NFPA 70E Arc Flash Class

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NFPA 70E Arc Flash Class
Presented by Brian Downie Project Manager
Town Country Electric PO Box 627 Appleton,
WI 54944 800-274-2345 ext. 6513 brian.downie_at_fai
th-technologies.com
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• This Course is Meant to
• Help Address the Following Areas
• Of Interest
• What is NFPA 70E
• Who is Affected
• How to Use Labels
• How to Use the Code Book (NFPA 70E)
• How to Interpret the Code
• How to Conduct Formal Assessments
• Scope Clarifications
• Proper Electrical Print Development
• Company Policy Ideas and Examples

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Our Role in Helping Customers with NFPA 70E

• Raise the level of understanding with the topic
  including
• PPE needs associated with live electrical work
  practices.
• Work with the EHS Departments in developing a
  plan
• that focus on real electrical assessments and
  good
• electrical principals required to manage the
  topic.
• Each employer must look beyond the initial topic
  of
• Arc Flash and realize that this topic involves
  all aspects
• of working towards a solid ESWP program.

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NFPA 70E Essentials

• (NFPA 70E) Challenges
• A written safety program with defined
  responsibilities for employees both (qualified
  and unqualified).
• Analysis of arc flash hazards and associated
• electrical work practice.
• Personal protective equipment (Clothing and
  tools, etc.) for all workers involved.
• Continued training efforts for your work force.
• Correct warning labels on all electrical
  equipment and what to look for to be complete on
  all aspects of ESWP.

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2005 National Electrical Code Book States
110.16 Flash Protection. Switchboards,
panelboards, industrial control panels, meter
socket enclosures, and motor control centers in
other than dwelling occupancies, that are likely
to require examination, adjustment, servicing, or
maintenance while energized, shall be field
marked to warn qualified persons of potential
electric arc flash hazards. The marking shall be
located so as to be clearly visible to qualified
persons before examination, adjustment,
servicing, or maintenance of the equipment.
FPN No. 1 NFPA 70E-2004, Electrical Safety
Requirements for Employee Workplaces, provides
assistance in determining severity of potential
exposure, planning safe work practices, and
selecting personal protective equipment. FPN No.
2 ANSI Z535.4-1998, Product Safety Signs and
Labels, provides guidelines for the design of
safety signs and labels for application to
products. Reprinted from NEC 2005
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Basic Arc Flash Label To Warn Personnel
!
WARNING
Arc Flash and Shock Hazard Appropriate PPE
Required per NFPA 70E
Safety relies on employees to fully understand
the hazards associated with each piece of
equipment
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Labeling Goals for 70E

• Clear and easy to follow approach to labeling
  plant systems must be considered. Keep in mind
  that plant floor labeling needs to be understood
  by your staff.
• Equipment identification should be specific
  enough to create individual identities for use
  with LOTO goals
• Labeling includes three key components which are
  flash hazards, shock hazards and a means for
  identifying what the item is and where it is
  being fed from

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110.16 Flash Protection. Switchboards,
panelboards, industrial control panels, and motor
control centers in other than dwelling
occupancies, that are likely to require
examination, adjustment, servicing, or
maintenance while energized, shall be field
marked to warn qualified persons of potential
electric arc flash hazards. The marking shall be
located so as to be clearly visible to qualified
persons before examination, adjustment,
servicing, or maintenance of the equipment.
FPN No. 1 NFPA 70E-2004, Electrical Safety
Requirements for Employee Workplaces, provides
assistance in determining severity of potential
exposure, planning safe work practices, and
selecting personal protective equipment. FPN No.
2 ANSI Z535.4-1998, Product Safety Signs and
Labels, provides guidelines for the design of
safety signs and labels for application to
products. Reprinted from NEC 2002
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WARNING
!
Arc Flash and Shock Hazard Appropriate PPE
Required
Shelving Cutter 12-4 Fed From DSC 124
Equipment Name
Courtesy E.I. du Pont de Nemours Co.
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WARNING
!
Arc Flash and Shock Hazard Appropriate PPE
Required
Shelving Cutter 12-4 Fed From DSC 124
Item Name
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It may be required in the next revision of NFPA
70E that labeling be required to have dates.
This tells us that outdated labeling has to be
eliminated and your programs need to be current.
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Shock Hazard Approach Boundaries (from NFPA
70E-2004)
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Multi-Employer Language

• 110.4 Multi-Employer Relationship. (Page 16) On
  multi-employer worksites (in all industry
  sectors), more than one employer may be
  responsible for hazardous conditions that violate
  safe work practices.
• Companies who do not qualify outside contractors
  leave themselves open for liability and make it
  harder on your in house staff when they are
  asked to wear PPE and yet contractors may not be
  up to speed.

