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Mark Scott Henrik von der Lippe Bob Candelario EETD Lunchtime Seminar February 21 st, 2013 The LBNL Electrical Equipment Safety Program (EESP)

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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

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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

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UNIVERSITY OF CALIFORNIA UNIVERSITY OF CALIFORNIA