MEGGER GettingDownToEarth

PCP-650

 Electrical Safe Practices For Personnel and Equipment Breakers). This includes drill motors, grinders, circular saws, soldering irons, cord lights, and the like. 26.3.

The P&G preferred method of protecting personnel from electric shock when using portable hand held tools is the use of portable GFCI’s to supply power whenever the tools are used. Portable GFCI’s for personal shock hazard protection should be a standard issue item for every employee who is expected to operate portable electric tools when ground fault or earth leakage protection is not available as part of the site wiring system.

27. Portable Electrical Equipment HS&E CBA 8018 establishes the expectations for inspections of portable electrical equipment. Portable (plug and cord connected) electrical equipment includes appliances and unit-operations which, are not permanently wired to the building electrical system, and that by their design, can be easily moved or relocated. Office equipment, such as lamps, PC’s, printers, copy machines, etc. that are rated and approved for their use by the local authority, (CE in the EU, U/L in the USA, CSA in Canada, etc.) are not included in this definition. 27.3. All portable, plug and cord connected, electrical devices, equipment, and appliances with exposed conductive surfaces, must have those surfaces properly and adequately bonded to ground. Normally this is accomplished by the manufacturer using a three conductor power cord and three prong  polarized plug, but may in some cases require an additional grounding conductor. Unless marked as “double insulated” by the manufacturer, all portable electrical equipment must have an equipment grounding conductor and a three-prong attachment plug. The grounding conductor in the power cord is an important safety feature than must remain intact to insure the safety of those who come in contact with the equipment. At most P&G sites this includes equipment such as; space heaters, floor fans, portable lights, electronic scales, lab ovens, mixers, etc. Such equipment should be powered by a GFCI’s where possible. 27.4. Portable, plug and cord connected, three phase electrical equipment, not protected by GFCI’s, must  be inspected visually prior to each use and tested periodically to verify the continuity of the equipment grounding conductor. The visual inspection should verify that the cord and plug are in good, serviceable working condition, and that the electrical enclosure on the equipment is intact. Departments that rely upon such portable equipment for their day to day operation should document the periodic testing of that equipment and track the equipment to insure that the safe working condition does not degrade over time. The test results should be documented and made available to electrical system auditors. Such equipment includes portable welders, air compressors, production unit-operation’s, or similar equipment and machines. When such equipment has been placed in storage, it should be electrically tested and inspected before returning it to service. 27.1. 27.2.

28. Electrical Power Tool Safe Practices When using hand held power tools: Always use a Ground Fault Circuit Interrupter (GFCI) to supply power, and test it before use. Always minimize your contact to ground while using power tools. Avoid allowing any part of your body to become a current path, between the tool and ground. Avoid laying down on the earth, damp concrete, or any grounded metallic surface. When you must do so, use a dry insulating mat. 28.5.  Never use an aluminum (or any metallic) ladder. Fiberglass safety ladders are the P&G standard. 28.1. 28.2. 28.3. 28.4.

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 Electrical Safe Practices For Personnel and Equipment 28.6.  Never use power tools while standing in water or the rain. 28.7.  Never stand barefoot on the soil, metal structures, or concrete, always wear proper footwear in good dry condition. 28.8.  Never use 3-prong to 2-prong adapters. These devices eliminate the safety ground connection.

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PCP-650

 Electrical Safe Practices For Personnel and Equipment PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications Tasks Performed on Energized Equipment

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

0

N

N

Circuit breaker (CB) or fused switch operation with covers on

0

N

N

CB or fused switch operation with covers off

0

N

N

Work on energized electrical conductors and circuit parts, including voltage testing

1

Y

Y

Remove/install CBs or fused switches

1

Y

Y

Removal of bolted covers (to expose bare, energized electrical conductors and circuit parts)

1

N

N

Opening hinged covers (to expose bare, energized electrical conductors and circuit parts)

0

N

N

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the panelboard

1

Y

Y

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

1

N

N

CB or fused switch operation with covers on

0

N

N

CB or fused switch operation with covers off

1

Y

N

Work on energized parts, including voltage testing

2*

Y

Y

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the panelboard or switchboard

2*

Y

Y

Panelboards or Other Equipment Rated 240 V and Below – Note 1

Tasks Performed on Energized Equipment

Panelboards or Switchboards Rated >240 V and up to 600 V (with molded case or insulated case circuit breakers, Note 1) Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

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 Electrical Safe Practices For Personnel and Equipment PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications (continued) Tasks Performed on Energized Equipment

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

1

N

N

CB or fused switch or starter operation with enclosure doors closed

0

N

N

Reading a panel meter while operating a meter switch

0

N

N

CB or fused switch or starter operation with enclosure doors open

1

N

N

Work on energized electrical conductors and circuit parts, including voltage testing

2*

Y

Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

0

Y

Y

Work on control circuits with energized electrical conductors and circuit parts >120 V, exposed

2*

Y

Y

Insertion or removal of individual starter “buckets” from MCC – Note 3

4

Y

N

Application of safety grounds, after voltage test

2*

Y

N

Removal of bolted covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

4

N

N

Opening hinged covers (to expose bare, energized electrical conductors and circuit parts) – Note 3

2*

N

N

Work on energized electrical conductors and circuit parts of utilization equipment fed directly by a branch circuit of the motor control center

