Mark Scott Henrik von der Lippe Bob Candelario EETD Lunchtime
Seminar February 21 st, 2013 The LBNL Electrical Equipment Safety
Program (EESP)
Slide 2
The LBNL Electrical Safety Program 2
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1.Prevent electrical-related injuries 2.Implement proactive
controls across the spectrum of expected hazards 3.Educate the lab
population about electrical hazards 4.Promote a vibrant electrical
safety culture 5.Demonstrate compliance to established standards
ObjectivesScope 3 Zero Electrical Injuries Qualified Electrical
Workers Safe Equipment Non- Electrical Workers Safe Work
Practices
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Reenergizing the Lab Electrical Safety Culture Safety is
Elemental 4
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Establishing an Effective Program Its a journey! 5 SLAC Injury
(2004) 10CFR851 (2006)
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Compliance-Driven Program Recognizing the drawbacks: Safety by
compliance becomes an endlessly frustrating policing exercise
Build-up of conflict between EH&S and process users Greatest
frustration is felt by the Facilities Department, which is caught
between internal science customers and EH&S requirements
Overall effectiveness is marginal: Most high-risk incidents are
prevented but many low risk violations antagonize the users
Perception indicates that safety processes are overly difficult and
do not improve safety Multitude of incidents cannot be corrected
without addressing the culture, which results in recurring incident
investigations and more ineffective corrective actions 2007-2011
6
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Culture-Driven Program Starts with recognizing the limits of a
compliance-driven program Reach out to the Lab population and
eliminate the word compliance from the vocabulary (its still there,
but in the background) Subject Matter Experts must be able to
defend all requirements on their own merit and logic, supported
with pertinent examples and best practices This includes the most
basic questions such as: Why should I lock out? Theres already a
lock! Why should I test? Its already turned off! Waving NFPA 70E
around is a sure way to lose the argument 2011 Present: Defining
the future state 7
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Electrical Safety Sub Committee Expanded membership, reaching
out to non-electrical worker community at LBNL Revised Charter:
more proactive role in setting goals, developing workable policies,
and promoting a vibrant electrical safety culture 8
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Electrical Equipment Hazards In the US between 2003 2007: 1,213
people were killed by electrical accidents. 13,150 people suffered
lost time injuries from electrical accidents The 3 rd leading
category of electrical fatalities involved workers coming into
contact with electric current from machines, tools, appliances, or
light fixtures. (Source: Brent C. Brenner, Occupational Electrical
Injury and Fatality Trends and Statistics: 19922007, IAEI Magazine,
May 5, 2009) 9
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Electrical Equipment Hazards Accidental electrocution due to
contact with tools and apparatus whose grounding conductors were
faulty accounted for 18 percent of all electrical fatalities and 35
percent of nonfatal electrical accidents [in the period 2003-2007].
(Source: Brent C. Brenner, Occupational Electrical Injury and
Fatality Trends and Statistics: 19922007, IAEI Magazine, May 5,
2009) FY2012: 50% of all LBNL scientific division occurrences have
been related to electrical equipment (23% of total) 10
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The Electrical Equipment Safety Program Overview of Basic
Requirements 11
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Electrical Equipment Approval Electrical equipment is Approved
only if it is Acceptable to the Authority Having Jurisdiction
(AHJ). Electrical equipment is Acceptable only if either: 1.It is
Listed by a Nationally Recognized Testing Laboratory (NRTL) This
includes UL, ETL, and others OSHA NRTL program:
http://www.osha.gov/dts/otpca/nrtl/index.htmlhttp://www.osha.gov/dts/otpca/nrtl/index.html
OR 2.It is inspected and/or tested and is found to meet applicable
codes and standards All electrical equipment used at Berkeley Lab,
or in the field by Berkeley Lab employees or affiliates, must be
Approved 12
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Electrical Equipment Approval If available, Listed electrical
equipment must be used and the inspection process does not apply.
