Electrical Safe Practices for Personnel and Equipment

Scope

This practice, PCP-650, provides minimum standards for Electrical Safe Practices at all Procter & Gamble Co. (P&G) sites and applies to employees and contractors engaged in work at P&G sites. This standard is to be followed by all sites unless the local laws and/or electrical codes require more stringent standards. P&G facilities and contractors working at P&G facilities may choose to be more stringent than this PCP but must follow these guidelines as a minimum.

Machine Safety is covered in CBA2050 Isolation of Hazardous Energy – Operate and Maintain, and not discussed in this practice.

Electrical System Owner (ESO)

The site Electrical System Owner (ESO) has responsibility for all electrical systems at the site down to 50 Volts, (the shock hazard threshold) including the following deliverables:

• The site electrical qualification program
• The site electrical safety program
• Electrical equipment maintenance and reliability
• Electrical power quality and reliability
• Electrical system master-planning
• Short circuit and fault coordination studies
• Flash hazard protection

The ESO may delegate as appropriate to accomplish the work, but is the single point of contact and is accountable for the deliverables. The ESO responsibilities may be shared between multiple persons allowing the site to retain staffing flexibility.

Every Facility must have an identified ESO and Back-up ESO that has been qualified per CBA 8014 - ESO Qualification CBA

Electrical Safety Program

All P&G sites will implement and maintain an Electrical Safety Program intended to protect all personnel from the hazards of electricity: electric shock, electrical arc flash, and arc blast.

Electrical Safety Program Principals

The Site Electrical Safety Program shall follow these principles:

• All employees will be trained to recognize, avoid and report specific electrical hazards as may exist in their work location.
• Employees performing electrical work will be qualified by the site to perform that work safely.
• Electrical work is to be planned such that the need for “energized work” is only permitted when de-energizing the equipment creates a greater hazard or the work cannot be completed in a de-energized state.
• The integrity of electrical enclosures, insulation systems, bonding and grounding will be maintained.
• A Risk Assessment shall be completed before executing any electrical work and safety measures applied as per the result of that analysis.

Hazards of Electricity

Shock Hazards:

• The hazards of electric shock are due to the fact that electric current can flow through the human body. The severity of the injuries will vary based upon the path that the current takes through the body and the level of that current flow. Minor shocks, while potentially painful, are short duration and usually cause no injury. As the duration of the shock incident or the level of current flow increases, the likelihood of a serious injury also increases.
• Shock injuries are in the form of surface and internal burns, and heart fibrillation. Fibrillation is a condition where the heart is rapidly twitching but not pumping, and will be fatal unless interrupted by the use of a medical defibrillator. Surface burns can be easily evaluated, while internal burns can initially go undetected and can potentially show up later as internal medical problems. For this reason it is important to P&G and the affected employee that all instances of electrical shock be reported as an incident and that the employee’s condition be evaluated by competent medical personnel. Shock injuries are prevented by proper grounding and bonding of electrical systems and avoiding contact with energized circuits or components.

Flash Hazards:

• Flash hazards result from the flame and radiant heat (over 19,000° C. - 35,000° F.) that is generated during an arcing fault. An arc is electric current flowing through the air. Arcing faults occur when contact is made between energized phases or an energized phase and ground, initiating very high current which can then sustain itself through the air. Arc faults can be initiated by faulty equipment, birds, rodents, insects, or human error. The incident energy of the flash is measured in Joules or Calories /sq. cm. and will vary, depending upon the fault current available from the upstream electrical distribution equipment, and clearing times of the circuit protective devices.
• Arc flash injuries can be burns ranging from 1st degree to severe 3rd degree. Clothing and hair can be instantly set on fire during arc flash incidents. Flash injuries are prevented through the proper use of the correct PPE for the hazard.

Blast Hazards:

• Blast hazards result from arcing faults and to some degree, always accompany the flash hazard. The blast results from the rapidly expanding gas generated during the arc flash and the force of the resulting pressure wave. The force can be strong enough to destroy electrical enclosures, knock people down, or off ladders, and propel shrapnel and molten metal droplets great distances through the air. Blast injuries include cuts, bruises, etc. from flying debris and potential falls, as well as potential sound induced hearing loss. Blast injuries to the face are mitigated by safety glasses and face shields. Protective equipment does not exist that will completely protect personnel from the potential effects of blast hazards. Blast incidents are best eliminated through effective switchgear maintenance, proper operational procedures, and safe practices.