2*

Y

Y

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

2

N

N

CB or fused switch operation with enclosure doors closed

0

N

N

Reading a panel meter while operating a meter switch

0

N

N

CB or fused switch operation with enclosure doors open

1

N

N

Work on energized electrical conductors and circuit parts including voltage testing

2*

Y

Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

0

Y

Y

Work on control circuits with energized electrical conductors and circuit parts >120 V, exposed

2*

Y

Y

Insertion or removal (racking) of CBs from cubicles, doors open or closed

4

N

N

Application of safety grounds, after voltage test

2*

Y

N

Removal of bolted covers (to expose bare energized electrical conductors and circuit parts)

4

N

N

Opening hinged covers (to expose bare energized electrical conductors and circuit parts)

2

N

N

600 V Class Motor Control Centers (MCC’s) Note 2 (except as indicated) Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

Tasks Performed on Energized Equipment

600 V Class Switchgear (with power circuit breakers or fused switches) – Notes 4 Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

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 Electrical Safe Practices For Personnel and Equipment PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications (continued) Tasks Performed on Energized Equipment

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

Removal of bolted covers (to expose bare, energized electrical conductors and circuit parts) Opening hinged covers (to expose bare, energized electrical conductors and circuit parts) Work on energized electrical conductors and circuit parts, including voltage testing

2*

N

N

1

N

N

2*

Y

Y

Application of safety grounds after voltage test

2*

Y

N

Revenue meters (kW-hour, at primary voltage and current) Insertion or removal Cable trough or tray cover removal or installation

2*

Y

N

1

N

N

1

N

N

Work on energized electrical conductors and circuit parts, including voltage testing

2*

Y

Y

Application of safety grounds after voltage test

2*

Y

N

Insertion or removal of plug-in devices into or from busways

2*

Y

N

Other 600 V Class (277 V through 600 V nominal) Lighting or small power transformers (600V, maximum)

Miscellaneous equipment cover removal or installation

Tasks Performed on Energized Equipment

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

NEMA E2 (fused contactor) Motor Starters, 2.3kV Through 7.2kV

Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

3

N

N

Contactor operation with enclosure doors closed

0

N

N

Reading a panel meter while operating a meter switch

0

N

N

Contactor operation with enclosure doors open

2*

N

N

Work on energized electrical conductors and circuit parts, including voltage testing

4

Y

Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

0

Y

Y

Work on control circuits with energized electrical conductors and circuit parts >120 V, exposed

3

Y

Y

Insertion or removal (racking) of starters from cubicles, doors open or closed

4

N

N

Application of safety grounds, after voltage testing

3

Y

N

Removal of bolted covers (to expose bare energized electrical conductors and circuit parts) Opening hinged covers (to expose bare energized electrical conductors and circuit parts)

4

N

N

3

N

N

Insertion or removal (racking) of starters from cubicles of arc-resistant construction, tested in accordance with IEEE C37.20.7, doors closed only

0

N

N

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PCP-650

 Electrical Safe Practices For Personnel and Equipment PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications (continued) Tasks Performed on Energized Equipment

HRC

Rubber Insulating Gloves

Insulated and Insulating Hand Tools

Perform infrared thermography and other non-contact inspections outside the restricted approach boundary

3

N

N

CB operation with enclosure doors closed

2

N

N

Reading a panel meter while operating a meter switch

0

N

N

CB operation with enclosure doors open

4

N

N

Work on energized electrical conductors and circuit parts, including voltage testing

4

Y

Y

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed

2

Y

Y

Work on control circuits with energized electrical conductors and circuit parts >120 V, exposed

4

Y

Y

Insertion or removal (racking) of CBs from cubicles, doors open or closed

4

N

N

Application of safety grounds, after voltage test

4

Y

N

Removal of bolted covers (to expose bare energized electrical conductors and circuit parts)

4

N

N

Opening hinged covers ( to expose bare energized electrical conductors and circuit parts)

3

N

N

Opening voltage transformer or control power transformer compartments

4

N

N

CB operation with enclosure door closed

0

N

N

Insertion or removal (racking) of CBs from cubicles, doors closed

0

N

N

Insertion or removal of CBs from cubicles with door open

4

N

N

Work on control circuits with energized electrical conductors and circuit parts 120 V or below, exposed Insertion or removal (racking) of ground and test device with door closed

2

Y

Y

0

N

N

Insertion or removal (racking ) of voltage transformers on or off the bus door closed

0

N

N

Metal Clad Switchgear 1kV Through 38kV

Arc-Resistant Switchgear Type 1 or 2 (for clearing times of 38kV in the U.S. but not in Europe. Two of the three distances would have had to be extended  beyond what was currently used had 38kV been used. The decision was made to use 36kV so the labeling on so many panels would not need to be changed knowing that there were a couple of plants that use 38kV. For those sites the Global Electrical Safety Leader can work with them individually as needed to provide them with the correct boundary distances for their region and they may also consider 38kV as MV or they may use the longer  boundary distances provided for High Voltage systems.

7. Qualified Person 7.1. 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. Such persons shall also be familiar with the  proper use of special precautionary techniques, PPE (personal protective equipment), insulating and shielding materials, and insulated tools and test equipment. A person can be considered qualified with respect to certain equipment and methods but still unqualified for others.

