Arc Flash and NFPA 70E

• Developed for MarquipWardUnited Field

Service Staff
Arc Flash and NFPA 70E • Installation and Troubleshooting in the field
• MWU FS doesd nott workk with
ith di
distribution
t ib ti or
MWU Shop Training switchgear
• Voltages below 600VAC (nominal)

Arc Flash Training Outline Times

1. Introduction
What is arc flash 4. Examples • Arc Flash Movie (30 sec)
Lock Out Tagout OSHA Style
Why do we need to follow the NFPA 5. PPE • Guys that had it happen (26 min)
70E GUIDELINES?
Head and Face
Arc Flash description
Eyes • Clothing Video (1min 30 sec)
2 Boundary descriptions
2. Body
Limited Gloves
• Gloves Video (9 min)
Restricted
Prohibited
Shoes • Live Accident Video (42 Sec)
Tools
Flash Protection
6. Application to FS
3. Flash Hazard Analysis PPE
NFPA Charts Supervision
Up to 240V Panel
Up to 600V Panel
Motor Control Center

Arc Flash Arc Flash – Something went wrong

1
 Screwdriver Slipped? It’s more than Electrical Safety!

Is it the Law? NFPA 70E – 2009 Edition

Standard
• Electrical Safety
• OSHA IS THE SHALL & Requirements for Employee
• NFPA 70E IS THE HOW Workplaces
IIndustry
d t consensus standards,
t d d such h as NFPA 70E
70E, – This requirement
req irement covers
co ers all aspects of
can be used by employers as guides to making worker safety associated with electrical
the assessments and equipment selections hazards in the workplace. Within this
required by the standard. Similarly, in OSHA standard are recommendations for
enforcement actions, they can be used as proper PPE (Personal Protective
evidence of whether the employer acted Equipment)
reasonably • http://www.nfpa.org
Interpretation of 07/25/2003

Why Now?
• While the potential for these explosions to occur has
existed as long as industrial and commercial applications
of electricity, two factors have pushed accident prevention
to the forefront.
• The first is a greater understanding of hazards and the risks
they pose to personnel. Research into blasts has been able
to quantify the powerful forces they unleash.
• The second factor is increased vigilance on the part of
OSHA.
• OSHA is using the requirements of NFPA 70E, the
industry's consensus standard for electrical safety, to judge
whether the employer "acted reasonably" in protecting its
workers from hazards. In many cases, this has resulted in
employers facing substantial fines after such accidents.
§1910.333
Selection and use of work practices --
electrical
“(a) General. Safety-related work practices shall be
employed to prevent electric shock or other injuries
resulting from either direct or indirect electrical
contacts, when work is performed near or on
equipment or circuits which are or may be
energized. The specific safety-related work
practices shall be consistent with the nature and
extent of the associated electrical hazards.”

2

1910.333(a)(1) Deenergized parts.
“Live parts to which an employee may be
exposed shall be deenergized before the
employee works on or near them, unless
the employer can demonstrate that
deenergizing introduces additional or
increased hazards or is infeasible due to
equipment design or operational
limitations.”
1910.333 (a)(1)
(a)(1)Note
Note 1:
“Examples of increased or additional
hazards include interruption of life
support equipment, deactivation of
emergency alarm systems, shutdown of
hazardous location ventilation
equipment.”

• Click on
product for
1910.333 (a)(1) Note 2: Infeasibility LOTO
“Examples of work that may be performed on or Procedure
near energized circuit parts because of
infeasibility due to equipment design or
operational limitations include testing of electric
circuits that can only be performed with the MWU Lock Out Procedures
circuit energized and work on circuits that form
an integral part of a continuous industrial
process in a chemical plant that would otherwise
need to be completely shut down in order to permit
work on one circuit or piece of equipment.”

Arc Flash Description Arc Flash Damage

3
OSHA regulations make it clear that, with very
few exceptions, equipment must be
deenergized before employees work on or
near it.
• When employers must make exceptions to the
above, the regulations also make it clear that it is the
employer's
employer s responsibility to evaluate the workplace
for hazards and protect workers from these hazards.
This requires:
– A hazard/risk assessment for the electrical
hazards associated with energized work
– selection of appropriate personal protective
equipment (PPE)
(B) Type of Training
• The training required by this section shall
be classroom or on-the-job type, or a
combination of the two.
• The degree of training provided shall be
determined by the risk to the employee
(D) Employee Training
• Qualified Person: A qualified person shall
be trained and knowledgeable of the
construction and operation of equipment
or a specific work method and be trained
to recognize and avoid the electrical
hazards that might be present with respect
to that equipment or work method.
(A) Safety Training
(A)Training requirements apply to employees who face
a risk of electrical hazard that is not reduced to a
safe level by the applicable electrical installation
requirements.
((B)Such
) employees
p y shall be trained to understand the
specific hazards associated with electrical energy
(C)They shall be trained in Safety related work
practices and procedural requirements as necessary
to provide protection from the electrical hazards
associated with their job or task assignments
(D)Employees shall be trained to identify and
understand the relationship between electrical
hazards and possible injury.
(C) Emergency Procedures
• Employees exposed to shock hazards shall
be trained in methods of release of victims
from contact with exposed electrical
conductors or circuit parts
• Employees shall be regularly instructed in
methods of aid and emergency procedures,
such as approved methods of resuscitation if
their duties warrant such training.
• Training of employees in approved methods
of resuscitation, including CPR, shall be
certified by the employer annually
(D)(1)(a)
• Such persons shall also be familiar with
the proper use of the special precautionary
techniques, PPE, including arc flash,
insulating and shielding materials
materials, and
insulated tools and test equipment.
• A person can be considered qualified with
respect to certain equipment and methods
but still be unqualified for others.
4