Electrical Qualification Program

All P&G sites are required to have an electrical qualification program that documents the qualification of all persons authorized by the site to perform electrical tasks. The program must list the level of qualification and the standard by which the qualification was awarded. The intention is to ensure that only persons who have received training and successfully completed a performance demonstration are authorized to perform electrical tasks. The site Electrical Qualification Program, should follow the principles of HSE CBA 8016 Electrical Safety Qualification of Employees Working on Electrical Systems, which includes the following five levels of qualification:

• General Awareness Training - All Employees
• Task Qualifications - Specific Tasks
• Low Voltage Qualification - Up to 1000V
• Medium Voltage Qualification - 1000V to 36kV*
• High Voltage Qualification - Above 36kV

*38kV would be the natural choice because of the MV equipment configuration of using metal enclosed switchgear, however, this safe practice originally used 15kV as the upper MV limit. The U.S. distances for two of the boundaries are more lax than the European boundaries. Many sites had labels up with distances for Limited Approach Boundary and Restricted Approach Boundary that were consistent with >38kV in the U.S. but not in Europe. These 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.

Qualified Person

A qualified person shall be trained and have demonstrated skills and knowledge relating to 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.

• Refresher training must be completed when changes of electrical safety policy occur, an employee is not complying with work practices, new or unique equipment is introduced, Electrical KEA findings or known outages in the facility occur, or every year to maintain full comprehension.
• Qualified Persons shall be trained in methods of release of victims from contact with exposed energized electrical conductors or circuit parts. Refresher training must be completed every year to maintain full comprehension.
• First responders, those persons responsible for acting in case of emergency, shall be regularly instructed in methods of first aid and emergency procedures, such as approved methods of resuscitation including cardiopulmonary resuscitation and automatic external defibrillator (AED) use. Refresher training must be completed at a minimum of every two years or per local requirements and properly documented. First responders must be able to reach and provide emergency care within 4 minutes.
• A person can be considered qualified with respect to certain equipment and methods but still unqualified for others.

Clear Work Space

A minimum clear work space of 0.9 meter (3 feet) deep must be maintained in front of, and /or beneath all electrical cabinets, Machine Control Panels, Motor Control Centers (MCC), switchboards or panelboards containing circuits energized at greater than 50 volts and access is required for troubleshooting or maintenance. 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. The width of this space must be at least 0.77 meter (30 inches) wide or equal to the total width of the equipment, whichever is greater. The panel door must be able to be opened 90° without obstruction. This area may not be used to store materials or equipment of any kind. The clear work space must be maintained.

Job Planning

Developing a Job Plan

• See Appendix D for an example job planning system (CBA 101)
• See Appendix E for an example job plan

Job Safety Analysis and Potential Problem Analysis

• A job safety analysis must be prepared for all medium or high voltage work.
• A Potential Problem Analysis should be conducted for all medium or high voltage work.
• The JSA and PPA can be combined into one document. Please see Appendix F for an example.

Job Briefing

Before starting each job, the employee in charge shall 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.

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.

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:

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

Energized Electrical Work

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.

Energized Work Defined

At P&G sites, energized work is governed by HS&E CBA 8015. CBA 8015, Part IV Paragraph C. Energized work involves working inside the Restricted Approach Boundary and/or Arc Flash Boundary (described in Section 17), 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.

Energized Work Examples

• 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, where operation must be completed with doors or panels open.
• 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 non-IP-20 circuits
• When working within the Restricted Approach and/or Arc Flash Boundaries of exposed low voltage energized conductors or parts for any reason, excluding troubleshooting tasks such as visual inspections, voltage measurements, and current measurements. Work on energized medium or high voltage equipment is not allowed for any reason.

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.

The EWP Process must meet following requirements.

