NREL Electrical Safety Program

Provider: Environment, Safety & Health Office
Related ES&H Policy: Policy 6-4, Worker Safety and Health.
Last updated: July 1997
Document #: ESH 6-4.15

Table of Contents

I. Purpose

The NREL Electrical Safety Program has been developed to ensure the safety of all employees who work with or around electrical equipment and distribution systems. Because of the diversity in job assignments throughout the Laboratory, NREL employees are at varying levels of potential exposure to energized components of electrical systems.

 

The Electrical Safety Program addresses a variety of potential exposure levels and describes precautionary measures that are to be implemented to minimize risks.

II. Program Authorization

The NREL Electrical Safety Program provides specific details for compliance with safety requirements established by Policy 6-4, Worker Safety and Health. All responsibilities, general rules, and procedures from Policy 6-4 apply to this program.

III. Scope

This program applies to all electrical installations as well as to work performed with or near electrical equipment and/or distribution systems. Since electrical equipment is present in office areas as well as laboratory areas, the program encompasses all areas and activities at NREL. This program applies to everyone performing work at NREL sites including, but not limited to; permanent and temporary NREL employees, visiting professionals, students, subcontractors, vendors, etc.

IV. References

V. Definitions

Electrical Distribution System: Electrical components and associated hardware, such as wall mounted switches, receptacles, conduit, circuit breaker panels, etc. that are permanently attached to buildings for the purpose of delivering electrical power.

 

Electrical Exposure Levels: Risk levels of exposure to energized electrical systems and components that employees face while performing their daily job assignments. Three levels have been identified. They are as follows:

 

Low: Employees with a low risk of potential exposure to energized electrical components are managers, financial and administrative support personnel, and other staff members who primarily work in an office environment. Electrical equipment in these areas is generally limited to 120 volt devices such as; computers, printers, typewriters, space heaters, coffee pots, extension cords, and other consumer electronics devices.

 

Moderate: Employees with moderate risk of potential exposure to energized electrical systems are researchers, engineers, technicians, machinists, copy center employees, and other staff members who routinely work with or around electrical or electromechanical equipment. Equipment used by these employees may operate with voltages up to 600 volts. These employees must be trained to recognize electrical hazards and must be able to safely shut off power to the equipment in the event of an emergency. Electrical equipment used by these employees may include; power supplies, signal generators, lasers, machining equipment, electric hand tools, test equipment, etc.

 

High: Employees with the highest risk of potential exposure to energized electrical components are electricians, electrical engineers, maintenance technicians, and research technicians who are responsible for maintenance, calibration, installation, modifications, and set up of equipment and electrical distribution systems. These employees may periodically work on equipment or systems that require 480 volts or higher and shall be thoroughly trained in hazard recognition, precautionary measures (including Lockout/Tagout and the use of personal protective equipment [PPE]), and emergency response procedures prior to beginning work on electrical systems and equipment. Equipment may include; electrical distribution systems, large electric motors, heating-ventilation-and-air conditioning (HVAC) equipment, uninterruptible power supplies (UPS), etc.

 

Energized Work: Any work performed on or close enough to exposed parts of electrical circuits and equipment operating at greater than 50 V to ground, or less than 50 volts to ground where the current exceeds 5mA, and the potential for injury exists.

 

Journeyman Level Electrician: An individual who has achieved a level of expertise in the electrical field and has completed at least 4 years of apprentice level training and hands-on experience. Formal trade school training and/or licensing by the state generally accompany this level of expertise.

 

Lockout/Tagout: A procedure which ensures that all hazardous energy sources are secured in a safe manner prior to any servicing or maintenance activities. The NREL Lockout/Tagout Program provides details of this procedure.

 

Safe Work Permit: A permit issued by the ES&H Office or other authorized staff for hazardous activities including work on energized electrical systems, as described in Policy 4-10, Occupational Safety & Health.

 

Two Worker Rule: An NREL rule which requires that a second worker be present whenever work is performed with or near energized electrical systems. The second worker shall be trained in emergency response procedures and shall be present only as an observer, and must not participate in the actual work that is being performed.

VI. Program Components & Assignments

All electrical installations and electrical practices at NREL shall be performed in compliance with the reference standards identified in Section IV of this program.

