ELECTRICAL SAFETY MANUAL - Berkeley Lab

1 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 1 of 217 ELECTRICAL SAFETY MANUAL LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 2 of 217 TABLE OF CONTENTS Revision History .. 7 1 Introduction .. 8 Purpose .. 8 Scope .. 8 Regulatory Drivers .. 9 Format .. 9 PART I ELECTRICAL HAZARDS .. 10 2 ELECTRICAL Hazards .. 11 Scope .. 11 ELECTRICAL Shock .. 11 ELECTRICAL Burn .. 18 Delayed Effects .. 21 Battery Hazards .. 21 Other 22 3 ELECTRICAL Hazard Classification .. 23 Explanation of the ELECTRICAL hazard classification 23 Classification Matrix .. 25 Hazard Class , 50-60 Hz Nominal Power .. 26 Hazard Class , DC .. 28 Hazard Class , Capacitors .. 30 Hazard Class , Batteries <100 VDC .. 34 Hazard Class , RF Circuits (3 kHz to 100 MHz) .. 36 Hazard Class , Sub-RF Circuits (1 Hz to 3 kHz).

2 38 PART II ELECTRICAL SAFE WORK PRACTICES .. 40 4 ELECTRICAL SAFETY Principles & 41 Principles of ELECTRICAL 41 Application of ISM to ELECTRICAL SAFETY .. 42 Planning ELECTRICAL Work .. 43 Hierarchy of controls .. 45 4. 5 Authorization .. 46 Executing the Plan .. 47 Self-Controls for the Qualified ELECTRICAL Worker .. 47 5 General ELECTRICAL SAFETY for All Persons .. 49 Scope .. 49 General requirements .. 49 Recognizing ELECTRICAL hazards .. 49 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 3 of 217 Portable electric equipment .. 55 Extension cords for temporary use .. 57 Relocatable Power Taps (Power Strips) .. 61 Adapter Cord Sets .. 64 Ground Fault Circuit Interrupters .. 64 Heating Tapes and Cords .. 69 Portable Heating Devices .. 70 Holiday Lights .. 70 Working Space Around ELECTRICAL 70 Switching .. 74 6 ELECTRICAL Safe Work Controls.

3 78 Scope .. 78 Qualified ELECTRICAL Workers (QEWs) .. 78 ELECTRICAL Work and Requirement for a QEW .. 79 Mode 0 Electrically Safe Work Condition .. 83 Mode 1 Process for Establishing an Electrically Safe Work Condition (LOTO) .. 84 Mode 2 Energized Diagnostics (Testing & Troubleshooting) .. 86 Mode 3 Energized Repair Work (EEWP) .. 89 ELECTRICAL Safe Work Procedure (ESWP) .. 90 Person in Charge (PIC) .. 93 QEW Skill of the Craft .. 93 Direct Field Supervision .. 94 Job Briefing .. 95 Working Alone or Accompanied .. 95 7 Shock Protection .. 100 Performing a Shock Hazard Analysis .. 100 Determination of a Shock Hazard .. 100 Shock Protection Boundaries .. 102 When Voltage Rated Gloves Are Required .. 108 When Leather Protector Gloves Are Required .. 108 When Voltage Rated Blankets or Sheeting Are Required .. 109 When Insulated Sticks (Hot Sticks) Are Required .. 109 Selection of Shock Protection PPE.

4 109 Primary vs. Secondary Shock Protection .. 110 8 Arc Flash Protection .. 112 Arc Flash Hazard Analysis .. 112 Determination of an Arc Flash Hazard .. 113 Incident Energy Analysis .. 115 Arc Flash Boundary .. 115 Working Distance .. 118 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 4 of 217 Incident Energy Analysis for Facility Power 118 Incident Energy Analysis for R&D Systems .. 119 Energy Reducing Maintenance Switches .. 119 Arc Flash Labeling .. 120 Arc Flash PPE Selection .. 121 Arc flash incident energy >40 cal/cm2 .. 123 MCC Buckets, Busway Plug-In Units and Drawout Type Circuit Breakers .. 124 Daily Arc-Rated Work Wear for ELECTRICAL Work .. 124 Body Positioning for Arc Flash .. 125 9 Zero Voltage Verification (ZVV) .. 126 Purpose .. 126 Live-Dead-Live Test Method .. 127 Steps to perform ZVV .. 127 Where to perform ZVV.

5 128 When to perform ZVV .. 129 Types of Voltage Detectors .. 130 ZVV where there is no exposed conductor .. 131 10 General ELECTRICAL Safe Work Practices .. 133 Minimum PPE for ELECTRICAL Work .. 133 Body Positioning .. 133 Controlling the Work Area (Alerting Techniques) .. 136 Other Precautions for Personnel Activities .. 139 11 High Voltage Facilities Distribution Systems (>750 VAC).. 145 Scope .. 145 Qualification requirements .. 145 Restricted Access to High Voltage Enclosures .. 145 Switching .. 146 Zero Voltage Verification .. 146 Personal Protective Equipment .. 147 Temporary Personal Protective Grounding of High Voltage Circuits .. 147 12 High Voltage/Low Current DC Systems (>1000 VDC, <40 mA) .. 151 Hazards .. 151 Design Considerations .. 151 SAFETY Practices .. 151 13 Distributed Generation .. 153 Permanently connected standby generators .. 153 Portable generator connection and 153 Uninterruptible Power Systems (UPS).