• A permit for all work on circuits or components energized above 50 Volts.
• Limits the work to systems operating at 1kV Volt or less. The selection of 1kV as the limit for an EWP is based on the types of injuries seen when shocks occur at these voltages. At about 1kV 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 continue through the individual forming a burn track with relatively low impedance and significant damage. This is the reason why EWP is limited to 1kV. It is not based on either equipment or the voltages normally seen or used in any region of the world.
• Documents sufficient cause.
• Documents the job specific hazards, safe practices, work procedures, personal protective equipment, limited approach, restricted 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.
• Identifies Emergency First Responder as defined by Section 7.3

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. Crossing the Flash and/or Limited Approach Boundaries for any reason, including during trouble shooting, requires careful thought and consideration. A qualified person must perform a self-audit before crossing all boundaries to make sure that all required safety precautions are followed. All meters / instruments must be verified to be in good working order, in the correct configuration, and rated for the measurement about to be performed. All proper PPE (voltage and flash hazard) and tools approved for the hazard must still be used, even if an energized permit is not required. 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.
• LV, MV, or HV Switching operations, (manually actuating switchgear) where the enclosures are intact and closed.
• Insertion or removal of buckets from LV MCC via racking, if equipment is designed to do so with doors closed. NEMA style MCCs are now available with racking mechanisms that allow for inserting and/or removing an MCC bucket with the doors closed. The bucket has a mechanical interlock that prevents racking the bucket out while the bucket isolation device is closed. (You physically cannot get access to the racking mechanism until the MCC bucket isolation device is open.) The bucket also has automatic shutters that close off access to the MCC energized bus after the bucket has been racked out so there is no exposed energized bus once the bucket has been removed. An example of a rackable MCC is the Allen Bradley 2100 SecureConnect MCC (see Appendix F for CBA Example). The required PPE must still be utilized.
• Insertion or removal of breakers from switchgear via racking if the equipment is designed to do so with the doors closed. Racking LV or MV breakers into or out of breaker cells switchgear with the breaker cell door closed (and intact) using either a local or remote racking tool. There must be a mechanical interlock that either prevents racking while the breaker is closed or automatically trips the breaker before the breaker stabs are withdrawn from the switchgear bus. There must be automatic shutters that close off access to the switchgear energized bus after the breaker has been racked out (while the breaker is out of the cell, there is no exposed main bus since the shutters are closed).

Prohibited Work

In all cases, work on energized electrical equipment, systems or components above 1kV is prohibited by the Procter & Gamble Co. EWP’s (Energized Work Permits) may only authorize work on circuits energized up to 1kV.

Energized Work Permits vs. Circuit Voltages

Approach Boundaries (Working Near Exposed, Energized Equipment)

There are 3 approach boundaries intended to protect workers from electrical hazards. Two are dedicated to shock protection and one is dedicated to arc 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.

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. Shock boundaries are defined in Appendix B, Table 1 – Approach Distances for AC & DC Systems. The Flash Boundary, as defined by Section 17.2, must still be observed. 17.1.1.1. Low Voltage, 50V-1kV

• Limited Approach Boundary; only qualified personnel, or nonqualified person escorted by a qualified person may enter within this boundary. Nonqualified persons must be made aware of all dangers associated with crossing the Limited Approach Boundary. Before a qualified person opens an MCC compartment door, exposing un-insulated terminals or bus bars, the limited approach boundary must be established to keep passers-by from unknowingly entering a hazardous area.
• Restricted Approach Boundary; only qualified personnel may enter within this boundary. A trainee, who has been previously educated on the hazards, and directly supervised by a qualified person may entire this area for the purpose of training. When an employee is working within the restricted approach boundary, the worker shall wear PPE in accordance with Section 19 of this document. Electrically insulated blankets may also be required as a means of protecting the worker from contact with phase or ground potential.

Medium and High Voltage, greater than 1kV

• Limited Approach Boundary; only qualified personnel or nonqualified person escorted by a qualified person may enter within this boundary. Nonqualified persons must be made aware of all dangers associated with crossing the Limited Approach Boundary.
• Restricted Approach Boundary; no access is permitted above 1kV. The limitation is based on the fact that the severity of shock incidents becomes much worse above 1kV. In addition to the possibility of cardiac arrest, present for any shock incident, common injuries resulting from shock at voltages in excess of 1kV 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.
• • Adding and removing safety grounding devices are exempt from this restriction if procedure detailed in Section 23 is followed for circuit isolation.