(D)(1)(c)
• Such persons permitted to work within the Limited Approach
Boundary of exposed live parts operating at 50 Volts or more,
shall, at a minimum, be additionally trained in all of the following:
1) The Skills and techniques necessary to distinguish exposed
energized parts from other parts of electrical equipment.
2)) The skills and techniques
q necessary y to determine the nominal
voltage of exposed live parts.
3) The approach distances specified in tables 130.2(c) and the
corresponding voltages to which the qualified person will be
exposed.
4) The decision-making process necessary to determine the
degree and extent of the hazard and the PPE and job planning
necessary to perform the task safely
Qualified Person
• Trained and Knowledgeable of the construction and
operation of equipment
• Trained to recognize and avoid the electrical hazards
that might be present
• Trained in emergency release procedures and First
Aid/CPR (certified annually)
• You may be qualified for one task but not for another
• To work within the Limited distance
– Distinguish exposed energized parts
– Determine Nominal Voltage
– Approach distances for corresponding voltages
– Determine the degree and extent of the hazard and PPE
required and job planning to perform the task Safely

There are specific steps NFPA 70E dictates to

Qualified Vs Unqualified ensure an electrically safe working condition
exists
1) Hot or not • Determine all possible sources of supply
• Open disconnecting device(s) for each source (deenergize)
2) Nominal voltage • Where possible, visually verify device is open
• Apply lockout/tagout devices
3) Distances • Test voltage on each conductor to verify that it is de-energized
• Apply grounding devices where stored energy or induced voltage could
4) PPE needed exist or where de-energized conductors could contact live parts.
• Establishing these safety procedures is part of the company safety plan
that must be in effect for each facility:
– Employers must formalize procedures and practices such as the qualification
of employees to work in hazardous areas, tasks they may perform, steps
needed to secure management approval for work to be done and audits.
– Employers must provide training for employees in the skills and techniques
needed to work with electrical equipment, equipment details and emergency
procedures.
– Employees must implement the practices according to the training.
– Companies must perform a flash hazard analysis before work is done on any
energized equipment.

Warning Label for energized Example 2

Equipment (Required)
• Sign a customer
placed on the
Singlefacer
Blower Circuit
Breaker box
• Note numbers
and Category!
• (Very Nice)

5
 What is an ARC FLASH
• When insulation or isolation between
electrified conductors is breached or can
no longer withstand the applied voltage,
an arc flash occurs.
occurs
• As employees work on or near energized
conductors or circuits, movement near or
contact with the equipment, or a failure of
the equipment, may cause a phase-to-
ground and/or a phase-to-phase fault.
Sequence of events
• Power feeds through a circuit breaker or fuse
• Something down stream of the protective
device shorts phase to phase or to ground
• The
Th protective
t ti device
d i ttakesk some ti time to
t
react (CB typically 6 cycles or 0.1 sec)
• Between the time of the short and when the
CB opens, how many Amps flow?
• Ohms Law V=IxR or V÷R=I

• The photograph
shows a side view of
Play 480 Arc Flash Movie an equipment rack
during an arc flash
explosion.
• 480 VAC same as our plants
• The actual fault current in the above
demonstration is not known, but is likely in
the range of 10,000 amps which is similar
to what our breakers may let through in a
case of short circuit
Photograph provided by Square D / Schneider Electric

What happens
• The temperature of an arc can reach more than
5000 F (some up to 35000F) as it creates a brilliant
flash of light and a loud noise.
• Copper melts around 2000F and boils about 4600F < 740 mph
IR
• An enormous amount of concentrated radiant
energy explodes outward from the electrical
equipment, spreading hot gases, melting metal, 15000 °C
C 165 db
Visible
causing death or severe radiation burns, and
creating pressure waves that can damage hearing
UV
or brain function and a flash that can damage 1000 °C
eyesight.
• The fast-moving pressure wave also can send
loose material such as pieces of equipment, metal
tools, and other objects flying, injuring anyone
standing nearby. 2000 psf 50 cal/cm2

6
 How they measure Arc Flash
• Incident energy is expressed in calories per centimeter squared • If this happens when
(cal/cm²). you are in the panel
• The flash protection boundary is the point at which the energy
number is 1.2 cal/cm², equating to a second-degree burn.
the Arc Flash is in
your face,
• As workers get closer to the energized
equipment, that energy figure rises. arms/hands, chest,
• This boundary is different for different types of equipment and and possibly legs
legs.
depends in part on the voltages involved.
• Typically, the higher the voltages, the larger the danger zone.
• A 10,000 A arc at 480 V is equivalent to 8 MW or
approximately eight sticks of dynamite, noted John
Lane, electrical safety engineer at AVO Training
Institute, Dallas, TX.
Photograph provided by Square D / Schneider Electric

• Because of electrical
Arc Flash and Electrical Safety safety and the
released energy
• Electrical safety is to keep you and the during an arc flash
electrons separated. Shock Hazard explosion, boundary
areas are defined.
• Arc Flash is to protect you from the fire
ball caused by a catastrophic fault
fault.
• Remember this when we refer to the PPE • Limited Approach
requirements, PPE is for the fire ball more • Restricted Approach
than for the shock hazard. • Prohibited Approach
– (Exception - gloves and tools) • Flash Protection
Photograph provided by Square D / Schneider Electric

Boundary Description
Flash Protection Boundary
• For systems that are 650V or less, the Flash
Protection Boundary shall be 4 feet unless a
Flash Analysis is performed.
• There must be a barricade to prevent entry to
the Flash protection Boundary.
• This is for the Flash, Flames and Fireball.