 

1. Program Elements

    

   The NREL Electrical Safety Program is comprised of six primary elements which are supported by various NREL ES&H programs, as follows:

    

   1. Policies & Procedures, and Programs: Various Policies/Procedures have been developed and implemented at NREL to ensure safe work practices by employees and safe working conditions. The parent document to this program is the NREL Policy 4-10, Occupational Safety and Health (OSH) which describes individual and line management responsibilities necessary for the implementation of an effective Electrical Safety Program.

      Another relevant subdocument to the OSH Policy/Procedure is the NREL Lockout/Tagout Program which has been implemented to ensure that equipment is deenergized and securely isolated from external and internal energy sources, prior to operations such as maintenance activities, in which the accidental startup or release of energy could cause injury.

      This Electrical Safety Program shall be used in conjunction with the above referenced documents.

       

   2. Safe Operating Procedures (SOP): Laboratory or project specific SOPs shall be developed and maintained which identify electrical hazards and prescribe precautionary measures which must be in place for specific research and maintenance activities. Additionally, SOPs must include specific information on energized work and/or Lockout/Tagout procedures for equipment covered under the SOP. These procedures must address multiple energy sources and the capacity for stored or residual energy, if present. SOPs are discussed in detail in NREL Policy 4-4, Risk Assessment

       

   3. Training: Electrical Safety and Lockout/Tagout training shall be provided for NREL employees on a continuing basis. Subsection G further details training requirements.

       

   4. Inspections: Inspections shall be conducted at regular intervals by qualified individuals to identify electrical deficiencies in all occupied areas serviced by electrical power. These inspections may be performed as a part of or in conjunction with Center safety inspections as described in the ES&H Inspection Program.

       

      1. Pre-Use - Fabricated Equipment - Equipment inspections are required for equipment such as specialized electrical devices fabricated at NREL or at other facilities such as a university or another laboratory. To ensure electrical integrity, fabricated devices must be inspected by a qualified staff member of Site Operations, the ES&H Office, or by a member of the NREL Electrical Safety Panel before being used. No inspection is required for commercially available devices that have been tested and approved by a reputable testing laboratory such as Underwriters Laboratories (UL), Factory Mutual (FM), or Canadian Standards Association (CSA) and are being used in unmodified form.

          

      2. Periodic - Inspections shall be conducted at regular intervals by qualified individuals to identify electrical deficiencies in all occupied areas serviced by electrical power. These inspections may be performed as part of or in conjunction with Center level safety inspections as described in the ES&H Inspection Program.

       

   5. Personal Protective Equipment (PPE): PPE including non-conductive head gear, insulated shoes, and eye and face protection, shall be made available by NREL for use by all employees who work with or near electrical equipment. Non-NREL employees (i.e. contractors) are responsible for providing their own PPE. The use of PPE is presented in NREL Policy 4-3, Personal Protective Equipment.

       

   6. Guarding and Shielding Techniques: Protective guards and shields which prevent individuals from coming in contact with energized electrical components shall be installed on all equipment and distribution systems.

    

2. General Requirements

    

   1. Included as Appendix A of this program is an Electrical Safety Inspection Guideline/Checklist developed by the NREL Electrical Safety Panel. This checklist serves as a quick reference to fourteen commonly found safety issues. Note: This checklist does not cover all electrical safety concerns. The National Electrical Code should be referenced for specific details and more complete information regarding electrical installations.

       

   2. The DOE Electrical Safety Guidelines (October 1994) is a document that has been prepared by the DOE Electrical Safety Committee and is to be used by DOE and subcontractor personnel. The guidelines describe best management practices and encompass the applications of electrical safety requirements, standards, and regulations including OSHA, NEC, and the National Electric Safety Code (ANSI C2). The Table of Contents for the document is included as Appendix B of this program. The guidelines document is available from the ES&H Office or the Site Operations Center.

       

   3. The DOE Electrical Safety Guidelines for Research and Development (DOD/ID-10600) are recognized best management practices and apply to NREL operations. This section contains safety criteria for the design, fabrication, modification, installation, inspection, testing, operation, and maintenance of R&D electrical apparatus.

