integrated safety management and electrical equipment inspection at the aps june 14, 2010

Integrated Safety Management and Electrical Equipment Inspection at the

APSJune 14, 2010

Boris Deriy, APS Electrical Safety Committee ChairJu Wang, Power Systems Group Leader

Why has Argonne adopted ISM?1. ISM program provides an organized

process for people to plan, perform, assess and improve the safe conduct of work at all levels.

2. DOE mandates ISM within our prime contract

3. ISM provides a framework for compliance with other regulatory requirements

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Argonne's Integrated Safety Management (ISM) program Formal approach to integrate safety into all aspects of the work process in the Lab

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B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

ISM based on seven principles and five core functions

Seven ISM Principles


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Five ISM Core Functions


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Everyone assigned for a job has to ask himself

Analyzing Hazards Example (Booster Magnet PS)Arc Flash Calculation, Stored Energy Warning


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This is an example of how ISM works based on LOTO Procedure for Booster Dipole. Every piece of equipment at the APS is provided with a label containing information based on Arc Flash Calculations -- what hazards present, the Arc Flash Boundaries, PPE required...

Implementing Controls Example (Booster Magnet PS)Warning Signs, Panel Meters, Power Alert UAP-100, LOTO Procedure


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An Example of Clear Roles and Responsibilities (Test&Measurement Authorization Form)

Division Director Responsibilities Appoints qualified electrical workers Approves conversion of task-specific one-time-use to extended-duration T&M

Authorizations Group Leader Responsibilities (For CATs: CAT Director ) Assures that the energized test & measurements can be justified Assures that the work can be done safely and that persons listed are authorized and

qualified to perform the work.ESH Coordinator Responsibilities Assures that the proper safety approval process has been followed.APS Electrical Safety Committee Member Responsibilities Approves and/or performs the hazard analysis. Approves and/or defines PPE and safe working practices for the task to be

performed. Self-certifies that they are qualified to address electrical safety issues with the work

for which the authorization is requested.Authorized Worker Responsibilities Participates in pre-job briefing Complies with criteria on the T&M Authorization. Understands the safety envelope of work before starting, and stops work if

conditions change beyond the original scope or safety envelope. Performs work according to established APS safe working practices.


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Unlisted electrical equipment approval program at the APS

By 2005, two independent safety issues obviously grew up:1. For almost 15 years of operation APS accumulated hundreds of

pieces of equipment facing aging and obsolescence. Some of them did not match with newer standard safety requirements.

2. With extensive growing of users’ programs, the APS beamlines became flooded with non-standard equipment brought by users for experiments. There was no trained personnel at beamlines to help users to set up non-APS equipment which compromised safe operation.

OSHA requires that electrical equipment must either be listed by an NRTL, or approved by the local AHJ. To meet these requirements ANL initiated an unlisted electrical equipment approval program performed by Designated Electrical Equipment Inspectors (DEEI).


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DEEI Program – Why we needed it

An example of equipment brought to APS by a user for a beamline experiment

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DEEI Program – Why we needed it

Same equipment -- modified, inspected and allowed for experiment

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Designated Electrical Equipment Inspectors (DEEI) Training Program

– Review of Electrical Basics– Codes and Standards– NEC– Code Violations– DOE Handbook– Managing Electrical

Hazards– NRTL by OSHA

– Approval by UL– Hazard Classification– Unlisted Equipment

Approval– Administrative Controls– Lessons Learned– Practical Electrical Safety

including Argonne Tour– NFPA 70E for R&D

The training program was initiated in 2005. Now we have more than 90 inspectors trained (33 at the APS)

Program included:

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What Needs Inspection?

Equipment not needing inspection, one or more of the following: NRTL listed, not modified, and used per mfgr’s instructions Equipment considered non-hazardous Prototype (i.e. equipment under construction) equipment for < 3 months Equipment not being used

All other electrical equipment requires inspection and inventorying

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Argonne Recognized Reputable Manufacturers (8/31/2009) allows to perform “light” inspection


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Guidelines for Equipment Approval Suitability for installation and Grounding

Some potential considerations of suitability for installation and use are as follows: – Operation, considering environmental conditions – Temperature, humidity, air pressure, radiation, outdoor/indoor, etc. – Normal and abnormal use, considering duty cycle, average and peak power, etc. – Properly sized and installed equipment grounding (chassis grounding) – Equipment design that includes consideration of the available short circuit and ground

fault current – Properly sized and installed over-current protection (fuses or circuit breakers) – Separation of high- and low-voltage components, especially where high voltage could

escape along a hidden fault path

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Guidelines for Equipment Approval Mechanical strength and Preventing from Arc Flash

Mechanical strength and durability considerations : Enclosure should:

– Prevent damage to internal components during use and transportation – Contain arching, heating, and explosion – Prevent injury to personnel from hazardous energized parts – Prevent damage to internal components from environmental conditions

Workmanship—unused openings effectively closed Integrity of electrical equipment and connections Any item that would adversely affect the safe operation or mechanical strength of

the equipment, such as damaged, corroded, or overheated parts

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Guidelines for Equipment ApprovalWiring and Insulation

Wire bending and connection space includes the consideration of assembly and potential repair :

– The protection of conductors and their insulation against damage by over-bending, over crowding,

– location near moving parts in equipment, and at termination points. The integrity of insulation ensures that the system:

– Prevents the escape/transfer of electrical energy to other conductors and to personnel; – Is free from short circuits or potential short circuits; – Uses listed conductors where possible; and – Is free from grounds other than those required or permitted by National Electrical Code.

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Guidelines for Equipment Approval Other factors contributing to the practical safeguarding of personnel

• Reviewing non-electrical hazards (X-rays, UV and IR, RF fields, excessive noise ). • Preventing electric shock, burn, or reflex hazards by eliminating personnel contact

with live parts of equipment operating at 50 volts or more. • Establishing a procedure of energy removal, e.g., disconnection, LOTO, removal of

stored energy, for both normal/emergency shutdown. • Use listed or recognized components where possible. Consider the loss of electrical power, automatic removal of stored energy, the use of

interlocks on enclosures and other systems.

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Unlisted Electrical Equipment Approval Form


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Purchased Equipment should be listed by an NRTL (Nationally Recognized Testing Laboratory)

The following are the NRTLs for electrical equipment recognized by OSHA

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Approval and Rejection Labels


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Electrical Equipment Inspection Discoveries


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Abandoned live wireOne fuse per 6 supplies

Spliced Ground Wire

Cracked Insulation

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Lab-wide Unlisted Electrical Equipment Database

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APS Electrical Equipment Inspection Status


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Questions?


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integrated safety management and electrical equipment inspection at the aps june 14, 2010

Documents

boris deriy

safety envelope of work

electrical safety issues

work process

mandates ism

ism principlesb

ism core functionsb

proper safety approval