The EESP inspection process applies for equipment where no Listed
product is available. If Listed equipment is modified or is used
outside of its listing intent, it is also subject to the EESP
inspection process. All electrical equipment used at Berkeley Lab,
or in the field by Berkeley Lab employees or affiliates, must be
Approved 13
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AHJ Delegations DOE Aundra Richards LBNL Director Paul
Alivisatos ENG Director Kem Robinson EESP Program Manager Mark
Scott R&D Equipment & Apparatus FAC Director Jennifer
Ridgeway Electrical Engineer Doug Burkhardt Facilities
Distribution, Wiring and Equipment EHSS Director Joe Dionne
Electrical Safety Officer Mark Scott Work Practices & Workplace
Conditions 14 EESP
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking The 5 Basic Inspection Points
15
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking Must be effective Usually
tested with a ground bond tester Ensures that the circuit breaker
will trip immediately if the casing becomes energized The 5 Basic
Inspection PointsGrounding 16
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking All exposed energized parts
must be covered, even during access for adjusting controls Casing
strength and material type must be suitable for the environment
Door interlocks to remove power The 5 Basic Inspection
PointsEnclosure 17
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking Fusing or circuit breakers
must be properly located and rated for the load current The neutral
cannot be fused The phase conductor(s) must be fused The 5 Basic
Inspection PointsOvercurrent Protection 18
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking Proper voltage and current
rating Must be listed by an NRTL Cord cap must be appropriate for
the amperage and application Not frayed or damaged The 5 Basic
Inspection PointsCord Condition 19
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The Inspection 1.Grounding 2.Enclosure 3.Overcurrent Protection
4.Cord Condition 5.Electrical Marking Power input must be marked
with nameplate information: Voltage, frequency, current, power
Fuses must be labeled with replacement types Shock and arc warning
Multiple source warning Stored energy warning Special instructions
The 5 Basic Inspection PointsElectrical Marking 20
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The Codes NFPA 790/NFPA 791 contain the basic requirements for
administering the inspection program The proper primary standard
must be selected based on the type of equipment: NFPA 70: National
Electrical Code NFPA 79: Industrial Machinery UL 508: Industrial
Control Equipment UL 508A: Industrial Control Panels UL 61010-1:
Laboratory Equipment UL 60950-1: IT Equipment Many others as
applicable 21
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New vs Legacy Equipment New equipment is expected to meet the
code in its entirety Waivers may be granted by the AHJ depending on
application and on a case by case basis Legacy equipment is
inspected to the 5 Basic Points, only major safety concerns are
corrected to meet acceptance requirement Equipment intended for use
in homes must meet Code-Plus: Code must be met as closely as is
allowed by the equipment type Failure modes must be eliminated as
much as possible to reduce risk of fire or shock to ALARA (as low
as reasonably achievable) 22
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The Electrical Equipment Safety Program Common Issues 23
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CE Equipment CE Standards are very similar to US standards, and
there is an ongoing process of alignment between the two CE
certification is a manufacturers self-declaration of conformity,
and is required for selling equipment in the European Union Most EU
countries have additional national requirements, some also include
3 rd - party verification NRTL Listing requires a 3 rd -party
verification of conformity to US standards Does not meet Listing
requirement 24
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Lack of Design Equipment built as a proof of concept must be
converted to a safe assembly through proper design. Some items
inspected can be corrected on the spot, but many lab-built items
need complete re-design to incorporate code requirements 25
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The Electrical Equipment Safety Program Recent Process Changes
& Improvements 28
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Benchmark LBNL Compared to Other Labs Note: Benchmark by phone
interview with AHJ at other labs 29 LabYear Initiated Number in
inventory Number inspected total/annual Staffing for Inspection
LBNL200827,00014,000/1,5001.5 FTEs, centralized Sandia2007~20,000
(recent audit indicates under estimate) 11,000/2,000135 trained,
decentralized ORNL20092,000 Estimate 30,000 1,000/50026 trained,
decentralized SLAC200529,0004,000/2,50060 trained, decentralized
LLNL2001No central inventory audit shows10% unlisted 26,000/7002
FTEs centralized, 24 decentralized BNL200840,00040,000/50050
trained, decentralized
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2008-2012 Performance Per Year SurveyedInspectedFail
12/31/08158866 12/31/0921,2973407148 12/31/1018324552266
12/31/1115703976322 4/18/1276295146 Total2704912892788 Significant
carryover of backlog from year to year Cumulative
SurveyedInspectedFail 12/31/08158866 12/31/0922,8853,413154
12/31/1024,7177,965420 12/31/1126,28711,941742
4/18/1227,04912,892788
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Implemented Risk-Ranked Inspection Approach SAC initiative with
EHSS 31 Risk Group DescriptionUninspected Low 120 VAC CE or
similarly marked Any CSA Identical to previously inspected
equipment Reputable manufacturer 975 Medium208 VAC CE or similarly
marked8,014 HighNot listed above (eg. custom)5,363 Total14,352
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Inspected (10/1/2012)Uninspected (10/1/2012) 32 FY 2013 FY 2014
27% (as of 1/31/13) Electrical Equipment Safety Program (EESP)
Inspection baseline and progress to date
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AHJ Acceptance Process Acquisition Procure only NRTL when
possible Survey All non-NRTL equipment is entered into tracking
database Inspection Surveyed equipment is risk-ranked and scheduled
for inspection Acceptance Equipment that passes inspection or
repair is accepted by AHJ 33
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Acquisition Continue existing requirement that equipment must
be NRTL approved or AHJ accepted before being put into operation.
Procurement will build etools to help users purchase NRTL listed
equipment (or confirm no listed equipment exits) Divisions will
purchase listed equipment when possible 34
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Survey Each division is responsible for identifying/surveying
all unlisted electrical equipment* Divisions to identify surveyors
by November 1, 2012 and trained by December 15, 2012* Survey all
division equipment before September 30, 2013 On-going assurance
through combination of EHSS and division programs 35 Survey looks
for UL or other NRTL Labels
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Inspection The cost of inspections of all non-NRTL equipment
identified by September 30, 2013 will be borne by the Electrical
Equipment Safety Program (EESP) Costs of repairs / alterations of
electrical equipment necessary to receive AHJ approval is borne by
the division/program/project that owns the equipment 36 Inspection
training at LBNL LBNL sticker
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Acceptance Permanently increase baseline +0.5 FTE for expected
annual influx Surge +2.5 FTE for 2 years to eliminate the current
backlog 1.FY13: Target 5,300 items in high-risk category 2.FY14:
Remaining 7,700 medium/low risk equipment 37 Footer
Slide 38
The LBNL Electrical Safety Program 1.Prevent electrical-related
injuries 2.Implement proactive controls across the spectrum of
expected hazards 3.Educate the lab population about electrical
hazards 4.Promote a vibrant electrical safety culture 5.Demonstrate
compliance to established standards ObjectivesScope 38 Zero
Electrical Injuries Qualified Electrical Workers Safe Equipment
Non- Electrical Workers Safe Work Practices