8. Clear Work Space 8.1. A minimum clear work space of 0.9 meter (3 feet) must be maintained in front of, an d /or beneath all electrical cabinets, MCC’s, switchboards or panelboards containing circuits energized at greater than 50 volts. This is a minimum distance and may need to be increased based upon the voltage level, the  proximity to other electrical equipment or grounded surfaces, and the authority having jurisdiction. Refer to local and country codes and regulations for specific clarifications. This area may not be used to store materials or equipment of any kind. The clear work space must be maintained.

9. Job Planning 9.1. Developing a Job Plan 5/21/2015

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PCP-650

 Electrical Safe Practices For Personnel and Equipment 9.1.1.

See Annex D for an example job planning system (CBA 101)

9.1.2.

See Annex E for an example job plan

9.2. Job Safety Analysis and Potential Problem Analysis 9.2.1.

A job safety analysis must be prepared for all medium or high voltage work.

9.2.2.

A Potential Problem Analysis should be conducted for all medium or high voltage work.

9.2.3.

The JSA and PPA can be combined into one document. Please see Annex F for an example.

9.3. Job Breifing 9.3.1.

Before starting each job, the employee in charge shal conduct a job briefing with the employees involved. The briefing shall cover such subjects as hazards associated with the job, work procedures involved, special precautions, energy source controls, and personal protective equipment requirements.

9.3.2.

If the work or operations to be performed during the work day or shift are repetitive and similar, at least one job briefing shall be conducted before the start of the first job of the day or shift. Additional job briefings shall be held if changes that might affect the safety of employees occur during the course of the work.

9.3.3.

A brief discussion shall be satisfactory if the work involved is routine and if the employee, by virtue of training and experience, can reasonably be expected to recognize and avoid the hazards involved in the job. A more extensive discussion shall be conducted if either of the following apply: 9.3.3.1. 9.3.3.2.

the work is complicated or particularly hazardous. The employee cannot be exptedcte to recognize and avoid the hazards involved in the job.

10.Energized Electrical Work 10.1. Each site must have a written policy governing work performed on or near energized equipment. The policy should require that all persons, authorized by the site to perform energized electrical work, be qualified according to the intent of Procter & Gamble Co. HSE CBA-8016 Qualification. 5/21/2015

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PCP-650

 Electrical Safe Practices For Personnel and Equipment 11. Energized Work Defined 11.1.

At P&G sites, energized work is governed by HS&E CBA 8015. HS&E CBA 8015, Part IV Paragraph C states: “Energized work involves working inside the Prohibited Approach Boundary as defined in NFPA 70E, or repairing, replacement, or installation of energized electrical equipment. Specific safety actions must be taken to ensure the task can be performed safely. If at any time the  person(s) doing the work, a supervisor, or person signing the permit determine that the task cannot be  performed safely, stop the work.”

12. Energized Work Examples 12.1. 12.2. 12.3. 12.4. 12.5. 12.6. 12.7. 12.8.

Making or breaking splices in energized wiring Connecting or disconnecting energized wires on terminal strips Making or breaking plug-in connections to energized bus bars, MCC buckets, bus-ducts, etc. Adjusting or aligning energized parts Using hand tools to tighten, remove, or replace energized components Pulling wire or cable into conduits containing energized circuits Removing or replacing fuses in energized circuits Crossing the LV Prohibited Approach Boundary for any reason including during troubleshooting.

13. Energized Work Permit (EWP) HSE CBA-8015 Energized Work Permit defines the official P&G policy governing EWP’s and should be followed whenever considering any energized electrical work on a P&G site. All work on or near energized electrical equipment is to be avoided where possible due to the inherent dangers involved. Most instances of proposed energized work can be temporarily postponed and accomplished at a time when the power can be turned off without causing additional risk to the  business, and thereby eliminate the risk to the employees. In cases where it is not possible to wait, or when waiting could actually increase the risk of a serious incident occurring, work may proceed by following the EWP process. 13.2. The EWP Process: 13.2.1. requires a permit for all work on circuits or compone nts energized above 50 Volts 13.2.2. limits the work to systems operating at 600 Volt or less The selection of 600 V as the limit for 13.1.

an EWP is based on the types of injuries seen when sh ocks occur at these voltages. At about 600V the skin no longer offers significant protection and we begin to see penetration wounds at the locations of where the current enters and leaves the body. In addition, the wounds con tinue through the individual forming a burn track with relatively low impedance and significant damage. This is the reason why EWP is limited to 600V. It is not based on either equipment or the voltages normally seen or used in any region of the world. 13.2.3. 13.2.4.

13.2.5. 13.2.6. 13.2.7.

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documents sufficient cause documents the job specific hazards, safe practices, work procedures, personal protective equipment, limited approach, restricted approach, prohibited approach, and flash  boundaries(Appendix B), special precautions, and tools required to ensure the work will be  performed in a safe manner. requires proper authorization insures proper communication identifies those to perform the work

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PCP-650

 Electrical Safe Practices For Personnel and Equipment 14. Work Not Requiring an EWP Routine maintenance activities by persons qualified to the level required for the work, often require that certain tasks (troubleshooting, voltage and/or current measurements, etc.) be completed with the circuit energized. These activities do not normally require an Energized Work Permit, although sites may choose to require a permit for such activities if they deem it necessary. All proper PPE and tools approved for the hazard must be used. Examples of these tasks are given below: Visually inspecting components (no disassembly required). Using approved test equipment to measure voltage, current, etc. Troubleshooting using ground fault detection equipment. Taking IR Scan measurements. M.V. or H.V. Switching operations, (manually actuating switchgear) where the enclosures are intact and closed.