    

3. Design Requirements

    

   1. General - In addition to complying with the NEC, all facilities and equipment designs, installations, and modifications must also conform to DOE 6430.1B, "General Design Criteri"a. For many types of installations, this order requires additional safety measures that are more stringent than the NEC. For example, the General Design Criteria requires that an independent ground wire be used in all metallic raceways in electrical distribution systems. These raceways cannot serve as the sole ground path as allowed by the NEC. Copies of this Order are available for reference from the ES&H Office and Site Operations.

       

   2. Commercially Available Equipment - This equipment must bear the approval of a recognized testing laboratory such as UL, FM, or CSA.

       

   3. NREL Fabricated Equipment - Listed components shall be used where available and the design shall comply with the general requirements (i.e. NEC, etc.).

       

   4. Vendor Fabricated Equipment - Listed components shall be used where available and certification is required from the manufacturer that the equipment complies with NEC, etc. Certification requirements should be included in the purchasing documents (i.e., statement of work, contract specifications, etc.).

       

   5. Foreign Manufactured/Fabricated Equipment - The Supplier of foreign manufactured equipment will have to provide documentation that demonstrates "equivalency" with the requirements of the NEC or corresponding guidelines established by nationally recognized testing laboratories (UL/CSA, etc.). The end user will be required to provide the equivalency certification during the pre-use inspection.

       

   6. Facilities - Site Operations shall review installations requiring moderate to large power demand (i.e., those requiring a disconnect switch) to ensure that adequate power is available.

    

4. Installation Approval

    

   1. Installations and modifications of building electrical systems shall only be performed by qualified journeyman level electricians. Installations are to be performed by the Site Operations or by a qualified contractor whose work has been authorized by the Site Operations. Exception: Research Center staff members may be allowed to work on or modify building electrical systems if they are qualified to safely perform the level of work to which they are assigned, and are working under the approval and direct oversight of the Site Operations Center. Electrical installations performed by contractors and research staff members must be inspected and approved by the Site Operations Center before connection is made to the building electrical system.

       

   2. Equipment installations which are hard wired must be installed with a readily accessible lockable disconnect switch that is capable of isolating the input electrical energy source. For equipment that is equipped with a power cord and plug combination, the plug will serve as an acceptable disconnecting means.

      Receptacles that are located within six feet of sinks, open sources of water, or in potentially wet locations must be protected a by Ground Fault Circuit Interrupter (GFCI).

       

   3. Research equipment installations and electrical connections shall be subjected to approval before being placed into service. The approval process is normally accomplished during required Readiness Verifications (RV), as described in Policy 4-4, Risk Assessment.

    

5. Work Authority

    

   1. Site Operations is responsible for maintaining and modifying the building electrical distribution systems. Only those employees who have completed a Journeyman level of expertise in the electrical trade (see definition) will be allowed to work on electrical distribution systems without direct supervision. Apprentice employees who have not yet completed the required four years of experience/educational requirements may be allowed to work on distribution systems under the direct supervision of a Journeyman level staff member.

       

   2. Center Directors and Team Leaders have the responsibility of ensuring that each employee under his/her direction is qualified to safely perform the level of work to which they are assigned. Following is a generic description of NREL positions and a corresponding explanation of the electrical work in which employees in these positions are allowed to perform:

      Electrician/Senior Maintenance Technician: Once the appropriate level of expertise has been demonstrated to their supervisor, these employees will be allowed to work on electrical distribution systems. Due to the nature of their work, these employees potentially have a High electrical exposure level, as defined in Section V. Therefore, these employees must have advanced training in hazard recognition, and electrical safety principles.

      General Maintenance Employees and Maintenance Apprentices: While working under the direct supervision of a Journeyman level technician, these employees will be allowed to work on electrical distribution systems.

      Employees working at Researcher/Research Technician and General Maintenance and Apprentice levels potentially have a Moderate electrical exposure level as defined in Section V, and are required to complete electrical safety training.

      Researchers/Research Technicians: Once the appropriate level of competence has been demonstrated to their Team Leader, these employees will be allowed to perform electrical work on research apparatus and associated equipment. However, these employees are prohibited from working on facility electrical distribution systems.

      Exceptions: Qualified researchers and research technicians may be allowed to work on electrical distribution systems when the work involved is part of a research project and the work has been approved by Site Operations.

