Jackie McAlhaney Vice Chairman, Senior Electrical Review Board

1. ESIP Project Area 5 Awareness/ Continuation Training Briefing to EFCOG ISM Working Group Electrical Safety Improvement Idaho Falls, Idaho October 11, 2006 Jackie McAlhaney Vice Chairman, Senior Electrical Review Board Savannah River Site Phone: (803) 208-3389 E-Mail: jackie.mcalhaney@srs.gov Lloyd Gordon Vice Chairman, Electrical Safety Committee Los Alamos National Laboratory

2. Project Area 5 Awareness/Continuation Training SCOPE I. Provide recommendation for a standardized approach for initial Electrical Safety Awareness and continuation training for non-electrical workers - Jackie McAlhaney II. Provide recommendations and materials for standardized approach for R&D Worker Electrical Safety Training - Lloyd Gordon

3. I. Nonelectrical Worker Training Jackie McAlhaney Savannah River Site

4. Project Area 5 Awareness/Continuation Training • Milestones: • Develop Recommended Approach for Initial and Continuation Electrical Hazards Awareness Training for Non-Electrical Workers - COMPLETE • Complete review of other industries approaches-COMPLETE • Develop and issue training materials and summary of good practices- COMPLETE • Issue implementation recommendations

5. Project Area 5 Awareness/Continuation Training • Team Members: DOE:Ray Blowitski, EH-32 - LEAD Richard Lasky, EH-32 EFCOG:Jackie McAlhaney, WSRC – LEAD Lloyd Gordon, LANL – Co-LEAD David Mills, WSRC Bill Reed, INL Paul Case, FH Jim Bird, INL Bobby Gray, FH Abby Crumpler, BWXP Dennis Wiatrak, FH T. Carrona, LBNL INPO: George Mortensen

6. Project Area 5 Awareness/Continuation Training • Recommended Approach: • Develop a General Training Module: Basic Electrical Safety for Non-Electrical Workers • Develop Targeted Training Modules for specific Non-Electrical Worker Groups • Identify and recommend other available training sources

7. Project Area 5 Awareness/Continuation Training Specific Non-Electrical Worker Groups Targeted: • Welders • Painters • Crafts (e.g., carpenters, pipefitters, construction workers, and including D&D workers) • Laboratory Researchers and Engineers • Excavation Workers • Heavy Equipment Operators • Radiological Workers • Office and Administrative Personnel – Basic Module & Electrical Cord Safety

8. Project Area 5 Awareness/Continuation Training Specific Modules Completed: • General Electrical Safety Awareness • Electrical Cord Safety • Electrical Safety for Arc Welding and Plasma Cutting • Laboratory Researchers and Engineers • Electrical Safety for Excavation and Trenching • Excavation for Skilled Worker • Electrical Safety Working Near Overhead Power Lines • Electrical Safety Awareness Study Guide (Instructors and Students)

9. Project Area 5 Awareness/Continuation Training Supplementary Training Sources Available: • NIOSH Electrical Safety Student Manual • Construction Safety Council Booklet “Managing Power Line Hazards” • Video “Boom Truck Contact with Overhead Power Line” • Links to electrical safety information: • http://www.electrical-safety.org/ • http://www.cdc.gov/elcosh/docs/hazard/safety_electricity.html • http://www.osha-slc.gov/SLTC/electrical/index.html

10. Project Area 5 Awareness/Continuation Training Team Recommendation: • Post all training modules and resources on EFCOG Electrical Safety WEB site • Communicate availability of training modules to all DOE facilities and stress use for non-electrical worker

11. Project Area 5 Awareness/Continuation Training Module 1: General Electrical Safety Awareness: • Introduces electrical terminology and how an electric shock can be received • Emphasizes hazard potential with 120 Vac and low currents • Provides graphic images of electrical burns • Several electrical hazard scenarios for discussion • Stresses importance of GFCI’s • Stresses proper electrical cord control • Stresses proper inspections prior to resetting breakers • Response during electrical emergency • Response to downed power lines

12. Project Area 5 Awareness/Continuation Training Module 2: Electrical Cord Control: • Short review of electric shock theory • Emphasizes cord inspection prior to use • Provides examples of cord hazards for discussion • Proper plug installation and removal • Stresses importance of GFCI’s and GFCI testing • Multi outlet adaptors • Stresses role of electrical safety officer for guidance

13. Project Area 5 Awareness/Continuation Training Module 3: Electrical Safety for Arc Welder and Plasma Cutter: • Discusses recent arc welding fatality • Introduces touch potential and open circuit voltage • Emphasizes safe practices for grounding with illustrations • Emphasizes safe practices using welding cables • Stresses importance of environmental conditions • Stresses importance to protect others in area • Stresses proper maintenance and modification control of equipment