Flash Hazard Boundary

The flash hazard boundary, also known as the “curable burn distance,” is the minimum distance from the arc source that a person who is not wearing flash protection PPE must be to ensure that any burn received will not cause permanent tissue damage. This occurs at incident energies of 1.2 calories per square centimeter. Persons within that boundary must be protected from the potential arc flash by arc rated PPE. Arc rated PPE may be used in conjunction with non-melting clothing and other required PPE within the flash protection boundary. Non-melting clothing and other PPE shall be worn under the arc rated PPE. The boundary distance and level of PPE must be determined by using one of the two methods defined in Section 18. The Shock Boundaries, as defined by Section 17.1, must still be observed.

• Non-Melting materials are defined as having a melting point above 315°C, 600°F, or natural fiber (e.g., cotton, wool, rayon, or silk, or a blend of these materials) with a fabric weight of at least 4.5 oz./yd2. Melting materials shall not be worn within the flash hazard boundary, even under Arc rated PPE. This includes undergarments, with the exception of the elastic band. If hair nets, high visibility vests, or other exterior articles must be worn, they must be constructed using non-melting materials. Flash hazard studies are required at all P&G sites.

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.
  • The “clear work space” requirements in front of the IP-20 panel shall still apply.
  • Limited approach boundary shall still apply for unqualified electrical workers.
  • As a minimum, non-melting shirt and pants must be worn within the flash hazard boundary.

The limited approach boundary shall be clearly and safely marked with safety signs and/or hazard tape in order to prevent or limit access to work areas containing exposed energized conductors or circuit parts.

Look-Alike Equipment - Where work is performed on de-energized equipment in a work area with other equipment that is similar in size, shape and construction, it shall be marked with appropriate signage and/or barricade to prevent accidental work on similar energized equipment.

Electrical equipment panels will observe clean visual practices. Only identifying/safety information relevant to the equipment will be installed on electrical panels to reduce visual pollution and risk of confusion. Conflicting information must also be removed and only most up to date label is permitted to be installed.

Note: Appendix B, Figure 1 and Figure 2 show graphical representations of the approach and flash hazard boundaries relative to exposed energized components.

Flash Hazard Protection

Preferred Method

The preferred method of determining the proper protection is to have a complete and detailed flash hazard study for the site power distribution system. PCP-1502 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 PCP-1502. 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 PPE to be worn while working at specific points in the electrical system.

• The preferred method consists of a 3 step process to select PPE for protecting their personnel from flash hazards.
• • First, use Appendix A - Table 1 Arc Flash Hazard Identification to determine if arc flash PPE is required. This table defines various electrical tasks on energized equipment with specific equipment conditions. If the table determines that no arc flash PPE is needed, then the minimum PPE and clothing for electrical work as defined by Section 17.2.1.1 still applies. If the specific task is not defined in the table, then arc flash PPE is required. For machine and motor local disconnects sized 100 amps or less, when operating a disconnect while the panel doors are closed, minimum PPE requirements does not apply if these conditions are met;
  • • The equipment is properly installed
    • The equipment is properly maintained
    • Covers for all other equipment are in place and secured
    • There is no evidence of impending failure.
    • For MCCs that allow for racking of buckets with the door closed, the Hazard/Risk level defined by the flash hazard study or by Appendix A must be used when inserting or removing buckets unless designed as arc resistant as defined by Appendix A Table 1.
  • Second, use results of the flash hazard study to identify the required level of PPE and the Arc Flash Boundary.
  • Third use Appendix A - Table 3 Protective Clothing and Personal Protective Equipment (PPE) Matrix, to define the specific PPE items to be worn in each PPE Level in order to provide adequate protection.

Alternate Method

In some situations, such as at an acquisition facility that may not yet have completed the required flash hazard study, facility will need to use the alternate method in the interim, until the study is completed. Also, although all facilities are required to use the computer model for first level MCC equipment and above, they have the choice to not extend the study below the first level MCC.