14.1.

14.2. 14.3. 14.4. 14.5. 14.6.

15. Prohibited Work In all cases, work on energized electrical equipment, systems or components above 600 Volts is  prohibited by the Procter & Gamble Co. EWP’s (Energized Work Permits) may only authorize work on circuits energized up to 600 Volts. 15.2. Energized Work Permits vs. Circuit Voltages 15.1.

0-50 V. 51-600 V. 600 V. & Higher

No permit required Energized work requires a Permit Not authorized by P&G

16. Approach Boundaries (Working Near Exposed, Energized Equipment) 16.1.

16.2.

There are 4 approach boundaries intended to protect workers from electrical hazards. Three are dedicated to shock protection and one is dedicated to flash protection. These boundaries are intended to limit access to areas of high hazard to electrically qualified personnel, specify when PPE is required, specify when an energized work permit is required, or prohibit access In IP-20 or “finger-safe” panels, where all energized components are fully enclosed, the enclosure is intact, and all guards are in place, and direct contact is not possible, there is therefore no exposure, and the “approach boundaries” do not need to be considered unless the worker is interacting with the equipment. An example of an individual interacting with the equipment would be taking voltage measurements. 16.2.1. The “clear work space” requirements in front of the IP-20 panel would apply.

17. Shock Protection Boundaries Shock Protection Boundaries must be observed whenever personnel are in the vicinity of exposed, energized conductors at 50 Volts or more. This includes times when an electrical enclosure door is opened, a cover or panel is removed that exposes un-insulated energized components or non-finger safe terminals. Also, anytime work is to be done on or near open power distribution lines such as  pole mounted feeders or switchgear. Any proposed work within these areas should be reviewed by the site ESO, or their designee, before beginning work. 17.2. Low Voltage, 50 – 1000 Volt Approach Boundaries are identified as follows: 17.1.

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PCP-650

 Electrical Safe Practices For Personnel and Equipment Limited Approach Boundary; for fixed conductors 1.2 meters (4 feet), for movable conductors 3 meters (10 feet). Only qualified personnel may enter within this boundary. This means that before a qualified person opens an MCC compartment door, exposing uninsulated terminals or bus bars, the limited approach boun dary must be established, to keep  passers-by from unknowingly entering a hazardous area. Restricted Approach Boundary; 0.3 meter (1 foot). Only qualified personnel wearing 17.2.2.  proper shock protection PPE may enter within this boundary. Electrically insulated blanket may also be required as a means of protecting the worker from contact with phase or ground  potential. 17.2.3. Prohibited Approach Boundary; 2.5 Centimeters (0 ft. 1 in.). Up to 600 Volts, only qualified personnel with an approved “Energized Work Permit”, wearing proper shock  protection PPE, and using insulated tools may enter within this boundary. Electrically insulated blanket may also be required as a means of protecting the worker from contact with ground/earth potential or phase potential from other sources in the vicinity of the energized electrical work. Medium Voltage, 1kV-36kV Approach Boundaries are identified as follows:17.3.1. Limited Approach Boundary; for fixed conductors 1.8 meters (6 feet), for movable conductors 3 meters (10 feet). Only qualified personnel may enter within this boundary. An example of a movable conductor is an overhead line which can be moved by the wind. 17.3.2. Restricted Approach Boundary, 1.0 Meter (4 feet) only qualified personnel wearing proper shock protection PPE may enter within this boundary. 17.3.3. Prohibited Approach Boundary, 0.3 meter (1 foot). No access is permitted above 600 volts. Individuals within the Prohibited Approach Boundary are considered to be in direct contact with the energized conductors. The limitation is based on the fact that the severity of shock incidents becomes much worse above 600 volts. In addition to the possibility of cardiac arrest, present for any shock incident, common injuries resulting from shock at voltages in excess of 600 volts also includes: entry and exit wounds, destruction of internal tissue and organs along the path of current flow, blood cell, vein and artery destruction as the blood typically provides the lowest resistance path, and increased current levels through the heart. These levels of tissue damage commonly result in the body becoming overwhelmed with the  byproducts from destroyed cells resulting in renal (kidney) failure. High Voltage, >36 kV-115kV Approach Boundaries are identified as follows; 17.4.1. Limited Approach Boundary: For systems up to these voltage levels typically movable conductor distances are appropriate. 3.6M (12 feet) Restricted Approach Boundary: 2.4M (8 feet) – No access allowed. (No shock protection 17.4.2. PPE available.) 17.4.3. Prohibited Approach Boundary: 1.2M (4 feet) – No access allowed. 17.2.1.

17.3.

17.4.

 Note: Appendix B, Figures 1 & 2, of this document show graphical representations of the approach and flash hazard boundaries relative to exposed energized components, the PPE to be used, and the procedures to be  followed when working within those boundaries.