14. Project Area 5 Awareness/Continuation Training Module 4: Electrical Safety working near Overhead Power Lines: • Discusses specific fatalities from contact with power lines • Provides general planning for safe work • Discusses importance of two barrier control system • Emphasizes power line clearances • Provides specific practices for operating cranes, dump trucks, material handling and use of ladders • Emergency actions

15. Project Area 5 Awareness/Continuation Training Module 5: Electrical Safety during excavation and trenching • Discusses serious injuries from jackhammer event • Identifies at-risk groups of workers • Emphasizes practices to identify underground hazards • Stresses proper field investigation and hand excavation where interferences known • Stresses PPE

16. Project Area 5 Awareness/Continuation Training Module 6: Electrical Safety for Skilled Worker: • Introduces worker to 70E requirements and boundaries • Stresses Lockout program • Stresses safe practices using portable electrical tools • Extension cord safe practices • Discusses electrical intrusion events and specific examples • Emphasizes importance to obey signs and barriers

17. II. R&D Worker Training Lloyd Gordon Los Alamos National Laboratory

18. Project Area 5 Awareness/Focused Training - R&D SCOPE • Provide recommendation for a standardized approach for Electrical Safety Modules on specific topics for workers in the R&D laboratory environment. • Provide recommendation for a standardized approach for training for contractor Electrical Safety Officers.

19. What is an R&D Worker? • Scientists, engineers, technicians, and others who: • work in an R&D laboratory environment performing research and development, often with custom built, or state-of-the-art equipment. • The degree of electrical work can vary from: • the operation of custom built equipment, largely protected by engineering controls, to • the design, fabrication, and maintenance of custom built R&D equipment, to • working inside of R&D equipment as a part of the research process

20. Electrical or Non-electrical Worker? • The difference between a facility electrical worker (e.g., electrician) and a facility non-electrical worker (e.g., welder, carpenter, heavy equipment operator) is clear. • An electrician/lineman has a formal licensing process. • An electrician/lineman’s job is electricity. • Experimental R&D workers learn some elements of electrical technologies in their academic education, especially in their specific fields. • There is no specific formal record of this electrical training. • They may know their specific equipment very well. • Working with electricity may only be a small part of their job. • Is the R&D worker a casual electrical worker?

21. Some Statistics • R&D electrical workers may account for 90% of the DOE complex electrical workers, BUT • R&D workers account for less than 30% of the electrical events in the complex. • R&D electrical incidents tend to be shocks or near shocks (NOT LOTO, arc flash, or penetration/excavation)

22. Project Area 5 Awareness/Focused Training - R&D • Recommended Approach: • Develop a General Training Module: Basic Electrical Safety for R&D Workers • Most sites have a variation of this. • Develop Targeted Training Modules for specific R&D Worker Groups • Few sites have these, need to be available. • Develop a Targeted Training Module for Electrical Safety Officers • A few sites have this, need to be available. • Identify and recommend other available training sources

23. 1. Core Training for R&D Electrical Workers • All R&D sites have some form of basic training for R&D workers. • There is considerable variation in: • method of delivery (live class, self study, web-based) • length • retraining requirements (none to 3 years) • material (a function of a site’s electrical safety program requirements) • Problem! • No site accepts the electrical safety training from other sites. Some roving scientists have to take basic R&D electrical safety multiple times (example, accelerator scientists working at LANL, SLAC, BNL)

24. 1. Core Training for R&D Electrical Workers - cont. • As electrical safety programs become more consistent across the complex, some components of the core training for R&D electrical workers can be identical • Common elements of training can be available for use by any site: • electrical hazard classification • unlisted electrical equipment approval • PPE for R&D workers • ISM for electrical work • The ONLY unique aspect of R&D electrical safety training at a site are the site’s unique features of their program requirements.

25. Project Area 5 Awareness/Focused Training - R&D 2. Specific R&D Topics Available: 1 - High Power (HV, HC, capacitor and inductor safety) 2 - RF and Microwave Safety 3 - Batteries and Battery Banks 4 - R&D Grounding and Shielding 5 - Computer Safety (CPU, monitors, ESD, and UPSs) 6 - Designing Safe R&D Equipment 7 - Basic Electrical Theory for R&D Workers 8 - Basic Facility Wiring Principles 9 - The Control of Hazardous Energy in the R&D Lab 10 - PPE for R&D Workers Based on NFPA 70E

26. Project Area 5 Awareness/Focused Training - R&D Module R&D 1: High Power Electrical Safety : • Covers the unique hazards encountered in the use of High Voltage, High Current, and High Power DC systems • Includes capacitor and inductor stored energy hazards • Includes electric and magnetic forces • Includes unique hazards of Pulsed Power • Induced voltages and currents • Potential gradients • Generated EMI • Covers capacitor hazard classification and proper PPE • Includes material from DOE Electrical Safety Handbook