7
 Limited Approach Boundary
• Limited Approach Boundary is the closest
distance an UNQUALIFIED person can
approach an energized conductor or circuit
part.
• For our equipment the Limited Approach
Boundary is set at 3 feet 6 inches
– 1.07 meters or 42”
Restricted Approach Boundary
• Restricted Approach Boundary is the closest
distance to exposed live parts a QUALIFIED
person can approach WITHOUT proper PPE
and tools. (PPE for Shock i.e. gloves!)
• Inside this boundary, accidental movement can
put a part of your body or conductive tools in
contact with live parts or inside the prohibited
approach boundary.
Prohibited Approach Boundary
• Prohibited Approach Boundary is the
minimum approach distance to exposed live
parts to prevent flashover or arcing.
• Approaching any closer is comparable to
making direct contact with a live part.
Exposed (Live Parts)
• NFPA 70E Definition
• Exposed – Capable of being inadvertently
touched or approached nearer than a safe
distance by a person. It is applied to parts
that are not suitably guarded, isolated or
insulated.
Restricted Approach Boundary
To cross the restricted approach boundary, the qualified
person must:
• Have a documented plan that is approved by the
manager responsible for the safety plan.
• Use PPE suitable for working near exposed live
parts and rated for the voltage and energy level
involved.
• Be certain that no part of the body enters the
prohibited space.
• Minimize the risk from unintended movement, by
keeping as much of the body as possible out of the
restricted space; body parts in the restricted space
should be protected.
Prohibited Approach Boundary
To cross the prohibited approach boundary, the qualified
person must:
a. Have specified training to work on exposed live
parts.
b. Have a documented plan with proper written work
procedures
d and
d justifying
j tif i the
th needd tto workk
energized. This is a work permit.
c. Do a written risk analysis. Document this.
d. Have (b) and (c) approved and signed by
management.
e. Use PPE appropriate for working near exposed live
parts and rated for the voltage and energy level
involved.
8
 Safety
• Strange as it may seem, most fatal The Effects of Shock
electrical shocks happen to people
who should know better. • Immediate • Long term
– Muscle contraction – Memory Loss

• It
It'ss not the voltage but the – Vital organs
g
Lungs, etc.)
((Heart,, –
–
Nervous disorders
Chemical imbalances
current that kills. – Tingling
– Pain
– Damage to vital
organs
• People have been killed by 100 volts AC – Breathing – Sometimes Fatal
in the home and with as little as 42 volts – Disorientation
– Dizziness
DC.

Effects of Current on the Body Why 50 volts?

Men Women • Ohm’s Law for Electric current (amps), voltage and
• Perception Threshold • Perception Threshold Body Resistance
– 0.001 Amps (1 mA) – 0.0007 Amps (0.7 mA) • The typical body has a contact resistance of 500
• Painful Shock • Painful Shock ohms at the point of contact with the electrical
– 0.009 Amps (9 mA) – 0.0012 Amps (1.2 mA) source.
• The body has an internal resistance of approximately
• Cannot Let-Go Level 100 ohms.
0.010 Amps (10 mA) • There is another point of contact to ground of maybe
• Ventricular Fibrillation 5000 ohms.
0.100 Amps (100 mA) 3 Seconds – 120v / (500Ω+ 100Ω+ 5000Ω) = 21mA
0.200 Amps (200 mA) 1 Second – 50v / (500Ω+ 100Ω+ 5000Ω) = 8.9mA
• Heart Failure • It is around 10mA that the “cannot let go” level is
0.5 Amps (500 mA) reached
• Organ Burn and Cell Breakdown • Once lock up occurs, exposure time is increased and
1.5 Amps (1500 mA) the possibility of electrocution may occur.

130.1 (3) Exemptions to Work Permits

Question!
• Work Performed on or near live parts by
qualified persons related to tasks such as:
– Testing
– Troubleshooting
g
– Voltage Measuring (etc.)
Does Electricity take the path of least resistance?
• Shall be permitted to be performed without
an energized electrical work permit
provided appropriate safe work practices
and PPE (IAW Chapter 1) are provided and
used.

9
 Table 130.2(C) Approach Boundaries to Live
Electrical and Arc Flash Parts for Shock Protection
• Boundary areas for Electrical safety
– Limited Approach
– Restricted Approach
– Prohibited Approach
• Boundary area for Arc Flash protection
– Flash Protection
• For us, the Flash Protection Boundary is
more limiting than the Limited or
Restricted area Boundaries

Boundary Distances Performing a Flash Hazard Analysis

• Boundary area for Arc Flash protection • NFPA 70E requires facility owners to
– Flash Protection 4 Feet
perform a flash hazard analysis prior to
• Boundary areas for Electrical safety allowing a worker to work on energized
– Limited Approach 3’-6”
equipment.
Restricted Prohibited
A
Approach h A
Approach h • The analysis is necessary for determining
the flash protection boundary distance and
<50V Not Specified Not Specified type of PPE required.
• To establish this information, an incident
<300V Avoid Contact Avoid Contact
energy calculation is generally necessary.
<750 One foot One inch

Hazard
15 A 480V CB
Analysis
• What does 15 Amp
mean?
• Power Limits
• 240 AC 18K • Transformers
• 480 AC 14K • Wire lengths
• 250 DC 10K • CB’s or Fuses
• Interrupting capacity • Line Layout

10
 Hazard/Risk Category Hazard/Risk Category
Classifications Classifications
• The best method of assigning the Hazard/Risk • Each Hazard/Risk has increasing danger
Classifications is an Incident energy analysis of and increased PPE requirements
130.3 (B) (1)
• Hazard Risk 0 (<4 cal/cm²)
• In Lieu of the analysis
y this table must be used.
• The Notes section lists assumptions that must • Hazard
H d Ri
Risk
k 1 (4 cal/cm²)
l/ ²)
be met. • Hazard Risk 2 (8 cal/cm²)
• For tasks not listed or for systems with greater • Hazard Risk 3 (25 cal/cm²)
than the assumed max currents or clearing
• Hazard Risk 4 (40 cal/cm²)
times, an analysis must be done.

