 gas Switchgear

• High resistance grounding

• Current limiting devices (molded case breakers and fuses)

• Arc Flash Calculations

– <40 cal/cm^2

– Protective device coordination (may have to sacrifice)

• Finger safe fuses

• See through rigid barriers

• Insulated terminal covers


February 11, 2009


• Line side shutters

• Identify and label equipment that has more than one power source

• Removable insulated boots

• Grounding balls for temporary personnel protective grounds

• IR Windows

• Mimic panels

• Umbilical cords (Chicken Switch)

• Remote racking

• Control voltage <50V


February 11, 2009

Reduce/Eliminate the Potential Hazard

• Preventative and Predictive Maintenance:.– Partial Discharge Detection System: Installed at all

MV installations, Cable testing for partial Discharge activity is schedule for March 2008

– PM programs/software: the Power Distribution dept. developed details PM programs for substations and load centers, the programs include detailed work scopes as per NETA recommendations.

– Process Information: Use of DCS and Process Historian as enabling tools to facilitate data driven decisions verses making decisions on perceptions.


February 11, 2009

Reduce/Eliminate the Potential Hazard

• Use of remote CB control switches Chicken Switch


February 11, 2009


• AF Resistant gear (Sub 31)

Through the specification and design of internal arc classified switchgear, where the energy and emissions resulting from and internal arc are suitably vented away from the operator and/or people in the vicinity, the ‘safe’ working distance (flash boundary) can be effectively managed without the need for excessive PPE


February 11, 2009

Electrical Safety Program - Summary• Electrical Safety Working Group

• Principles

• Controls

• Classification of work/voltage rating/work group/requirements

• Training Leading to Qualification Leading to Awareness and Discipline Leading to empowerment.

• Arc Flash Hazard Analysis Label/PPE ATPV

• Simple program that empowers personnel to be responsible for their own safety.

• Designing the potential electrical hazard out of the equipment


February 11, 2009

Thank You

Electrical Safety Program Baytown Site, Texas Houston Business Round Table

Documents

Transcript of Electrical Safety Program Baytown Site, Texas Houston Business Round Table