    

6. Work on Energized Systems

    

   Work on energized systems that incorporate hazardous circuits shall be strenuously avoided. A hazardous circuit is defined as one operating at greater that 50 Volts, or operating a 50 Volts or less with a current greater that 5 mA, or a hazardous energy level exceeding 10 joules. This includes the maintenance and repair of research equipment. This applies to both NREL employees and contractors/vendors. When it cannot be avoided, only qualified personnel who have been trained to work safely on energized circuits shall perform the work.

    

   If an experimental process or a research activity requires employees to routinely work near or with unshielded energized electrical components, the hazard and precautionary measures must be addressed in the SOP. If the exposure is an isolated occurrence, and the employee has not achieved a journeyman level status, a Safe Work Permit issued by the ES&H Office shall be obtained before the start of work. Individuals performing these tasks must adhere to safety-related work practices at all times to prevent electric shock or other electrically induced injuries.

    

   The following safe work practices must be adhered to when working with energized systems:

    

   Exception: Taking voltage and current measurements using standard test equipment such as voltmeters and current probes is not considered performing work on energized systems.

    

   1. Two Worker Rule: Two persons must always be present whenever work is performed on an energized system. One person must be assigned as a safety watch and will not participate in the actual work being performed. The safety watch must be within sight and hearing from the person performing the electrical work (less than 50 feet) and must be trained in emergency response procedures including CPR.

       

   2. Personal Protective Equipment (PPE): Workers must wear appropriate PPE including rubber soled shoes, Class "O" gloves, protective eyewear and headgear if necessary, and use insulated hand tools.

       

   3. Preplanning and Safety: Before work begins, the sequence of events for the project should be planned, and appropriate written safety procedures should be established.

       

   4. Tools and Equipment: All tools that will be required for the job should be readily available and inspected to ensure that they are in good working order. Only qualified workers shall operate tools and equipment.

       

   5. Posted Warnings and Barricades: Safety signs shall be posted to warn other employees of potential electrical hazards. In addition, barricades will be used when necessary to limit access to work areas where there is a potential for contact with exposed or uninsulated energized conductors.

       

   6. Restricted Work Area: The immediate work area shall be restricted to authorized and qualified workers.

       

   7. Work Stoppage: If unsafe conditions develop during the work process, the work shall be suspended and the Center Director and Team Leader must be immediately notified.

    

7. Training

    

   Employees shall be trained in and be familiar with safety-related work practices that pertain to their respective job assignments.

    

   1. For those employees who fall within the High and Moderate electrical exposure levels as defined in Section V, Electrical Safety Training shall be completed prior to starting work and at least every three years.

       

   2. Training will be optional for employees with Low electrical exposure levels.

       

   3. The training shall be provided by the NREL ES&H Office and scheduled by Human Resources on a regular basis.

       

   4. Additional specialty training may be required for employees in the High electrical exposure level, as determined by their Team Leader. This training shall be provided by qualified organizations outside NREL.

Appendix A

Electrical Safety Inspection Guidelines/Checklist

1. A 36 inch clearance must be maintained in front of all electrical panels. (area is usually marked by striped black and yellow tape)

    

2. Note any missing covers for electrical devices. (junction boxes, receptacles, switches, etc.)

    

3. Ensure that flexible cords do not protrude through walls, ceiling tiles, windows, or doors.

    

4. Ensure that flexible cords are not attached to walls or piping.

    

5. Note missing or improperly installed flexible cord connectors. (area where cord is attached to device)

    

6. Inspect ground plugs on extension cords and portable electric tools.

    

7. Inspect condition of flexible cords. (covering cracked, cut, or otherwise physically damaged)

    

8. Note open or exposed terminal connections.

    

9. Note any exposed wiring.

    

10. Ensure that extension cords are properly sized with respect to length and load capacity.

     

11. Multi-outlet strips must have overcurrent protection. (circuit breaker)

     

12. Circuit breaker panels must have an updated schedule in place identifying the circuit that each breaker controls.

     

13. Electrical cords and equipment should not be located near (or inside of) sinks or other water sources unless a ground fault circuit interrupter (GFCI) protects them.

     

14. Insure that any equipment undergoing repairs or maintenance work is properly locked/tagged out.

Appendix B

Table of Contents for
DOE Electrical Safety Guidelines
May 1993

Note: These documents are available in the ES&H Office and the Site Operations Center.

ES&H Home || ES&H News & Events || NREL ES&H Manual || ES&H Reference Materials || theSOURCE