• In these situations the site may follow the 3 step alternate method to select PPE for protecting their personnel from flash hazards.
• • First, use Appendix A - Table 1 Arc Flash Hazard Identification to determine if arc flash PPE is required. This table defines various electrical tasks on energized equipment with specific equipment conditions. If the table determines that no arc flash PPE is needed, then the minimum PPE and clothing for electrical work as defined by 18.3 still applies. For machine and motor local disconnects sized 100 amps or less, when operating a disconnect while the panel doors are closed, minimum PPE requirements does not apply if these conditions are met;
    • The equipment is properly installed
    • The equipment is properly maintained
    • Covers for all other equipment are in place and secured
    • 18.2.1.1.4. There is no evidence of impending failure.
    If the specific task is not defined in the table, then this method cannot be used and the calculated method must be utilized.
  • Second, use Appendix A - Table 2 Arc-Flash Hazard PPE Levels, to identify the required level of PPE and the Arc Flash Boundary. If the equipment parameters are not within Table 2 requirements, then this method cannot be used and the calculated method must be utilized.
  • Third, use Appendix A - Table 3 Protective Clothing and Personal Protective Equipment (PPE) Matrix, to define the specific PPE items to be worn in each PPE Level in order to provide adequate protection.
• For substation and above power equipment at all voltages, and for all medium and high voltage equipment, the alternate method cannot take precedence over the study, once completed, for tasks that require panel doors to be open to expose energized components and conductors.

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 an enclosure door is open and the Flash Hazard Study states that the hazard risk level is “Dangerous” there is no PPE available to protect personnel from the hazard and no work may be performed.

• Opening and closing breakers in equipment with “Dangerous” flash hazard level with the equipment enclosure intact and the doors closed is permitted while wearing level 4 PPE.
• Opening and closing breakers in any equipment that is “over duty” by having the available fault current being greater than the equipment short circuit current rating is not permitted.
• Racking in and out (inserting or withdrawing) breakers in equipment with “Dangerous” flash hazard level is NOT permitted. The equipment must be de-energized and locked out prior to racking any breakers. Racking in and out with a remote racking device is permitted if the remote racking device allows the technician to be outside the flash hazard boundary or outside the room containing the electric equipment.
• Racking in or out of energized equipment that is overdutied is not allowed in any situation.

P&G Default PPE Selection

Based upon documented testing conducted by the IEEE, P&G now recognizes the default Minimum PPE and Clothing 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 Minimum PPE with 455mm (18 inches) 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.

Both methods assume working distance described in Section 19.6. If task being performed brings worker closer than distance used to calculate incident energy, then proper PPE selection must be reevaluated to protect from increased energy at actual working distance.

Electrical PPE (Personal Protective Equipment)

Electrical PPE includes, but is not limited to; 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, non-conductive safety glasses (small screws are allowed), 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.

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.

Rubber gloves are required to be inspected before each use and tested every 6 months. Unless local code is more restrictive, gloves are considered compliant for 6 months after opening package, up to one year from last test or production date. In cases where testing facilities are not available in the region or country purchasing new gloves every 6 months is acceptable with proper tracking.

Arc flash PPE, such as clothing and face shields, is rated in Calories per square centimeter. Appendix A of this document lists arc flash PPE for specific tasks where personnel are exposed to those hazards. Arc Flash clothing shall be rated to provide protection from the known flash hazard, or as a minimum, be selected according Section 18 of this document. All personnel within the flash hazard boundary (curable burn distance) must be protected from the known arc flash hazard.

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. Also, while the maximum rating currently available for arc resistant clothing is 100 cal/cm2, P&G does not allow to perform any energized work on level dangerous (>40 cal/cm2) flash hazard class equipment 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 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 cal/cm2/square cm. Flash hazard studies dictate the minimum required 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:
• • Medium-voltage switchgear - 910mm (36 inches)
  • Low-voltage switchgear - 610mm (24 inches)
  • Low-voltage MCCs and panelboards - 455mm (18 inches)
  • Cable - 455mm (18 inches)
  • Other - Field determined
• 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 hotstick while voltage testing and applying temporary protective safety grounding and this results in 910mm (36 inches).
• 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:
• • Increasing the PPE level,
  • Increased vigilance when voltage testing, and
  • Using a hotstick/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.

General Lockout/Tag out (LOTO) Guidelines

All sites must have documented LOTO guidelines in place 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.

Never trust anyone else’s padlock for your safety.

Always inform the machine owner or customer that you have a LOTO in place and why.