NFPA 70E – Hazard Risk 1 Panel boards Rated 240V and Below
(4 cal/cm²) Tasks Performed on Energized Equipment

• This hazard risk category Panelboards or Other Equipment Rated 240 V and Hazard/Risk
Category
Rubber
Insulating
Insulated and
Insulating Hand

poses some risk. Some

Below –Note 1
Gloves Tools

examples of tasks in this

Perform infrared Thermography and other non-contact 0 N N
inspections outside the restricted approach area

category are tasks that Circuit breaker (CB) or fused switch operation with covers on 0 N N

involve:
CB or fused switch with covers off 0 N N
Work on energized electrical conductors and circuit parts, 1 Y Y
– Circuit breaker or fused
including voltage testing
R
Remove/install
/i t ll CBs
CB or fused
f d switches
it h 1 Y Y
switch operation with Removal of bolted covers (to expose bare, energized electrical 1 N N
covers off when working conductors and circuit parts)

with Panel boards rated Opening hinged covers (to expose bare, energized electrical
conductors and circuit parts)
0 N N

240 V and below. Work on energized electrical conductors and circuit parts of
utilization equipment fed directly by a branch circuit of the
1 Y Y

– Opening hinged covers (to panelboard

expose bare, energized • (a) Rubber insulating gloves are gloves rated for the maximum line-to-line voltage which work will be done.
• (b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line voltage upon
parts) when working with which work will be done, and are manufactured and tested in accordance with ASTM F 1505, Standard
"Other 600 V Class (277 V •
Specification for Insulated and Insulating Hand Tools.
(f) For equipment protected by upstream current limiting fuses with arcing fault current in their current limiting
through 600 V, nominal) range (1/2 cycle fault clearing time or less), the hazard/risk category required may be reduced by one number.
Equipment. • Note1. Maximum of 25 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing time.

Table 130.7(C) (9) Notes You do need gloves for 120V

• General Notes (applicable to the entire table):
• (a) Rubber insulating gloves are gloves rated for the maximum line-to-line voltage which work will
be done.
• (b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line
voltage upon which work will be done, and are manufactured and tested in accordance with ASTM
F 1505, Standard Specification for Insulated and Insulating Hand Tools.
• (c) Y=yes (required), N=no (not required).
• (d) For systems raged less than 100 volts, the fault currents and upstream protective device
clearing times are based on an 18 in. working distance.
• ( )F
(e) For systems
t rated
t d 1 KV andd greater,
t the
th Hazard/Risk
H d/Ri k C
Categories
t i are b basedd on a 36 iin.
working distance.
• (f) For equipment protected by upstream current limiting fuses with arcing fault current in their
current limiting range (1/2 cycle fault clearing time or less), the hazard/risk category required may
be reduced by one number.
• Specific Notes (as referenced in the table):
• 1. Maximum of 25 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing
time.
• 2. Maximum of 65 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault clearing
time.
• 3. Maximum of 42 kA short circuit current available; maximum of 0.33 sec (20 cycle) fault clearing
time.
• 4. Maximum of 35 kA short circuit current available; maximum of up to 0.5 sec (30 cycle) fault
clearing time.

11
 NFPA 70E – Hazard Risk 2 Panel boards or Switchboards Rated Between
(8 cal/cm²) 240V and 600V
• This hazard risk category involves Panelboards Or Switchboards Rated >240 V and up Hazard/Risk
Category
Rubber
Insulating
Insulated and
Insulating Hand

tasks that pose a moderate risk.

to 600 V (with Molded case or insulated case circuit
Gloves Tools
breakers) – Note 1

Some examples of tasks in this

Perform infrared Thermography and other non-contact 1 N N
inspections outside the restricted approach area
CB or fused switch operation with covers on
category are tasks that involve:
0 N N
CB or fused switch with covers off 1 Y N

– Circuit breaker or fused switch Work on energized electrical conductors and circuit parts,
including voltage testing
2*
2 Y Y

operation with enclosure doors closed Work on energized electrical conductors and circuit parts of
utilization equipment fed directly by a branch circuit of the
2* Y Y

when working with 600 V Class Motor

panelboard

Control Centers (MCCs).

