Sunday, March 29, 2015

The Proper Installation of Equipment is the Foundation to Electrical Safety

As I noted in last month’s blog, there are three components to ensuring personnel are safe from workplace hazards associated with equipment:
  • Proper Installation of Equipment (normal operation)
  • Proper Maintenance of Equipment (maintenance)
  • Proper Safety Procedures when working on or near Energized Circuits (abnormal operation)

The National Electrical Code (NFPA 70) describes the minimum requirements for the installation of equipment.  Components (e.g. circuit breakers, fuses, conductors, etc.), equipment (e.g. switchboards, industrial machines, control panels, surge protective devices, etc.), and systems (e.g. emergency power, etc.). All components, equipment, and systems have general and specific minimum requirements to ensure safe installation and operation.  While there are a number of general requirements, the three general requirements that I think are the most important to ensure that the equipment is safe for operation are Article 110.3, Article 110.10, and Article 110.16.

The first important requirements (NFPA 70, Article 110.3) is that equipment be suitable for the environment, of sufficient mechanical strength, and be installed and used in accordance with any manufacturer’s instructions, listing, or labeling requirements.  This broad requirement is intended to make sure that the equipment is used in accordance with its intended application.  For example, if an industrial machine is intended to be intended to be connected to a power source with a rated voltage of 208Y/120, 3-phase Delta, 4W+G, then connecting to a power source of another voltage can cause the machine to be inoperable or create a hazardous condition.

The second important requirement (NFPA 70, Article 110.10) is that the short circuit current rating (SCCR) of the equipment be equal to or greater than the short circuit (fault) current at the point of application.  If the analysis of the power system finds that the short circuit at a specific point in the power system is 33,500 A, then any equipment installed at that point must have a short circuit current must have a SCCR that exceeds 33,500 A.  Common values of SCCR range from 5,000 A to 200,000A.  The next closest SCCR value to 33,500 A is 42,000 A.

The third important requirement (NFPA 70, Article 110.16) is that specific equipment for use other than dwelling units shall be field marked to warn qualified persons of potential arcing hazards.  This includes switchboards, switchgear, panelboards, industrial control panels, motor control centers, and meter socket adapters.  Equipment labels should meet the requirements noted NFPA 70E, Standard for Electrical Safety in the Workplace, and ANSI Z535.4, Product Safety Signs and Labels.  The dangers associated with arc hazards are well documented. There are many changes that have been introduced and I will discuss those in more detail in the coming months.

Where I still see gaps related to electrical safety is ensuring that equipment is installed in accordance with the manufacturer’s requirements, and ensuring that the equipment has a SCCR that is equal to or greater than the short circuit (fault) current at the point of installation.  

If equipment is not installed properly and within its rating, then the foundation of electrical safety is on shaky ground.  Like any program, starting with a solid foundation provides the opportunity to be successful.  Ensuring that equipment is installed in accordance with the requirements detailed in the National Electric Code (NFPA 70) provides the solid foundation to ensure that your electrical safety program is successful.

If you have questions equipment design or installation, or issues related to electrical safety, send me an e-mail at cole3250@gmail.com.


Monday, February 23, 2015

The Trilogy of Electrical Safety

There are a number of changes that have been introduced in 2014 that will affect people working on or near exposed live (energized) circuits.  Over the next couple of months, I will explain a few of the most important changes detailed in NFPA 70E.  In general, the 2015 edition of The Standard for Electrical Safety in the Workplace (NFPA 70E) reflects changes that make sense.

Before looking at the details, one must consider a holistic approach to safety to obtain a complete picture.  There are three standards that affect the interaction of people with electrical hazards.  These are the National Electric Code (NFPA 70), The Standard for Electrical Safety in the Workplace (NFPA 70E), and Recommended Practice for Electrical Equipment Maintenance (NFPA 70B).  To workplace free from electrical hazards, one needs to make sure that all three standards are used.