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:

• The ability to isolate all forms of potential energy, electrical, pneumatic or hydraulic, mechanical, or stored energy.
• A system of identifying who placed the lock on the isolator, method of contacting the individual and why.
• 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 on the isolating device until their portion of the work is completed or they leave the site.

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.

Review and update LOTO procedures at least annually.

All persons who could be affected by LOTO must be retrained when the procedure is modified, when not complying with work practices or every year to insure full comprehension. LOTO training must be properly documented.

Note: For reference see HSE CBA 2052.

Construction (contractor) LOTO Procedures

During Construction the contractor is responsible for maintaining 100% control of involved equipment until it is turned over to P&G and cannot depend on P&G locks for LOTO. 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.

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.

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 complete control and ownership of the machine or process. After the ownership transfer, the normal P&G plant LOTO procedures shall be followed.

Note: For reference see HSE CBA 133

Safety Grounding (temporary protective grounds)

Simply following LOTO procedures alone does not ensure 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 stored energy 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.

During scheduled maintenance power outages there is a very real risk of circuits being energized or retaining hazardous energy from:

• Re-energizing from the normal feed.
• “Back feeds” from portable generators used to provide local lighting and portable tool power.
• Energy stored and dissipated as direct current (DC). Typical medium voltage testing equipment is NOT capable of detecting this voltage. Because this energy cannot be detected, temporary protective grounding is required to ensure safety. Energy can be stored in capacitive or inductive conductive surfaces, which can remain on recently de-energized circuits. If of sufficient length, circuit conductors can behave like capacitors with respect to ground or grounded surfaces and retain energy sufficient to deliver serious shocks. Windings on transformers rated for >1kV can also store inductive energy that must be dissipated before it can be safely worked on.
• Magnetic coupling with nearby energized circuits can induce voltages onto de-energized conductors.

Proper application of safety grounds eliminates the hazards 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 during the installation/removal of a feeder or when working with some MV motor starters.

Note: Many substation transformer installations at P&G do not include secondary protection. In such cases the incident energy available at the low voltage bus can be extremely high, often over 150 Cal/cm2. 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.

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.

• Wear the proper PPE for the hazard involved (arc flash protection, voltage gloves and hotstick).
• Open the primary switch and lock and tag.
• Select the proper test equipment for the system voltage.
• Test all voltage testers (contact or non-contact), glow sticks, etc. on a known energized source just prior to use.
• Maintain the maximum practical distance while working.
• Test all phases of the circuit for any voltage indication to verify that there is no voltage.
• After the tester shows no voltage, retest the voltage tester to confirm proper functionality.
• 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. If Calculations to find correct size are not completed, the P&G default minimum size is that all 4 cables are AWG 4/0 or 95 mm2 and that the cluster uses a ”star” design.
• Using the hotstick, touch each phase with the ground cluster to discharge any residual energy stored by the line capacitance.
• Using the hotstick, individually connect the three phases to the ground cluster.
• Remove PPE as desired and begin maintenance work.
• When removing protective grounds, begin by using proper PPE (voltage rated gloves and hotstick), then begin by first disconnecting the phase leads and then disconnect the ground connection last.

Temporary Wiring

NOTE: Insubstantial or unsafe wiring cannot be considered safe or acceptable because it is temporary.

At P&G sites temporary wiring is subject to the following limitations:

• 90 days maximum installation lifetime or the duration of the associated construction effort.
• Must be installed by qualified person(s).
• All connections, other than those made with approved plugs and receptacles, must be made inside electrical enclosures.
• The installation must meet all applicable codes and standards.
• All components used must be listed and approved for the purpose as used.
• 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.
• All temporary electrical equipment must meet the requirements of HS&E CBA 8018.The ESO is responsible to review temporary wiring plans and ensure timely removal.

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.

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. Do not run portable cords through windows or doors.

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.

Ground Fault (Earth Leakage ) Protection for Portable Tools

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.

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 Breakers). This includes drill motors, grinders, circular saws, soldering irons, cord lights, and the like.

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.

Portable Electrical Equipment

HS&E CBA 8018 establishes the expectations for inspections of portable electrical equipment. This CBA sets minimum expectations for inspections and local laws must still be satisfied.

Portable (plug and cord connected) electrical equipment includes appliances and unit-operations which are not permanently wired to the building electrical system, and by 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, but construction and maintenance tools such as drills, grinders, circular saws, and welders are.