– Work on control circuits with energized Legend:
• Voltage-rated gloves are gloves rated and tested for the maximum line-to-line voltage upon which work will be done.
parts 120 V or below, exposed when •
•
Voltage-rated tools are tools rated and tested for the maximum line-to-line voltage upon which work will be done.
2* A double-layer switching hood and hearing protection are required for this task in addition to the other hazard/risk
working on Metal Clad Switchgear, 1 category requirements.
Notes:
kV and above •
•
1. 25 kA short-circuit current available, 0.03 second (2-cycle) fault-clearing time.
2. 65 kA short-circuit current available, 0.03 second (2-cycle) fault-clearing time.
• 3. For less than 10 kA short-circuit current available, the hazard/risk category required may be reduced by one number

600 V Class Motor Control Centers

600 V Class Switchgear
Hazard/Risk Rubber Insulated and
Category Insulating Insulating Hand Hazard/Risk Rubber Insulated and
600 V Class Motor Control Centers (MCCs) – Note Gloves Tools Category Insulating Insulating Hand
2 (except as indicated) 600 V Class Switchgear (with power circuit breakers Gloves Tools

Perform infrared Thermography and other non-contact or fused switches) – Note 4

1 N N
inspections outside the restricted approach area Perform infrared Thermography and other non-contact 2 N N
CB or fused switch or started operation with enclosure doors inspections outside the restricted approach area
0 N N
closed CB or fused switch operation with enclosure doors closed 0 N N
Reading a panel meter while operating a meter switch 0 N N Reading a panel meter while operating a meter switch 0 N N
CB or fused switch or started operation with enclosure doors 1 N N CB or fused
f d switch
i h operation
i with
i h enclosure
l doors
d open 1 N N
open
Work on energized electrical conductors and circuit parts, Work on energized electrical conductors and circuit parts, 2* Y Y
2* Y Y including voltage testing
including voltage testing
Work on control circuits with energized electrical conductors Work on control circuits with energized electrical conductors 0 Y Y
0 Y Y and circuit parts 120 V or below, exposed
and circuit parts 120 V or below, exposed
Work on control circuits with energized electrical conductors Work on control circuits with energized electrical conductors 2* Y Y
2* Y Y and circuit parts >120 V , exposed
and circuit parts >120 V , exposed
Insertion or removal of individual starter “buckets” from MCC Insertion or removal (racking) of CBs from cubicles doors 4 N N
4 Y N open or closed
– note 3
Application of safety grounds, after voltage test Application of safety grounds, after voltage test 2* Y N
2* Y N
Removal of bolted covers (to expose bare, energized electrical Removal of bolted covers (to expose bare, energized electrical 4 N N
4 N N conductors and circuit parts) – Note 3
conductors and circuit parts) – Note 3
Opening hinged covers (to expose bare, energized electrical Opening hinged covers (to expose bare, energized electrical 2 N N
1 N N conductors and circuit parts) – Note 3
conductors and circuit parts) – Note 3
Work on energized electrical conductors and circuit parts of 2* Y Y
utilization equipment fed directly by a branch circuit of the
motor control center

Other 600 V Class Equipment Equipment over 600 V

Tasks Performed on Energized Equipment Hazard/Risk Rubber Insulated and
Other 600 V Class (277 V through 600V, nominal) Hazard/Risk Rubber Insulated and
Category Insulating Insulating Hand
Equipment – Note 2 (except as indicated) Category Insulating Insulating Hand
Gloves Tools
Gloves Tools
Charts for voltages over 600 V exist but have not Up to 4 See Chart See Chart
Lighting or small power transformers (600 V,
been included
nominal)

Removal of bolted covers (to expose bare, energized electrical 2* N N

conductors and circuit parts)
Opening hinged covers (to expose bare
bare, energized electrical 1 N N
conductors and circuit parts)
Work on energized electrical conductors and circuit parts,
including voltage testing
2* Y Y • From my understanding our facilities are 460 V
Application of safety grounds, after voltage test 2* Y N (575V for Canadian machines)
Revenue meters (KW-hour, at primary voltage and current) 2* Y N
Insertion or Removal
Cable trough or tray cover removal or installation 1 N N
• Maintenance may deal with some switchgear at
Miscellaneous equipment cover removal or installation 1 N N higher voltages, in which case they need to look
at the tables or have an analysis performed
Work on energized electrical conductors and circuit parts, 2* Y Y
including voltage testing
Application of safety grounds, after voltage test 2* Y N
Insertion or removal of plug-in devices into or from busways 2* Y N

12
 NFPA 70E – Hazard Risk 3
(25 cal/cm²)
NFPA 70E – Hazard Risk 4
• This hazard risk category involves (40 cal/cm²)
tasks that pose a high risk. Some • This hazard risk category
examples of tasks in this category represents tasks that pose the
are tasks that involve: greatest risk. Some examples
of tasks in this category are
– Insertion or removal of circuit breakers tasks that involve:
from cubicles
cubicles, doors open
open, when – Removal of bolted covers (to
working with 600 V Class Switchgear expose bare, energized parts)
(with power circuit breakers or fused when working with NEMA E2
switches). (fused contactor) Motor Starters,
2.3 kV through 7.2 kV.
– Opening hinged covers (to expose – Opening voltage transformer or
bare, energized parts) when working control power transformer
with "Metal Clad Switchgear, 1 kV and compartments when working
above. with Metal Clad Switchgear, 1kV
and above.

Panel board and Switch board Motor

• Panel Board Control
– A single panel or group of units designed for assembly in
the form of a single panel, including buses and automatic
overcurrent devices and equipped with or without
Center
switches for the control of light, heat or power circuits:
designed to be placed in a cabinet or cutout box placed
in or against
g a wall,, p
partition or other support:
pp and
accessible only from the front.
• Switch Board
– A large single panel, frame or assembly of panels on
which are mounted on the face, back, or both, switches,
overcurrent and other protective devices, buses, and • An assembly of one or more enclosed
usually instruments. Switchboards are generally sections having a common power bus and
accessible from the rear as well as from the front and are
not intended to be installed in cabinets. principally containing motor control units

!!!!WARNING!!!!