18. Flash Hazard Boundary 18.1.

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PCP-650

 Electrical Safe Practices For Personnel and Equipment received will not cause permanent tissue damage. This occurs at incident ener gies of 1.2 calories per square centimeter. Persons within that boundary must be protected from the potential arc flash by flash protection PPE. Flash hazard studies are required at all P&G sites. As a minimum, the following flash hazard boundaries shall be observed: 18.1.1. >600 volt systems – as determined by an Arc Flash Study. 50 to 600 volt systems down to and including MCCs - As determined by an Arc Flash 18.1.2. Study. 50 to 600 volt systems below the MCCs. - 1.2 meters (4 feet) (when using the table method 18.1.3. from Appendix A)

19. Flash Hazard Protection Preferred Method The preferred method of determining the prope r protection is to have a complete and detailed flash hazard study for the site power distribution system. IEEE-1584 is the Procter & Gamble Co. standard methodology for conducting a detailed flash hazard analysis, and should be used for all flash hazard studies at P&G sites. Engineering contractors hired to complete Short Circuit, Coordination and Flash Hazard studies must be listed as approved engineering resources in PCP1502. Flash hazard studies calculate the available incident energy (in calories per square centimeter), which allows the site to define the flash hazard boundary to be observed at each bus in the system. Further, this information allows qualified persons to determine the proper minimum PPE to be worn while working at specific points in the electrical system. 19.2. Power System Study software packages are available to assist with calculating via the IEEE-1584 method. 19.3. Alternate Method Some sites, such as a new acquisition site, may not have completed the required flash hazard study. Also, a site’s power system computer model, used to p erform the short circuit, coordination, and flash hazard studies will have a lower equipment limit. For example the computer model may not extend below the motor control center level. In these situations the site may choose to follow the guidance of Appendix A to select PPE for protecting their personnel from flash haza rds. 19.3.1. Appendix A - Table 1 defines the Hazard/Risk Category classifications for various electrical tasks on energized equipment at specific voltages, and specifies the default category of PPE to be used for flash hazard protection while performing those tasks. 19.3.2. Appendix A - Table 2 defines the specific PPE items to be worn to provide adequate  protection for each Hazard/Risk Category. 19.4. P&G Default Flash Hazard Category 0 Based upon documented testing conducted by the IEEE, P&G now recognizes a default Hazard Risk Category 0 for all portions of electrical systems which operate at less than 240 Volts 3 phase, and that have less than 10 KA 3 phase symmetrical fault current available. Typically, fault currents of this level are found in smaller electrical systems supplied by transformers less than 125 KVA. The IEEE-1584 testing found that, given these system limitations, arcing faults cannot be sustained. Therefore, sites may eliminate the Flash Hazard calculations in areas of their electrical system where these system limitations exist, and simply label them as Category 0 Flash Hazard with a 4 foot (1.2 meter) Flash Protection Boundary. Electrical systems with voltages of 240 and higher or with available fault currents of 10KA or higher, must continue to have their flash hazard level calculated  by following one of the methods outlined in other portions of this document. 19.1.

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PCP-650

 Electrical Safe Practices For Personnel and Equipment P&G Default Flash Hazard Category 2* 19.5.1. For 50-1000 volt exposed energized conductors sites may default to Flash Hazard Category 2* PPE. This allowance is based on Annex H of NFPA 70E-2009. 19.5.2. The following low voltage tasks require higher leve ls of PPE per Appendix A Table 1. As a result individuals are not allowed to perform these tasks using Default Flash Hazard Category 2* PPE: 19.5.2.1. Insertion or removal of low-voltage motor starter “buckets,” 19.5.2.2. Insertion or removal of power circuit breakers from switchgear cubicles or 19.5.2.3. Removal of bolted covers from switchgear, motor control centers, or power distribution panels. Equipment Interaction/Operation With Enclosure Doors Closed 19.6. 19.6.1. For MCCs PDPs (Power Distribution Panel)Hazard/Risk Category 0 is adequate for interaction/operation of the electrical equipment with the e nclosure doors closed. (This is  based on Appendix A table method for determination of Flash Hazard PPE.) 19.6.2. Above the MCC/PDP level interaction/operation of electrical equipment, with the enclosure doors open or closed, the PPE specified by the Flash Hazard Study must be utilized. When the enclosure door is closed and the Flash Hazard Study states that the hazard risk category is “Dangerous” a maximum PPE level of Category 4 is required. When  possible, additional administrative or engineering controls should be used to reduce or eliminate the risk of an incident. (In cases where the required Flash Hazard study has not  been completed the Appendix A Table Method must be used and the Flash Hazard Study must be completed.)

19.5.