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 where possible.

Portable, plug and cord connected, three phase electrical equipment that is 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 ensure 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-operations, 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.

Electrical Power Tool Safe Practices

When using hand held corded 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.
• Never use an aluminum (or any metallic) ladder. Fiberglass safety ladders are the P&G standard.
• Never use power tools while standing in water or the rain.
• Never stand barefoot on the soil, metal structures, or concrete. Always wear proper footwear in good dry condition.
• Never use 3-prong to 2-prong adapters. These devices eliminate the safety ground connection.

Appendix A, Arc Flash PPE Selection

PCP-650, Appendix A, Table 1 – Arc Flash Hazard Identification

PCP-650, Appendix A, Table 2 – Arc-Flash Hazard PPE Levels

PCP-650, Appendix A, Table 3

Protective Clothing and Personal Protective Equipment (PPE) Matrix

AN = As needed (optional)

AR = As required

SR = Selection required

Notes:

1. If rubber insulating gloves with leather protectors are required by Appendix A Table 1, additional leather or arc-rated gloves are not required. The combination of rubber insulating gloves with leather protectors satisfies the arc flash protection requirement.
2. Face shields are to have wrap-around guarding to protect not only the face but also the forehead, ears and neck, or, alternatively, an arc-rated arc flash suit hood is required to be worn.
3. Arc rating is defined in Article 100 and can be either the arc thermal performance value (ATPV) or energy of break open threshold (EBT). ATPV is defined in ASTM F 1959, standard test method for determining the arc thermal performance value of materials for clothing, as the incident energy on a material, or a multilayer system of materials, that results in a 50% probability that sufficient heat transfer through the tested specimen is predicted to cause the onset of a second-degree skin burn injury based on the Stoll curve, in cal/cm2. EBT is defined in ASTM F 1959 as the incident energy on a material or material system that results in a 50% probability of break open. Arc rating is reported as either ATPV or EBT, whichever is the lower value.

PCP-650, Appendix A, Table 4 – Protective Clothing Characteristics

Minimum PPE and Clothing Protection

Clothing shall meet the non-melting requirements of Section 17.2.1.1 when Appendix A, Table 1 indicates arc flash PPE is not required. Those tasks identified as “No” in the “Arc Flash PPE Required” column have an extremely low probability of initiating an arc flash occurrence; it does not mean that an arc flash occurrence is not possible. If working in the Arc Flash boundary, where the incident energy is 1.2 Cal/cm2 or greater, Minimum PPE is not adequate and PPE with sufficient ATPV must be utilized.

Level 1 and Higher

For Level 1 and higher arc flash hazards, Arc Rated PPE with certified ATPV ratings are required to provide adequate protection when doing exposed, energized electrical work. Arc Rated clothing can be layered to provide an increased level of protection, but must be done according to methods tested and approved by the PPE manufacturer.

The threshold incident energy level for a second degree burn on bare skin is 1.2 Cal/cm2.

Caution: In Europe, when tested per standard ENV 61482-1-2, Level 1 is 3.2 Cal/cm2 and Level 2 is 10.1 Cal/cm2. Please note that the term Level 1 means 4 Cal/cm2 and is based on IEEE 1584 and NFPA 70E while the term Level 1 means 3.2 Cal/cm2 and is based on ENV 61482-1-2. In every case, adequate arc flash hazard protection is required based on the Cal/cm2 rating of the clothing when compared to the arc flash study hazard identified.

Notes:

• Arc rating or ATPV (arc thermal protection value) is the maximum incident energy resistance demonstrated by a material or layered system of materials, prior to “break open”, that point at which one or more holes are formed through the innermost layer of arc rated clothing, that allow flame to pass through the material, or at the onset of a 2nd degree burn based on the Stoll curve. Arc ratings are normally expressed in Calories per square centimeter.
• 100% cotton clothing provides only minimal protection. In addition, cotton will ignite and continue to burn in an arc flash incident!
• Injuries resulting from arc flash incidents are usually minimal if workers are wearing proper Arc Rated PPE!
• Eyes and face are protected by safety glasses and face shields, and the body is protected by clothing unless the clothing ignites. Serious burn injuries will usually result if the clothing is ignited.