Guys that had it happen

• Next slides show photos after
NIOSH video an arc flash or electrocution

13
IF CLOTHING
IGNITES
CLOTHED
AREAS CAN BE
BURNED MORE
SEVERELY
THAN
EXPOSED SKIN

EXTENSIVE
3RD DEGREE
BURNS RESULT

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 Protective Clothing and PPE

Hazard/Risk Category 0
Protective clothing, Non-melting (according to ASTM
F 1506-00) or Untreated Natural Fiber
FR Protective Equipment
Shirt (long sleeve)
Pants (long)
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Personal Protective Equipment
Leather gloves (AN) (Note 2 )

Hazard/Risk Category 1
FR clothing, Minimum Arc Rating of 4 (Note 1)
Arc-rated long-sleeve shirt (Note 3)
Arc-rated pants (Note 3)
Arc-rated coverall (Note 4)
• (1) General. When an employee is working
within the Flash Protection Boundary he/she
FR Protective Equipment
Arc-rated face shield or arc flash suit hood (Note 7)
Arc-rated jacket, parka, or rainwear (AN)

shall wear protective clothing and other personal

Hard Hat
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)

protective equipment in accordance with 130.3.

Leather gloves (Note 2 )
Leather work shoes (AN)

P
Protective
i Hazard/Risk Category 2
FR clothing, Minimum Arc Rating of 8 (Note 1)
Arc-rated long-sleeve shirt (Note 5)
Arc-rated pants (Note 5)
• OSHA/NFPA 70E states:
t t “F
“For energized
i d
Clothing and
FR Protective Equipment Arc-rated coverall (Note 6)
Arc-rated face shield or arc flash suit hood (Note 7)
Arc-rated jacket, parka, or rainwear (AN)
circuits over 50 volts or more, safety tools
Hard Hat
and personal protective equipment must be
Personal Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Leather gloves (Note 2 )
used.”
Protective
Leather work shoes

Hazard/Risk Category 2* Arc-rated long-sleeve shirt (Note 5)

Arc-rated pants (Note 5)

Equipment
FR clothing, Minimum Arc Rating of 8 (Note 1)
FR Protective Equipment Arc-rated coverall (Note 6)
Arc-rated arc flash suit hood (Note 10)
Arc-rated jacket, parka, or rainwear (AN)

PPE Table Hard Hat

Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)

130.7(C)(10)
Leather gloves (Note 2 )
Leather work shoes

Protective Equipment (B) Care of Equipment

• (A) General. Employees working in areas where • Protective equipment shall be maintained
electrical hazards are present shall be provided with, and in a safe, reliable condition.
shall use, protective equipment that is designed and
constructed for the specific part of the body to be • The protective equipment shall be visually
protected and for the work to be performed
performed. inspected before each useuse.
• PPE is described in two areas,
– 130.7 (C) PPE equipment
• FPN: Specific requirements for periodic
– 130.7 (C) (13) Arc Flash Equipment testing of electrical protective equipment
• 130.7 (C) (9) are the Hazard/Risk Charts on the are given in 130.7(C)(8) and 130.7(F).
previous slides

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 (C)(3) Head, Face, Neck, and Chin
Head and Face Protection
Protection
• 2* Hazard level requires • Employees shall wear nonconductive head
a Switching Hood protection wherever there is a danger of head
injury from electric shock or burns due to contact
• The Balaclava and with live parts or from flying objects resulting
hardhat + face shield from electrical explosion.
provides equivalent • Employees shall wear nonconductive protective
protection equipment for the face, neck, and chin whenever
• Face shield must there is a danger of injury from exposure to
supply UV and IR electric arcs or flashes or from flying objects
resulting from electrical explosion.
protection (tinted)

Clothing
130.7(C)(13)(b) Face Protection
• Different energy levels available
• Face shields shall have an arc rating suitable for the arc • Can be treated fiber (Indura) or
flash exposure. synthetic (Nomex) or a blend of both
• Face shields without an arc rating shall not be used. (Cool Touch)
• Eye protection (safety glasses or goggles) shall always
be worn under face shields or hoods along g with hearingg
protection.
• FPN: Face shields made with energy-absorbing
formulations that can provide higher levels of protection
from the radiant energy of an arc flash are available, but
these shields are tinted and can reduce visual acuity.
Additional illumination of the task area might be
necessary when these types of arc protective face
shields are used.

(C)(5) Body Protection

• Employees shall wear FR clothing wherever there is
possible exposure to an electric arc flash above the
threshold incident-energy level for a second degree
burn, 5 J/cm² (1.2 cal/cm2).
Clothing Video
• Exception: For incident-energy exposures 8.36
J/cm² (2 cal/cm2) and below, employees may wear NFPA 70E HRC 2
non-melting clothing described in Hazard/Risk
Category 0 in Table 130.7(C)(ll)
• Arm protection shall be accomplished by apparel
described in 130.7(C)(5). Long Sleeves!

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 Table 130.7(C)(11) Protective Clothing
Characteristics
FR Kits
Hazard/Risk Clothing Description Required Minimum Arc
Category Rating of PPE
[J/cm² (cal/cm²)]
0 Non-melting, flammable materials (i.e., N/A
untreated cotton, wool, rayon or silk or
blends of these materials) with a fabric
weight of at least 4.5 oz/yd²
1 Arc-rated FR shirt and FR pants or FR 16.74 (4)
coveralls
2 Arc-rated FR shirt and FR pants or FR 33.47 (8)

3
coveralls
Arc-rated FR shirt and FR pants or FR 104.6 (25)
• Packages are available for users
coveralls and arc flash suit selected for
that the system arc rating meets the
required minimum
• Multiple calorie levels available
4 Arc-rated FR shirt and FR pants or FR
coveralls and arc flash suit selected for
167.36 (40)
– 4,8, 25, 40 for level 1,2,3 and 4 hazards
that the system arc rating meets the
required minimum
– Other levels are available including higher