20. Electrical PPE (Personal Protective Equipment) Electrical PPE includes, but is not limited to; safety glasses, arc rated face shields, flash hoods w/ arc rated face shields, hearing protection, rubber gloves with leather covers, insulating mats, hard hats, fire retardant clothing, safety shoes, insulated hand tools, etc. Anytime that tools or test equipment are used to make contact with energized circuits, at or above 50 Volts, PPE rated to provide  protection from the existing hazards must be worn. This includes IP-20 touch safe equipment. PPE is used to provide protection from both the shock hazards and the flash hazards. Both hazards must be considered when defining the proper PPE for a task. 20.2. Electrical insulating PPE, such as rubber gloves, mats and sleeves are voltage rated and must be used only on voltages of that rating or less. Leather protectors (gloves) shall be worn over rubber insulating gloves at all times. Rubber insulating mats should be used as needed to provide additional  protection when the work is in close quarters with grounded or energized surfaces. 20.3. Rubber gloves are required to be inspected before each use and tested every 6 months. In cases where testing facilities are not available in the region or country purchasing new gloves every 6 months is acceptable with proper tracking. 20.4. Arc flash PPE, such as flame resistant (FR) clothing and face shields, are rated in Calories per square centimeter. Appendix A of this document lists arc flash, and shock protection, PPE for specific tasks where personnel are exposed to those hazards. FR clothing shall be rated to provide protection from the known flash hazard, or as a minimum, be selected according to Appendix A, section 18.4, or section 18.5 of this document. All personnel within the flash hazard boundary (curable burn distance) must be protected from the known arc flash hazard. 20.1.

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PCP-650

 Electrical Safe Practices For Personnel and Equipment 20.5.

20.6.

Properly utilized PPE provides protection to the level indicated by the rating of that specific PPE item. PPE cannot provide adequate protection in situations where the level of voltage or the available incident energy is beyond their rated capability. For example; rubber gloves are available rated up to 36 KV (Class 4, 36,000Volts), but no higher, and the maximum rating currently available for arc resistant clothing is 100 cal/cm sq. Hazard levels may exist at some sites that are beyond the level of protection that PPE can provide. Working Distance As a worker approaches an arc source the incident energy increases. For example, at a 20.6.1. great distance from a strong arc source no PPE is needed while very near to a strong arc source adequate PPE is not commercially available or recommended, i.e. > 40 calories/square cm. Flash hazard studies dictate the minimum requ ired PPE to protect an individual at a specific distance from the arc source. The distance is measured from the arc source to the individual’s head/chest. This distance is provided by IEEE 1584 as follows: 20.6.1.1. Meduim-voltage switchgear 910mm (36 inches) 20.6.1.2. Low-voltage switchgear 610mm (24 inches) 20.6.1.3. Low-voltage MCCs and panelboards 455mm (18 inches) 455mm (18 inches) 20.6.1.4. Cable 20.6.1.5. Other To be determined in the field. 20.6.2. These distances are based on the typical distances a person’s head and chest should be from the arc source while working on that equipment. For most low voltage equipment the distance is based on the length of a person’s arm and was set by IEEE 1584 at 455mm (18 inches). In the case of low-voltage substation switchgear, i.e. power circuit breakers, the distance is based on arm’s length plus 155mm (6 inches). The additional 155mm is because the arc source for a low voltage power circuit breaker is about this far behind the front of the  breaker. In the case of medium-voltage switchgear a person is expected to use a hot stick while voltage testing and applying temporary protective safety grounding and this results in 910mm (36 inches). 20.6.3. If an individual is working with their head or chest closer to the equipment than the distance used in the arc flash study and a fault occurs the amount of incident energy will be higher than predicted by the study and the flash hazard PPE specified by the study may not  be adequate. The working distance for each piece of equipment should be on the flash hazard labeling and workers are expected to observe the working distance. In cases where this is not  possible special precautions and procedures must be employed. An example is the application of clamp type safety grounds to medium voltage switchgear prior to the installation of ground  balls. In this instance the following are examples of effective techniques to control the risk: 20.6.3.1. increasing the PPE level, 20.6.3.2. increased vigilance when voltage testing, and 20.6.3.3. using a hot stick/ground cluster combination, while observing the required working distance, to strike down the phase conductors prior to installing, by hand, a clamp type safety grounding cluster.

21. General Lockout/Tag out (LOTO) Guidelines 21.1. 21.2. 21.3. 5/21/2015

All sites must have documented LOTO guidelines in p lace for personnel to follow whenever work is to be done on electrical systems, powered equipment, or equipment with stored energy. Always follow the site specific or Global HSE guidelines for LOTO procedures. Always use a unique padlock and keep the key in your personal control. Page 12 of 35

PCP-650

 Electrical Safe Practices For Personnel and Equipment 21.4.  Never trust anyone else’s padlock for your safety. 21.5. Always inform the machine owner or customer that you have a LOTO in place and why. 21.6. The implementation details may vary from region to region, or site to site, but all LOTO procedures, for P&G employees and contractors, must have the following features: 21.6.1. The ability to isolate all forms of potential energy, electrical, pneumatic or hydraulic, mechanical, or stored energy. 21.6.2. A system of identifying who placed the lock on the isolator and why. 21.6.3. A deliberate, documented process for removing a lock in the event that one is mistakenly left in place and the originator is not available for removal. All individuals working on a system or machine must have a personal lock and tag in place 21.6.4. on the isolating device until their portion of the work is completed or they leave the site. 21.7. Electrical equipment must be maintained in an electrically safe work condition at all times. This means that when exposed electrical conductors exist, either a lock out and appropriate safety grounding is in place or, in the case of troubleshooting or energized electrical work, effective  boundaries have been established including the Limited Approach Boundary.  Note: For reference see PCP-345and HSE CBA 2052.