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Article 130 Goals

• Article 130 is the main article within NFPA 70E
  that helps to identify the topic of Working on
  or Near Live Parts. The following articles are
  key components of this section.
• Justification for Work (Article 130.1) Live
  parts to which an employee might be exposed shall
  be put in an electrically safe work condition
  before an employee works on or near them, unless
  the employer can demonstrate that de-energizing
  introduces additional or increased hazards or is
  infeasible due to equipment design or operational
  limitations.
• FPN No 1. Examples of increased or additional
  hazards include but are not limited to
  interruption of life support equipment,
  deactivation of emergency alarm systems and
  shutdown of hazardous location ventilation
  equipment.

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130.7 Personal and Other Protective Equipment

• 130.7 (A) Employees working in areas where
  electrical hazards are present shall be provided
  with, and shall use, protective equipment that is
  designed and constructed for the specific part of
  the body to be protected and for the work to be
  performed. (Page 28)
• Article 130 kicks off the PPE needs behind NFPA
  70E including tables etc.

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(130.7C9) PPE Task Based Table
Note 1 - gt25kAIC and a no more than .03 sec fault
clearing time Note 3 - lt10kAIC then you can
reduce the category by one
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Task Based PPE Programs implemented through NFPA
70E tables
Task Based PPE requirements poster located in
MCC. Approx. 4 feet from starter
Task Based PPE Programs are better than not
having a program but can still fall short when it
comes to implementation of your programs.
Employees often do not take the appropriate
amount of time to evaluate what is needed and
how to use the PPE.
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(130.7C10) Protective Equipment Table
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130.7C11 Hazard Selection Table
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130.1(A)2 Energized Electrical Work
Permit (Elements of Work Permit)

• A description of the circuit and equipment to be
  worked on and their location.
• Justification for why the work must be performed
  in an energized condition
• A description of the safe work practices to be
  employed
• Results of the shock hazard analysis
• Determination of shock protection boundaries
• Results of the flash hazard analysis
• The flash protection boundary
• Necessary PPE to safely perform the assigned task
• Means employed to restrict access of unqualified
  persons
• Evidence of completion of job briefing, including
  a discussion of any job-specific hazards
• Energized work approval (Authorizing or
  responsible management, safety officer or owner,
  etc.) signature's).

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130.1(A)(3) Energized Electrical Work
Permit (Exemptions to Work Permit)

• Work performed on or near live parts by qualified
  persons related to tasks such as testing,
  troubleshooting, voltage measuring, etc. shall be
  permitted to be performed without an energized
  electrical work permit, provided appropriate safe
  work practices and personal protective equipment
  in accordance with Chapter 1 are provided and
  used.

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Live Work Permit Contents

• ENERGIZED WORK SPECIFICATIONS FORM
• Requesting Person________________________ Division
  _________________
• Job Number_____________________________ Job
  Name________________
• Equipment/Machine to be Locked Out and Tagged
  Out________________________
• Equipment and/or Circuits to be worked on
  energized_________________________
• Date(s) of work to be performed
  ___________________________________________
• Work to be performed _____________________________
  ______________________
• Energy Source and Location _______________________
  _______________________
• Statement of why equipment cannot be
  de-energized____________________
• __________________________________________________
  ____________________
• Is it possible to reschedule work at a later date
  when equipment may be de-energized? YES
  NO
• Hazards (risk to personnel, property, production)
  ___________________________

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Live Work Permit Contents Cont

• Results of Shock/Flash Hazard Analysis
• Hazard Risk Category __________________
• Flash Protection Boundary ______________ Limited
  Approach Boundary _______
• Restricted Approach Boundary ___________ Prohibite
  d Approach Boundary _____
• Employees who will be performing the energized
  work ___________________________
• Have employees been properly trained? Yes
  No
• Have affected employees been notified of
  procedures and hazards? Yes No
  
• Date of Notification _________________________
  Competent person assigned ________
• Energized Work Category 50v
  50-250v 250-600v 600v
• List personal protective equipment
  needed_______________________________________
• Date equipment last tested _______________________
  __ Tested by _________________
• Has written plan/Task Safety Analysis (TSA) been
  completed for energized work?
• Authorized customer representative
  approval_________________ Date ____________
• Customer representative understands all risks
  injury, damage and loss of production

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How to Proceed With a Program to Address NFPA 70E?