Gloves… most common Gloves…

are your first line of defense
• Insulated Rubber Gloves, ASTM Spec.
• Leather Protectors, ASTM Spec.
• Tested / Certified, OSHA 1910.137
“Electrical Protective Devices”
• Gloves must be tested for leaks and
general condition EVERY time.
Class 0 Class 2 • Must be recertified every 6 Months
• Class 00 for 500V Class 0 for 1000V
• Leathers are matched for the rubbers

(C)(6) Hand and Arm Protection

• Employees shall wear rubber insulating gloves
where there is danger of hand and arm injury
from electric shock due to contact with live parts.
Gloves Video
• Hand and arm p protection shall be worn where
there is possible exposure to arc flash burn.
• The apparel described in 130.7(C)(13) shall be W H Salisbury
required for protection of hands from burns.
• Arm protection shall be accomplished by apparel
described in 130.7(C)(5). Body Protection

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 WARNING
Tools
Insulated Hand Tools Insulated
Hand Tools
1000 Volt Rated / V-Rated

The insulation
Th i l ti on VVrated
t d ttools
l iis iimpactt
resistant and flame retardant. Each tool
should be inspected prior to use for cuts,
cracks or other damage. If the yellow
insulation becomes visible through the outer
orange layer, the tool should be removed
from service immediately.

Insulated tools are to be used as Voltage rated tools

SECONDARY protection from
SHOCK….They are NOT to be use
as a replacement for proper
personal protective equipment – shall be rated for the voltage on which they are
used

WARNING
– shall be double insulated
• built to ATSM F1505 standards (double triangle
marking)
• many tool are available in composite construction
• rated at 1000 volts, tested to 10,000 volts
Whenever possible, DE-ENERGIZE lines, and equipment » 3M 33+ wrapped tool is not an insulated tool
prior to working on or around them.
• tool must be inspected before each use

Certified symbol for 1000V Meters

• Meters need to be CAT III
– Three-phase distribution, including single-phase commercial lighting

If you don’t see this • Leads must also be rated Cat III or with double Diamond
y
symbol ...
It’s NOT truly insulated

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Overvoltage Installation Categories Do I need all this stuff?
• No, You do not want to!!!
• You've done it a thousand times.
• It comes naturally to you.
• You know what you're doing, its what
you've been trained to do your whole life.
• Nothing could possibly go wrong, right ?

Think Again.

Accident Live Video

MarquipWardUnited
• What affects MWU Service is: Why do we need this PPE
– Work on energized parts, including voltage testing
• For a 240V panel PPE is category 1 • Remember: This PPE is for the fire ball more
– FR (4) pants and long-sleeved FR (4) shirt than for the shock hazard.
– or FR (4) Coveralls
• Gloves are for the Shock Hazard
• For a 600V ((480V)) PPE is Category
g y 2 or 2*
– FR (8) long-sleeved shirt & pants over natural fiber short- • With the
th finger
fi safe
f components t we have
h
sleeved T-shirt and pants
– FR (8) coveralls over natural fiber short-sleeved T-shirt and
very few “exposed” parts.
pants • Our history is very good on not getting
– FR (8) long-sleeved shirt & pants
– * Adds the hood or face shield requirement to protect the
Zapped but it does happen.
face, forehead, ears and neck. • Our equipment does not tend to explode but
• Plus Gloves for each case some parts, like drives, can.

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 PPE – You and Plants Example
• Note numbers and
• You should know the PPE requirements Category!
for the Hazard/Risk category where you • This plant had
are working. done a Hazard
• Plants can set the required PPE higher Analysis to
than NFPA for a greater margin of safety. achieve this rating
• As a vendor or contractor we need to • Flash Boundary of
follow the requirements set by the plant. 7.6”
• Or NFPA 70E if none have been stated or • This is not by the
posted. charts.

Remember
Lockout Tagout • Power Down and Lock out all power!
• With a Locked out machine there is no Arc • With a ZES machine, the PPE is the
Flash PPE required!!! standard Eyes, Ears and Toes.
• Power Down and Lock it out • Any voltage testing, troubleshooting, CB
operation
ope at o o
on a po
powered
e ed cab
cabinet
et requires
equ es
• VERIFY No
N PPower – Measure!!
M !!
the Hazard/Risk PPE to be worn!
• Now the PPE may be removed
• Our policies require the machine to be
– Personal PPE Locked out when working on the
– Boundary Markers equipment unless you are troubleshooting
or voltage testing.

Supervising the Troubleshooting Questions

• If you are not able to meet the plant • If you have any questions or comments,
requirements, you cannot go into the Flash please send or reply to me or your
Protection Boundary area. manager.
p
• You can still supervise the troubleshooting,
g,
voltage testing or other operations from
outside the Flash Protection area.
• This will allow continued repair and service of
the equipment without your donning of the
PPE.