6 154 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 5 of 217 14 Batteries .. 155 Scope .. 155 Qualification & Training .. 155 Hazards .. 156 Operation and Maintenance .. 156 15 Capacitors .. 159 Scope .. 159 Qualification & Training .. 159 Hazards .. 159 Stored Energy Hazard Assessment .. 161 Capacitor Discharge Time .. 167 Capacitor Hazard Labeling .. 169 Hard Grounding vs Soft Grounding .. 169 Establishing an Electrically Safe Work Condition (Mode 1) .. 170 Testing capacitors (Mode 2) .. 172 Personal Protective Equipment (PPE) .. 172 Storage & Disposal .. 173 16 Inductors .. 174 Scope .. 174 Hazards .. 174 Design and Construction .. 175 17 Personal Protective Equipment .. 176 Rubber Insulating Gloves .. 176 Rubber Insulating Blankets .. 181 Rubber Insulating Sheeting .. 182 PVC Insulating Sheeting .. 183 Arc-Rated PPE.

7 183 Other PPE .. 187 18 ELECTRICAL Tools & Equipment .. 188 Testing Equipment .. 188 Insulated Tools .. 190 Insulated Sticks .. 190 Temporary Personal Protective Grounds for R&D Equipment (Ground Hooks) .. 191 Temporary Personal Protective Grounds for Utilities (Ground Straps) .. 192 Other Tools .. 194 PART III DEFINITIONS AND APPENDICES .. 195 Acronyms and Abbreviations .. 196 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 6 of 217 Definitions .. 197 Appendix A: Standards on Personal Protective Equipment .. 208 19 Appendix B: Standards on Other Protective Equipment .. 209 Appendix C: In-Service Specifications for Personal and Other Protective Equipment .. 210 Appendix D: Reference Sheet for the QEW Skill of the Craft Work .. 211 Appendix E: List of Pre-Approved Voltage Detectors for Zero Voltage Verification .. 213 LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 7 of 217 Revision History Revision Date Published Summary Initial July 2015 Initial edition implementation of NFPA 70E-2012, Standard for ELECTRICAL SAFETY in the Workplace, and DOE-HDBK-1092-2013, ELECTRICAL SAFETY Handbook.

8 Additional material from IEEE Std , Recommended Practice for ELECTRICAL SAFETY in Industrial and Commercial Power Systems. Rev 1 Jan 2017 Revision 1 of the ELECTRICAL SAFETY MANUAL incorporates a number of refinements and edits, including: Incorporated ESM Correction Notice 1-2015, adding balaclava for level 1 of arc flash PPE Incorporated ESM Correction Notice 2-2015, requiring rackout of rackable breakers for LOTO Changed capacitor thresholds to 10 J, 100 V Complete rewrite of Section 15 for Capacitors Clarified requirements for extension cords and temporary wiring Clarified requirements for relocatable power taps Clarified requirements for non-QEW switching thresholds Refined the definition of ELECTRICAL work Added QEW-R level for researchers not exposed to line source hazards Added in QEW exceptions from PUB-3000 Chapter 8 Refined definition of Direct Field Supervision Job briefing requires a detailed discussion of the scope of work SAFETY Watch only needs to know the location of an AED unless performing Mode 3 (EEWP) work.

9 Refined requirements for when to wear rubber insulating gloves Added ANSI details for temporary barricade tape and signage Added specifications for ground hooks for R&D equipment Modified requirements for temporary personal SAFETY grounds for facilities equipment Cord-and-plug exemption extended to multiple plugs provided exclusive control can be maintained Clarified two-person and barricade requirements for visual inspections Added requirement for arc-rated SAFETY vests and cold-weather gear for personnel assigned with daily arc-rated wear. Removed requirement for minimum PPE when working on cord-and-plug 120 V equipment that has been unplugged. Clarified ZVV requirements and supplementary voltage checks. LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 8 of 217 1 Introduction Purpose The purpose of this ELECTRICAL SAFETY MANUAL is to establish Berkeley Lab site-specific ELECTRICAL safe work practices that meet regulatory requirements and match the types of hazards found on site.

10 The ELECTRICAL safe work practices prescribed in this MANUAL are mandatory, unless specifically indicated as a recommended practice. Scope This MANUAL establishes ELECTRICAL safe work practices for both Qualified ELECTRICAL Workers (QEWs) and Non-QEWs. It includes work on facilities distribution and premises wiring, and commercial and R&D type equipment. Institutional requirements for the overall ELECTRICAL SAFETY Program are found in Chapter 8, ELECTRICAL SAFETY Program and are not repeated in this MANUAL . These include: a. Scope and structure of the overall ELECTRICAL SAFETY Program b. Roles and responsibilities, including ELECTRICAL SAFETY Officers and ELECTRICAL SAFETY Advocates c. ELECTRICAL Authority Having Jurisdiction (AHJ) d. Training and qualification requirements e. Emergency response to an ELECTRICAL shock incident f. ELECTRICAL incident severity score calculation g. Subcontractor requirements LAWRENCE Berkeley NATIONAL LABORATORY ELECTRICAL SAFETY MANUAL Revision: Rev 1 Date: January 2017 Page 9 of 217 Regulatory Drivers DOE 10 CFR 851, Worker SAFETY and Health Program NFPA 70, National ELECTRICAL Code (NEC), 2011 edition NFPA 70E, Standard for ELECTRICAL SAFETY in the Workplace, 2012 edition OSHA 29 CFR , Definition and requirements for a nationally recognized testing laboratory OSHA 29 CFR , Personal Protective Equipment OSHA 29 CFR , ELECTRICAL protective devices OSHA 29 CFR 1910 Subpart S (.)