• Two methods are recognized by the industry. It
  is worth noting the table approach is limited in
  design and should not be used for long term
  safety program goals.
• Method 1 Arc Flash Calculation
• Method 2 Use NFPA 70E Tables (Notes 1-6 Must Be
  Verified in 130.7C9)

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Incident Comparison
Case 1 Town Country

• Injuries sustained
• 2nd 3rd degree burns to head, arm, hand
• Nearly lost ear
• Med-evac from site to University Hosp
• Off work for a month
• Several surgeries

• March 2001
• 400A 480V Service Entrance
• Small-Medium sized industrial facility (wood
  processing)
• Employee knew it was hot
• No PPE Worn

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Case 1
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Case 1
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Incident Comparison
Case 2 Town Country

• Injuries Sustained
• NONE

• July 2001
• 480V 800A slide in tub gear
• Late night Preventive Maintenance
• Telecommunications Provider

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Case 2
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Case 2
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Case 2
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Case 2
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Training Implementation Success

• Your employees can retain 90 percent of what
  theyve learned after an hour, 50 percent after a
  day, 25 percent after 2 days and 10 percent after
  30 days if there isnt additional reinforcement.
  
• In fact, the content needs to be revisited six
  times for retention that gets results!
• NFPA 70E is a topic that has challenged even the
  most experience Safety Directors

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Clothing Material Characteristics

• 130.7(C)(14)(b) (Page 34)
• Flammability. Clothing made from nonmelting
  flammable natural materials, such as cotton,
  wool, rayon, or silk shall be permitted for
  Hazard/Risk Categories 0 and -1 considered
  acceptable if it is determined by flash hazard
  analysis that the exposure level is 8.36J/cm2
  (2.0 cal/cm2) or less, and that the fabric will
  not ignite and continue to burn under the arc
  exposure hazard conditions to which it will be
  exposed (using data from tests done in accordance
  with ASTM F 1958.) See also 130.7(C)(12)(a) for
  layering requirements.

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Print Development Scope Evaluations
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Value of Good Prints

• A good electrical print should show all
  connecting devices including engineering
  information, OEM information along with short
  circuit findings in order to consolidate all
  aspects of maintenance and safety LOTO needs.
• Engineering software program one-lines are not
  recommended for LOTO use and not recognized by
  OSHA.

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What is Required in Print Format?

• 8.4.3An up-to-date short-circuit and coordination
  study is essential for the safety of personnel
  and equipment.
• The momentary and interrupting rating
  requirements of the protective devices should be
  analyzed, that is, will the circuit breaker or
  fuse safely interrupt the fault or explode in
  attempting to perform this function?

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What is Required in Print Format?

• 26.1.1 Copies of single-line diagrams and system
  study data should be given to the facility
  maintenance department. It is critical to
  efficient, safe system operation that the
  maintenance department keep the single-line
  diagrams current and discuss significant changes
  with the facility engineering department or
  consulting electrical engineer.
• It should be noted, however, that the information
  required for system studies is highly
  specialized, and outside help might be necessary.

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Comments

• When evaluating arc flash assessments, the most
  valuable portion of the project entails spending
  the appropriate amount of time in the plant to
  truly verify the electrical systems. Dont
  assume any existing labeling is accurate, and put
  some thought into how your prints will be
  created. We have found that real electrical
  prints will help not only support safety
  implementation needs, but engineering and
  maintenance functions as well. Software driven
  diagrams are not sufficient enough to support
  those needs.- Dominic Garcia Horizon Milling

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How to Evaluate Your Program and Subsequent
Findings
Be sure to spend time evaluating your end
results. Item or Bus Names and Protective Device
references are usually driven by engineering and
not always focused on LOTO needs.
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(No Transcript)
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Arc Flash Hazard Analysis
Newly created AutoCAD prints are a must for LOTO
support. Software driven impedance diagrams do
not work for ESWP needs
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Arc Flash Hazard Analysis 1-Line
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Up-to-Date Drawings

• OSHA standards define a requirement for labels
  to
• identify the location of disconnecting means for
  lockout purposes.
• Electrical drawing maintenance is not required
  by OSHA however, NFPA 70E standards and NFPA 70B
  do call for up to date AutoCAD drawings to be
  followed for LOTO use.
• Most Managers and/or Production Supervisors
  strategy is to keep the plant running and keep
  product moving out the door. EHS Managers are
  responsible for the safety of the staff. This
  difference in strategy means both parties must
  work together on NFPA 70E plans.

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Successful NFPA Projects and Scope Recognitions
Step 1

• First, make sure you invest the appropriate
  time in verifying the true electrical sources for
  your labeling of equipment.
• In any scope you evaluate please question and ask
  for detailed explanation of the term Data
  Collection. When you see these two words you
  should immediately ask your vendor to qualify
  this process. From an engineering point of view
  what is required for data entry in a software
  program is the equipment type, setting
  information, wire size and an approximate length
  of wire run.
• Few vendors will assume any accountability for
  the accuracy of your labeling or they will ask
  you to confirm this vital aspect to a quality end
  product.