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 Ward United Lockout

From Customer Manual

O.S.H.A. defines the following as: O.S.H.A. defines the following as:
• “SERVICING and/or MAINTENANCE. Workplace activities such as • “TAGOUT. The placement of a tagout device on an energy isolating
constructing, installing, setting up, adjusting, inspecting, modifying, device, in accordance with an established procedure, to indicate that
and maintaining and/or servicing machines or equipment. These the energy isolating device and the equipment being controlled may
activities include lubrication, cleaning or unjamming of machines or not be operated until the tagout device is removed.”
equipment and making adjustments or tool changes, where the • “TAGOUT DEVICE. A prominent warning device, such as a tag and
employee may be exposed to the unexpected energization or a means of attachment, which can be securely fastened to an
startup of the equipment or release of hazardous energy.” energy isolating device, to indicate that the energy isolating device
• “LOCKOUT.
“LOCKOUT The Th placement
l t off a lockout
l k t device
d i on an energy and
d th
the equipment
i tb
being
i controlled
t ll d may nott be
b operated
t d until
til the
th
isolating device, in accordance with an established procedure, tagout device is removed.”
ensuring that the energy isolating device and the equipment being
controlled cannot be operated until the lockout device is removed.”
• “LOCKOUT DEVICE. A device that utilizes a positive means such • “When a tag is attached to an energy isolating means, it is not to be
as a lock, either key or combination type, to hold an energy isolating removed without authorization of the authorized person responsible
device in the safe position and prevent the energizing of a machine for it, and is never to be bypassed, ignored, or otherwise defeated.”
or equipment.”

LOCKOUT/TAGOUT PROCEDURE LOCKOUT/TAGOUT PROCEDURE

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LOCKOUT/TAGOUT PROCEDURE LOCKOUT/TAGOUT PROCEDURE

Marquip Lockout

SAFETY Splicer SAFETY LOCKOUT (ZES)

• To safely operate Marquip machinery, operators and maintenance personnel must
undergo training by Marquip. It is the customer's responsibility to provide training to new
individuals. If you need assistance training new individuals, please contact Marquip Field • Perform safety lockout before performing any maintenance. Follow the
Service. Safety Lockout procedure to obtain a Zero Energy State (ZES).
• This Marquip equipment operates with minimal operator intervention. However, • DANGER! Failure to perform Safety Lockout procedure before
maintenance personnel are required to be in the area of potentially dangerous performing maintenance of jam clearing may result in severe injury or
mechanical and electrical devices. Use EXTREME CAUTION while operating or death.
servicing the machines.
1. Place the splicer controls in the Thread-Up Mode. (Turn keyswitch from run
• False external inputs may cause the equipment to operate in an abnormal sequence. to thread-up or manually move run/thread valve to thread-up position.)
When servicing machines, shut off all pneumatic, hydraulic, and electrical power and
relieve
li pressure iin pneumatic
ti anddhhydraulic
d li systems.
t Pl
Place th
the machine
hi iin a zero 2
2. Turn off and lockout air at pneumatic lockout valve
valve.
energy state by following the Safety Lockout procedure in the Operation section. 3. Push Control Power button Off.
• Obey all safety signs! 4. Turn primary disconnect Off.
• The safety precautions given in this manual are for operation and maintenance
personnel's protection. Observe all rules of safety and good judgment for coworkers' and 5. Lock out primary disconnect.
your protection. 6. Sever web at forward end of Splicer.
• Many safety agencies' regulations recommend the use of hearing protection when work 7. Loosen the airline on both ends (home & thread-up) of either cable cylinder
place noise exceeds an 8-hour time weighted average sound level of 85 dBA. to allow any trapped air to escape from the dancer system.
Furthermore, the use of hearing protection is required when work place noise exposures
exceed 90 dBA over an 8-hour work day. Marquip strongly recommends that all 8. Lockout pneumatic valve.
operating personnel use adequate hearing protection to prevent possible PERMANENT • WARNING! Potential energy exists in the Dancer system when the web
HEARING LOSS. is tensioned. Relieve tension on web before entering machine. Failure
• SAFETY INFORMATION This manual is an integral part of the machine and has to be to do so could result in severe injury or death.
stored in the immediate proximity of the machine.

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Slitter SAFETY LOCKOUT (ZES) Stacker Safety Lockout (ZES)
• Perform safety lockout before performing any maintenance. Follow the Safety Lockout • Perform safety lockout before performing any maintenance. Follow the Safety
procedure to obtain a Zero Energy State (ZES). Lockout procedure to obtain a Zero Energy State (ZES).
• DANGER! Failure to perform Safety Lockout procedure before performing • DANGER! Failure to perform Safety Lockout procedure before performing
maintenance may result in severe injury or death. maintenance may result in severe injury or death.
• DANGER! If the Slitter/Scorer is equipped with a Manual Auxiliary Section, the 1. Lower all lifts and other devices to their lowest possible position (if applicable).
section must be locked out before entering. Lock out the Manual Auxiliary Section • DANGER! Support lifts and other devices by their locking pins or bottom stops.
by attaching the safety hold-up bolt assembly. Do not rely on normal stopping mechanisms only. Failure to do so may result
1. Lock out the Manual Auxiliary Section according to Specific Safety Instructions in Safety in severe injury or death.
section.
section 2
2. P h Control
Push C t lP Power button
b tt Off.
Off
2. Place the machine in an Intermediate Energy State (IES) according to Turning Control 3. Turn Control Power Lockout keyswitch to 0 (if applicable).
Power Off (IES) procedure in Operation section. 4. Remove key (if applicable).
3. Turn the primary disconnect Off. 5. Turn primary disconnect Off.
a. Shout "Power off."
b. Pause, look, and listen.
6. Lock out primary disconnect.
c. Turn off the primary disconnect. 7. Turn air Off at pneumatic lockout valve.
4. Lock out the primary disconnect. 8. Lock out pneumatic valve.
5. Turn the air Off at pneumatic lockout valve. • * NOTE: If maintenance requires that personnel be positioned under the lift, follow
a. Shout "Air off." the Lift Lock procedure in Maintenance section before continuing this lockout
b. Pause, look and listen.
procedure.
c. Turn air off by rotating the air disconnect valve handle.
6. Lock out pneumatic lockout valve.

Arc Flash

Why we need to spend the Money

23