21. Construction (contractor) LOTO Procedures During Construction the contractor is responsible for all switching and LOTO’s until the involved equipment is turned over to P&G ownership and control. Disconnects used to isolate power from circuits under construction must be locked and tagged with a lock that remains under the control of the contractor's representative. 21.2. During commissioning activities, all P&G personnel working on a given circuit must add their  personal lock and tag to the disconnect switch even though the contractor may still have a lock in  place. Commissioning personnel must remove their locks when finished with their work or whenever leaving the site. 21.3. Construction Completion. When all commissioning work is completed and the machine or process is accepted by P&G, a formal hand off must occur during which all contractor locks and tags are removed, and the start-up team and plant personnel are informed that P&G has co mplete control and ownership of the machine or process. After the ownership transfer, the normal P&G plant LOTO  procedures shall be followed. 21.1.

22. Safety Grounding (temporary protective grounds) Simply following LOTO procedures alone, does not insure safety during power outage maintenance activities. “Safety Grounding” is the practice of connecting all three phases of a power circuit to ground (earth) after testing and confirming them to be de-energized. This is done primarily to  prevent inadvertent re-energizing, but also to ensure that all capacitively stored or induced voltages are dissipated, and the circuit remains at ground potential while the work is underway. Safety grounding protects personnel who otherwise would be at great risk as they climb in and on normally energized surfaces to clean, inspect, test and repair power circuit components. 22.2. During scheduled maintenance power outages, there is a very real risk of circuits being energized or retaining hazardous energy from: 22.2.1. re-energization from the normal feed. 22.2.2. “back feeds” from portable generators used to provide local lighting and portable tool power. 22.1.

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 Electrical Safe Practices For Personnel and Equipment capacitively stored electrical charges that remain on recently de-energized circuits. If of sufficient length, circuit conductors can retain energy sufficient to deliver serious shocks due to inter-electrode capacitance or capacitance to ground/earth. Capacitively stored charge is direct current (DC) and typical medium voltage testing equipment is capable on testing for alternating current only. The result is that capacitively stored charge cannot be detected using this equipment and temporary protective grounding is required to ensure safety. 22.2.4. magnetic coupling with nearby energized circuits can induce voltages onto de-energized conductors. 22.3. Proper application of safety grounds eliminates the haza rds listed above, and is a requirement for establishing a safe working condition on systems with nominal voltages over 1000 volts. Safety grounding is accomplished either by using integral grounding switch mechanisms, or by installing temporary protective grounds or “ground clusters”. Ground clusters are an assembly of clamps and cables manually attached to ground and all three-phase conductors. Ground clusters are not required when using grounding switch mechanisms provided the grounding switch mechanism is rated for the available short circuit current. In rare cases where it is not possible to install temporary protective safety grounds the specific hazards in Section 22.2 must be addressed and it must be shown that there is no possibility for induced voltage. These cases sometimes occur d uring the installation/removal of a feeder or when working with some MV motor starters. 22.2.3.

 Note: Many substation transformer installations at P&G do not include secondary protection. In such 2 cases the incident energy available at the low voltage bus can be extremely high, often over 150 Cal/cm . This makes measuring the secondary voltage a very hazardous task that should never be undertaken when the equipment is known to be energized. When it is necessary to verify the absence of voltage at the secondary bus, the following procedure should be followed to minimize the risk.

23. Detailed Safety Grounding Procedure Always confirm, as much as possible, that the switchgear is unloaded before opening the transformer  primary (medium or high voltage) switch. 23.2. Wear the proper PPE for the hazard involved. 23.3. Open the primary switch and lock and tag. 23.4. Select the proper test equipment for the system voltage. 23.5. Test all voltage testers, glow sticks, etc. on a known energized source just prior to use. 23.6. Maintain the maximum practical distance while working. 23.7. Test all phases of the circuit for any voltage indication to verify that there is no voltage. 23.8. After the tester shows no voltage, retest the voltage tester to confirm proper functionality. 23.9. Once it is verified that there is no voltage on the circuit, connect one end of the ground cluster to an effective ground connection, ideally this would be a grounding point specifically provided for such use.  NOTE: Use only ground clusters designed for the purpose and of sufficient wire size to safely carry the  fault current available at that point in the system. The P&G standard minimum size is AWG 4/0 or 95 mm2. To order proper ground clusters for your site, go to the Salisbury Grounding Configurator at www.whsalisbury.com. 23.10. Using the hot stick, touch each phase with the ground cluster to discharge any residual energy stored by the line capacitance. 23.1.

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 Electrical Safe Practices For Personnel and Equipment 23.11. Using the hot stick, individually connect the three phases to the ground cluster. 23.12. Remove PPE as desired and begin maintenance work. 23.13. When removing protective grounds, first disconnect the phase leads and then disconnect the ground connection last.

24. Temporary Wiring  NOTE: Insubstantial or unsafe wiring cannot be considered safe or acceptable because it is temporary. 24.1. At P&G sites temporary wiring is subject to the following limitations: 24.1.1. 90 days maximum installation lifetime or the duration of the associated construction effort. 24.1.2. Must be installed by qualified person(s). 24.1.3. All connections, other than those made with approved plugs and receptacles, must be made inside electrical enclosures. 24.1.4. The installation must meet all applicable code s and standards. 24.1.5. All components used must be listed and approved for the purpose as used. 24.1.6. Each end of temporary feeder cables must be tagged indicating the anticipated date of removal, date of installation, project name, and the project contact’s name. 24.1.7. All temporary electrical equipment must meet the requirements of HS&E CBA 8018. 24.1.8. The ESO is responsible to review temporary wiring plans and ensure timely removal.