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Successful NFPA Projects and Scope Recognitions
Step 1

• Actual Scope Example (Is this how you want to
  proceed with a Safety Audit for NFPA 70E?)
• The data collection process will include
  recording nameplate and setting information from
  circuit breakers, fuses, relays (over-current and
  ground-fault), switchboards, and transformers as
  well as feeder conductor sizes and lengths. To
  accomplish this, our Representative(s) and/or
  your Facility Representative(s) may be required
  to remove panel covers and open disconnects
  enclosures exposing energized components and
  conductors.
• XXXX is not responsible for the labeling of
  panels or the accuracy of those labels. If there
  are mislabeled or unlabeled over-current
  protection devices it is the responsibility of
  the facility to rectify these if they are to be
  included in the analysis. This may include
  collecting circuit data and providing it to XXXX
  after our site visit.

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Successful NFPA Projects and Scope Recognitions
Step 2

• After you have qualified the plant investigation
  phase of the safety audit you must then qualify
  the electrical print development stage of your
  process and the end deliverables of those prints.
• Most vendors are using software programs to enter
  key electrical information needed to indicate PPE
  choices and risks. These software programs like
  SKM Power Tools Tutorial and Easy Power for
  example are good programs but simply engineering
  tools.
• The prints or electrical one-lines created via
  software programs are simply reflective of what
  was needed for the engineering aspects of NFPA
  70E compliance.

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Successful NFPA Projects and ScopeRecognitions
Step 2

• Your goal should be to ask for a newly created
  set of AutoCAD drawings PRIOR to any engineering
  work done during your NFPA Safety Audit. This is
  your chance to ensure an accurate drawing is
  created by a real AutoCAD program and reviewed by
  your team for accuracy before engineering work
  done.

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Why Perform Maintenance?
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Flash Hazard Analysis Do Not Account for
Maintenance Issues

• Maintenance is a very critical part of the flash
  hazard issue.
• A preventive maintenance program on these circuit
  protective devices is needed.
• Inadequate maintenance can cause unintentional
  time delays.

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Flash Hazard Analysis

• Example
• A low-voltage power circuit breaker had not been
  operated or maintained for several years
• The lubrication had become sticky or hardened
• Circuit breaker could take several additional
  cycles, seconds, minutes, or longer to clear a
  fault condition.

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Flash Hazard Analysis

• Flash Hazard Analysis is performed
• Based on what the system is suppose to do - 5
  cycles
• Unintentional time delay, due to a sticky
  mechanism
• Breaker clears in 30 cycles
• The worker could be seriously injured or killed
  because he/she was under protected.
• Arc/Flash situation 20,000-amp short-circuit,
  480 volts, 3-inch arc gap, the worker is 18
  inches from the arc, with a 5 cycle clearing time
  for a 3-phase arc in a box (enclosure).
• Next slide illustrates this

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Calculation for 5 cycles
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Calculation with a 5 Cycle Clearing Time This
value of 1.89431 cal/cm2 is based on a
single-phase arc in open-air. As a general rule
of thumb, the value of 1.89431 would be
multiplied by a factor of 2 for a single-phase
arc in a box (2 x 1.89431 3.78862 cal/cm2
Category 1) and by a factor of 3.4 for a
multi-phase arc in a box (3.4 x 1.89431
6.440654 cal/cm2 Category 2). (The protection
category is based on NFPA 70E-2000, Part II,
Table 3-3.9.3.)
Due to a sticky mechanism the clearing time
increases to 30 cycles. Next slide illustrates
this
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Calculation for 30 cycles
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Calculation with a 30 Cycle Clearing Time The
value of 11.36586 cal/cm2 is based on a
single-phase arc in open-air. Again, as a
general rule of thumb, the value of 11.36586
would be multiplied by a factor of 2 for a
single-phase arc in a box (2 x 11.36586
22.73172 cal/cm2 Category 3) and by a factor of
3.4 for a multi-phase arc in a box (3.4 x
11.36586 38.643924 cal/cm2 Category 4). (The
protection category is based on NFPA 70E-2000,
Part II, Table 3-3.9.3.)
As can be seen, maintenance is extremely
important to an electrical safety program.
Maintenance must be performed according to the
manufacturers instructions in order to minimize
the risk of having an unintentional time delay in
the operation of the circuit protective devices.
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Summary

• Proper maintenance can be performed and power
  systems kept in a safe, reliable condition with
  the proper mixture of
• Common sense (Be concerned on who is providing
  common sense when discussing plans for
  reliability of your systems.)
• Training There can never be enough education to
  support ESWP
• Manufacturers literature and spare parts OEM
  specs are vital to consider

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• A Special Thanks to
• Quad Graphics (Linda Ernsberger)
• Rockwell Automation (Cally Edgren)
• Phillips Plastics (Dan Andersen)
• Square D Services
• Pat Ostrenga (OSHA)
• Rockwell Automation (Cally Edgren)
• Ted Sommer (Town Country)
• Cementex Tools
• Westex PPE Samples

All of these parties have played a large role in
helping to promote safety in the workplace.
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Thank You for Coming!!!!