The National Electric Code (NEC) provides the basic requirements to ensure that equipment is installed properly.  The NEC describes the “normal” operation of equipment.  When equipment is designed and installed in accordance with the NEC, at that point there is minimal potential electrical hazards: shock hazards or arcing hazards.  For example, an electrical panel installed in accordance with the articles in NFPA 70 Chapter 408 does not present a shock or arc flash hazard when the deadfront covers are properly installed. 


The Recommended Practice for Electrical Equipment Maintenance standard provides the basic requirements for properly maintaining equipment.  This includes the development of an electrical preventative maintenance (EPM) program and recommended practices for equipment and conductors.  NFPA 70B provides the requirements after the equipment has been installed and operated, and subsequently temporarily removed (de-energized) from service for maintenance.  For example, an electrical panel has been de-energized, locked out and tagged out, and is undergoing examination and testing of the panelboard itself, the internal molded case circuit breakers (MCCBs), and the conductors entering and exiting the panelboard.

The Standard for Electrical Safety in the Workplace provides the basic requirements for working on equipment in an “abnormal” condition.  It is an abnormal condition as the equipment is not being used as intended nor is it being maintained.  For example, an electrical panelboard undergoing voltage testing to determine if circuits are operating properly is an abnormal condition.  In this scenario, the deadfront covers are removed and personnel are exposed to live (energized) parts.  Because there is an interaction with exposed live (energized) circuits, there is a shock hazard risk and an arc flash hazard risk.


Many consider that the safety of personnel from shock and arc flash hazards are only associated with the practices detailed in The Standard for Electrical Safety in the Workplace.  However, this is not true.  Safety from electrical hazards starts with the proper installation of equipment, followed by the proper servicing and maintenance of the equipment.  When the equipment is properly installed and maintained, then qualified personnel following safe work practices and using proper personal protective equipment (PPE) can work on exposed live (energized) circuits under specific conditions.

Friday, January 2, 2015

Working IN Safety v. Working ON Safety – An Equipment Design Perspective

2014 was a very busy and exciting year for me.  I have helped a number of people and organizations this year in the control of hazardous energy (lockout tagout), lab equipment design, safety review of equipment.  Additionally, I have trained more than 300 people in basic electrical safety (including shock and arc flash hazards), arc flash hazard analysis, and electrical equipment design.

While I was putting together my plan for blog postings this year, I ran across a LinkedIN posting on “WorkingIn Safety v. Working On Safety” [1] that I thought was very informative and timely.  When we work in safety we are performing specific tasks.  Working IN Safety includes working on risk assessments, evaluating equipment to safety standards, performing functional safety testing, etc.

In contrast, Working ON Safety requires setting goals, establishing processes and procedures to ensure that the organization has the capabilities to meet the established goals.  This includes having the appropriate personnel and resources are dedicated to meet the established goals.

Goals should be established using the SMART system are:
  • Specific
  • Measureable
  • Attainable
  • Relevant
  • Time bound

Organizations that design, manufacturer, or sell equipment should have an organization goal of ensuring that the equipment designed or sold in 2015, when used in accordance with the defined operating conditions, does not create any hazards that would result in more than minor first aid.  The establishment of the aforementioned goal is more than ensuring that their products meet the defined safety requirements (National Electric Code or UL Standards).

For safety leaders, Working ON Safety in meeting this goal can include:
  • Obtaining and training the appropriate personnel
  • Ensuring that sufficient financial resources are available
  • Incorporation of equipment safety personnel into the design, development, manufacturing processes
  • Defining the methodologies that will be used to determine the safety of the equipment
    • Risk assessments
    • Failure Modes Effects Analysis (FMEA)
    • Process FMEA
  • Defining, developing, and establishment of an equipment validation and verification process
  • Creation of Product Safety review process

Organizations that design, manufacturer, or sell equipment play an important component in determining if people are injured while working.  Safety leaders who spend time Working ON Safety will play a pivotal role ensuring that ALL workplace injuries are reduced.


I hope everyone has a successful, prosperous and SAFE year! 

Reference:
  1. http://www.safetycultureexcellence.com/e/working-in-safety-vs-working-on-safety/