25. Portable Cords HS&E CBA 8018 establishes the expectations for inspections of portable cords. Type SO (heavy duty oil resistant) cords are not acceptable for permanent wiring except as power cords for portable equipment, extension cords, push button pendants, or drops from bus ducts. The  jacket of SO cord is rubber which is flammable and therefore not approved for use in conduit, cable tray, or air return plenums. SO cord may be used for single phase and 3-phase circuits up to 600 volts. Do not install or use portable cords on circuits operating at over 300 volts potential to ground. The recommended maximum length is 50 feet (15 m). Limit the length of all portable cords to as short as practical for the need. 25.3. Do not expose portable cords to vehicle traffic, or other forms of mechanical damage. Route cords in a manner to protect them from mechanical damage, moisture and chemicals. Install cords such that the strain and wear will be minimized. 25.4. For 3 phase systems, use a 4 conductor cord to maintain the safety ground. 3-phase, 480 volt, plug connected equipment must not be plugged-in or un-plugged under load. A means of de-energizing must be provided at or near the receptacle to allow safe connecting and disconnecting. 25.1. 25.2.

26. Ground Fault (Earth Leakage ) Protection for Portable Tools 26.1.

HS&E CBA 8018 establishes the expectations for ground fault protection of portable tools. An RCD (Residual Current Device) rated at 30 mA or less is considered equivalent protection when compared to a GFCI.

26.2.

All portable, hand held electrical tools used by personnel during construction, remodeling, maintenance, repair or demolition of buildings, structures, equipment or similar activities must be  protected by GFCI’s (Ground Fault Circuit Interrupters) or ELCB’s (Earth Leakage Circuit

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 Electrical Safe Practices For Personnel and Equipment Breakers). This includes drill motors, grinders, circular saws, soldering irons, cord lights, and the like. 26.3.

The P&G preferred method of protecting personnel from electric shock when using portable hand held tools is the use of portable GFCI’s to supply power whenever the tools are used. Portable GFCI’s for personal shock hazard protection should be a standard issue item for every employee who is expected to operate portable electric tools when ground fault or earth leakage protection is not available as part of the site wiring system.

27. Portable Electrical Equipment HS&E CBA 8018 establishes the expectations for inspections of portable electrical equipment. Portable (plug and cord connected) electrical equipment includes appliances and unit-operations which, are not permanently wired to the building electrical system, and that by their design, can be easily moved or relocated. Office equipment, such as lamps, PC’s, printers, copy machines, etc. that are rated and approved for their use by the local authority, (CE in the EU, U/L in the USA, CSA in Canada, etc.) are not included in this definition. 27.3. All portable, plug and cord connected, electrical devices, equipment, and appliances with exposed conductive surfaces, must have those surfaces properly and adequately bonded to ground. Normally this is accomplished by the manufacturer using a three conductor power cord and three prong  polarized plug, but may in some cases require an additional grounding conductor. Unless marked as “double insulated” by the manufacturer, all portable electrical equipment must have an equipment grounding conductor and a three-prong attachment plug. The grounding conductor in the power cord is an important safety feature than must remain intact to insure the safety of those who come in contact with the equipment. At most P&G sites this includes equipment such as; space heaters, floor fans, portable lights, electronic scales, lab ovens, mixers, etc. Such equipment should be powered by a GFCI’s where possible. 27.4. Portable, plug and cord connected, three phase electrical equipment, not protected by GFCI’s, must  be inspected visually prior to each use and tested periodically to verify the continuity of the equipment grounding conductor. The visual inspection should verify that the cord and plug are in good, serviceable working condition, and that the electrical enclosure on the equipment is intact. Departments that rely upon such portable equipment for their day to day operation should document the periodic testing of that equipment and track the equipment to insure that the safe working condition does not degrade over time. The test results should be documented and made available to electrical system auditors. Such equipment includes portable welders, air compressors, production unit-operation’s, or similar equipment and machines. When such equipment has been placed in storage, it should be electrically tested and inspected before returning it to service. 27.1. 27.2.

28. Electrical Power Tool Safe Practices When using hand held power tools: Always use a Ground Fault Circuit Interrupter (GFCI) to supply power, and test it before use. Always minimize your contact to ground while using power tools. Avoid allowing any part of your body to become a current path, between the tool and ground. Avoid laying down on the earth, damp concrete, or any grounded metallic surface. When you must do so, use a dry insulating mat. 28.5.  Never use an aluminum (or any metallic) ladder. Fiberglass safety ladders are the P&G standard. 28.1. 28.2. 28.3. 28.4.

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 Electrical Safe Practices For Personnel and Equipment 28.6.  Never use power tools while standing in water or the rain. 28.7.  Never stand barefoot on the soil, metal structures, or concrete, always wear proper footwear in good dry condition. 28.8.  Never use 3-prong to 2-prong adapters. These devices eliminate the safety ground connection.

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