PCP-650, Appendix B

Procter & Gamble Co. Global Electrical Safety Program

Approach Boundaries

Figure 1: Graphical Representation of Approach Boundaries

(From NFPA 70E, Figure C.1.2.3 – 2015 Edition)

Figure 2: Graphical Representation of Approach Boundary Distances

PCP-650, Appendix B, Table 1 – Approach Distances for AC & DC Systems

This table specifies safe approach distances to be observed at all P&G sites by persons exposed to energized circuits. All persons within limited approach boundary of exposed energized surface must be qualified to corresponding voltage or supervised by a qualified person. Distances are from exposed energized conductor or surface to person.

PCP-650, Appendix C

Procter & Gamble Co. Global Electrical Safety Program

Ground Fault Circuit Interrupter use in P&G N.A. Corporate Buildings

Background:

Dwelling Units

GFCI’s (ground fault circuit interrupters) are widely used in residential applications to provide shock hazard protection for people using 125 volt receptacles in and around the home where it is likely that moisture or water will present an increased shock hazard. The NEC, in article 210.8(A) lists eight specific locations in dwelling units where GFCI’s are required. They include bathrooms, garages, outdoors, crawl spaces, unfinished basements, kitchens, laundry or utility rooms and boathouses.

Commercial Buildings

The GFCI requirements for commercial or industrial applications are very different, even though some workplace applications are very similar to those we are familiar with at home. This is because the code recognizes that at home electrical devices are often operated by children or others with little or no understanding of the hazards electricity around water. At work there are requirements for General Electrical Awareness Training to provide employees with the knowledge they need to work safely.

In commercial buildings, the NEC (Art. 210.8(B)) requires GFCI’s to be installed only in these clearly defined areas. They include bathrooms, kitchens, rooftops, sinks, and outdoor locations.

NEC article 210.8 (B) (5) requires GFCI protection for receptacles within 6 ft. of a sinks including laboratory sinks. The 6 Foot distance is derived from the U/L standard 6 ft. cord length for appliances that effectively prevents devices from being accidentally placed in the sink while still connected. We will follow this guidance relative to receptacle outlets near wet locations.

Safety Showers

According to NEC article 406.8, receptacles in damp or wet locations, Section C states: A receptacle shall not be installed within a bathtub or shower space. Therefore, all receptacles within 6 feet of Safety Shower spaces must be removed. This can be done simply and inexpensively by replacing the outlets with blank, gasketed covers.

Eyewash Stations

Use of Eyewash Stations creates an increased hazard when in the close proximity of electrical outlets. This is due to the intentional flushing and splashing that will occur, and the fact that the person using them is temporarily sight impaired, and likely to reach blindly for a towel or tissue with wet hands and face. For these reasons receptacles located within 6 feet of Eyewash Stations must be removed or protected by a GFCI. Again, this is not an expensive task.

Laboratory Sinks (without eyewash stations)

The 2008 NEC requires all sink receptacles to be GFCI protected. This was not found in the code prior to the 2008 revision. As a result, the P&G lab space owner will need to decide which of the following three options is appropriate for existing installations. All new installations must meet the 2008 NEC requirement. Also, changes to the existing installation must also meet requirements of the 2008 NEC.

1. Remove all receptacles within 6 ft. of a sink. This will remove the hazard, but also remove the capability of using electrical devices at all, in that location. This option involves minimal costs.
2. Install GFCI protection for all receptacles within 6 ft. of a sink in accordance with the 2008 NEC. This will provide shock hazard protection for the lab personnel, and allow the continued use of electrical devices close to the sink. However, GFCI’s installed in your space need to be tested monthly to insure proper operation. It would be the responsibility of the space owner to test and document monthly and forward the documentation to the site ESO annually. GFCI’s should not be used to supply power to long term experiments, CT rooms, freezers, or any device that cannot handle being temporarily powered down. This option involves moderate costs of purchasing and installing one or two GFCI’s per sink.
3. Provide portable GFCI’s, for use in the lab, whenever electrical devices are used within 6 ft. of a sink. Portable GFCI’s must be tested before each use. This option involves minimal costs, but, requires developing and delivering training and periodic testing per HS&E CBA 8018.