27. Project Area 5 Awareness/Focused Training - R&D Module R&D 2: Radiofrequency and Microwave Safety: • Presents the effects of rf shock and burn • Covers the dangers of exposure to rf electromagnetic fields • Provides tools for the identification of rf and microwave hazards • Safe work practices are discussed • Includes material from DOE Electrical Safety Handbook • Covers the IEEE/ANSI C95 Standard, “Exposure to RF and Microwave Electromagnetic Radiation”

28. Project Area 5 Awareness/Focused Training - R&D Module R&D 3: Batteries and Battery Banks: • Covers the multitude of hazards associated with batteries and battery banks, including: • shock • burn • explosion • chemicals • environmental contamination • Proper design and safe work practices are presented • Covers battery hazard classification and PPE • Covers the issues with UPS battery replacement including: • training requirements • procedures • proper disposal of batteries

29. Project Area 5 Awareness/Focused Training - R&D Module R&D 4: R&D Grounding and Shielding : • Covers the basics of electromagnetic interference (EMI), including conductive and radiative coupling. • Basic techniques are presented for controlling EMI, inluding: • clean power (isolation transformers, isolated grounds, etc.) • grounding (single point grounds, ground loops, etc.) • shielding • filtering • The focus of this module is finding solutions to EMI problems in data acquisition WITHOUT the violation of NEC requirements, especially in power delivery and grounding

30. Project Area 5 Awareness/Focused Training - R&D Module R&D 5: Computer Safety : • Hazard identification and safe work practices work working on computers are presented. • Module is geared towards nonelectrical worker. • Covers three main topics: • electrical hazards (shock) • ElectroStatic Discharge (ESD) • UPSs (maintenance, battery replacement, and disposal) • Addresses the conflict between electrical safety and ESD safety

31. Project Area 5 Awareness/Focused Training - R&D Module R&D 6: Designing Safe R&D Equipment : • Covers guidelines to design and fabricate electrical equipment for laboratory use, that meets OSHA, NEC, and NRTL standards. • Includes topics of overcurrent protection, enclosure, grounding, and protection of the operator. • This course helps the designer builder meet requirements for the approval of unlisted electrical equipment.

32. Project Area 5 Awareness/Focused Training - R&D Module 7: Basic Electrical Theory for R&D Workers : • Covers the basics needed to understand and control electrical hazards in the R&D laboratory. • Includes electrical parameters, electromagnetic fields, Ohm’s Law, impedance, induction, energy storage, resistive heating, conductors and dielectrics, and dielectric breakdown. • It helps the worker understand principles that can be directly applied to laboratory electrical safety. • Examples are chosen that are relevant, e.g., load calculations, daisy chaining, grounding, etc. • This module is aimed towards the “nonelectrical” scientist, e.g., biologist, chemist, mechanical engineer, IH, etc.

33. Project Area 5 Awareness/Focused Training - R&D Module 8: Basic Facility Wiring Principles : • Addresses the basic principles, terminology, and requirements for facility wiring including: • overcurrent protection • types of outlets and plugs • single and three phase circuits • grounding • This module is NOT for the electrician or NEC knowledgeable facility engineer. • Explains common mysteries, such as • polarization • boot legging a ground • phase rotation

34. Project Area 5 Awareness/Focused Training - R&D Module 9: The Control of Hazardous Energy in the R&D Lab : • Covers the principles of OSHA 1910.147, The control of hazardous energy • Presents three methods of energy isolation: • plug control (material from DOE Electrical Safety Hnbk) • Lockout/Tagout • engineering controls (e.g., Kirk key systems) • Discusses verification and zero energy checks • Discusses the removal of capacitive stored energy

35. Project Area 5 Awareness/Focused Training - R&D Module 10: PPE for R&D Workers Based on NFPA 70E : • Discusses the principles from NFPA 70E for worker protection using PPE • Discusses shock boundaries (limited, restricted, and prohibited) • Adapts NFPA 70E shock boundaries for ac to dc • Presents the principles of arc flash injury • Presents methods of calculating arc flash boundaries for dc and capacitor systems • Presents types and use of PPE for R&D work • Discusses the hazards of facility work, and the need for additional training for facility workers

36. 3. Electrical Safety Officer Training • Two labs led the development of the training of Electrical Safety Officers (also know by other terms): • LANL (also used at BNL and ANL), beginning in 1998 • LLNL (also adapted by SLAC), beginning in 2000 • Courses are 4 to 5 days • The most common element in this training is for the approval of unlisted electrical equipment: • basic codes and standards (NEC, OSHA, UL, etc.) • inspection and approval techniques • laboratory for equipment approval • Other training modules for ESOs include: • hazard classification • work control • lessons learned • managing a electrically safe work place

37. QUESTIONS?