Electrical safety handbook

Revised to include references to the 2005 edition of the National Electrical Code and current Occupational Safety and Health Administration regulations, this reference source for the range of aspects of electrical safety opens with chapters on the necessity of electrical safety, types of electrical safety equipment, electrical safety procedures, an

Author Notes

John Cadick, P.E., is a registered professional engineer and the founder and president of the Cadick Corporation. Mr. Cadick has specialized for over three decades in electrical engineering, training, and management. His consulting firm, based in Garland, Texas, specializes in electrical engineering and training and works extensively in the areas of power system design and engineering studies, condition-based maintenance programs, and electrical safety. Prior to creating the Cadick Corporation and its predecessor, Cadick Professional Services, he held a number of technical and managerial positions with electric utilities, electrical testing companies, and consulting firms. In addition to his consultation work in the electrical power industry, Mr. Cadick is the author of Cables and Wiring and of numerous professional articles and technical papers.

Mary Capelli-Schellpfeffer, M.D., M.P.A., delivers outpatient medical care services to employees in occupational health service centers. Board-certified as a physician in general preventive medicine and public health, she is also a consultant to both the NJATC (National Joint Apprenticeship and Training Committee of National Electrical Contractors Association and International Brotherhood of Electrical Workers) and IEEE (Institute of Electrical and Electronics Engineers) Standards Committees. She lives in Chicago, Illinois.

Dennis K. Neitzel, C.P.E., is a certified plant engineer and has 33 years of experience in the electrical field. During eight years with the U.S. Air Force he served consecutively as an electrician, electrical shift supervisor, quality control inspector, and evaluator. Subsequent civilian employment included positions at the Idaho National Engineering Laboratory and at Westinghouse Idaho Nuclear, where he advanced to senior project engineer. Mr. Neitzel went to AVO International Training Institute in 1986 and has progressed from senior training specialist to Institute Director. He has served as a principal committee member for NFPA 70E standards since 1992 and is currently working on the revision of OSHA regulations. Mr. Neitzel has published articles on electrical safety, holds a master's degree in electrical engineering applied sciences, and is a certified electrical inspector.

Foreword	p. xvii
Preface	p. xix
Acknowledgments	p. xxi
Chapter 1 Hazards of Electricity	p. 1
Introduction	p. 1
Glossary	p. 1
Hazard Analysis	p. 2
Shock	p. 2
Description	p. 2
Influencing Factors	p. 3
Arc	p. 7
Definition and Description	p. 8
Arc Energy Release	p. 9
Arc Energy	p. 12
Arc Energy Input	p. 12
Arcing Voltage	p. 13
Arc Surface Area	p. 13
Incident Energy	p. 14
Arc Burns	p. 16
Blast	p. 16
Affected Body Parts	p. 17
General	p. 17
Skin	p. 19
The Nervous System	p. 20
Muscular System	p. 21
The Heart	p. 22
The Pulmonary System	p. 23
Summary of Causes-Injury and Death	p. 23
Shock Effect	p. 23
Arc Flash Effect	p. 24
Causes of Injury	p. 24
Causes of Death	p. 25
Protective Strategies	p. 25
References	p. 26
Chapter 2 Electrical Safety Equipment	p. 1
Introduction	p. 1
Glossary	p. 1
General Inspection and Testing Requirements for Electrical Safety Equipment	p. 2
Flash and Thermal Protection	p. 2
A Note on When to Use Thermal Protective Clothing	p. 2
Thermal Performance Evaluation	p. 3
Clothing Materials	p. 4
Non-Flame-Resistant Materials	p. 5
Flame-Resistant Materials	p. 6
Work Clothing	p. 9
Flash Suits	p. 11
Head, Eye, and Hand Protection	p. 13
Head and Eye Protection	p. 14
Hard Hats	p. 14
Safety Glasses, Goggles, and Face Shields	p. 15
Rubber-Insulating Equipment	p. 15
Rubber Gloves	p. 16
Rubber Mats	p. 20
Rubber Blankets	p. 21
Rubber Covers	p. 22
Line Hose	p. 25
Rubber Sleeves	p. 26
In-Service Inspection and Periodic Testing of Rubber Goods	p. 29
Hot Sticks	p. 44
Description and Application	p. 44
When to Use	p. 47
How to Use	p. 47
Testing Requirements	p. 47
Insulated Tools	p. 48
Description and Application	p. 48
When to Use	p. 49
How to Use	p. 49
Barriers and Signs	p. 49
Barrier Tape	p. 49
Signs	p. 49
When and How to Use	p. 50
Safety Tags, Locks, and Locking Devices	p. 51
Safety Tags	p. 51
Locks and Multiple-Lock Devices	p. 52
Locking Devices	p. 53
When/Where to Use Lockout Tagout	p. 53
Voltage-Measuring Instruments	p. 54
Safety Voltage Measurement	p. 54
Proximity Testers	p. 55
Contact Testers	p. 56
Selecting Voltage-Measuring Instruments	p. 57
Instrument Condition	p. 59
Low Voltage Voltmeter Safety Standards	p. 60
Three-Step Voltage Measurement Process	p. 60
General Considerations for Low-Voltage Measuring Instruments	p. 62
Safety Grounding Equipment	p. 63
The Need for Safety Grounding	p. 63
Safety Grounding Switches	p. 64
Safety Grounding Jumpers	p. 65
Selecting Safety Grounding Jumpers	p. 70
Installation and Location	p. 74
Ground Fault Circuit Interrupters	p. 74
Operating Principles	p. 74
Applications	p. 75
Safety Electrical One-Line Diagram	p. 78
The Electrician's Safety Kit	p. 78
References	p. 79
Chapter 3 Safety Procedures and Methods	p. 1
Introduction	p. 1
The Six-Step Safety Method	p. 1
Think-Be Aware	p. 2
Understand Your Procedures	p. 2
Follow Your Procedures	p. 2
Use Appropriate Safety Equipment	p. 2
Ask If You Are Unsure, and Do Not Assume	p. 2
Do Not Answer If You Do Not Know	p. 3
Pre-Job Briefings	p. 3
Definition	p. 3
What Should Be Included?	p. 3
When Should Pre-Job Briefings Be Held?	p. 3
Energized or De-Energized?	p. 3
The Fundamental Rules	p. 3
A Hot-Work Decision Tree	p. 5
After the Decision Is Made	p. 6
Safe Switching of Power Systems	p. 6
Introduction	p. 6
Remote Operation	p. 7
Operating Medium-Voltage Switchgear	p. 7
Operating Low-Voltage Switchgear	p. 11
Operating Molded-Case Breakers and Panelboards	p. 15
Operating Enclosed Switches and Disconnects	p. 17
Operating Open-Air Disconnects	p. 18
Operating Motor Starters	p. 20
Energy Control Programs	p. 23
General Energy Control Programs	p. 23
Specific Energy Control Programs	p. 24
Basic Energy Control Rules	p. 24
Lockout-Tagout	p. 26
Definition and Description	p. 26
When to Use Locks and Tags	p. 26
Locks without Tags or Tags without Locks	p. 26
Rules for Using Locks and Tags	p. 27
Responsibilities of Employees	p. 27
Sequence	p. 28
Lock and Tag Application	p. 28
Isolation Verification	p. 28
Removal of Locks and Tags	p. 28
Safety Ground Application	p. 29
Control Transfer	p. 31
Nonemployees and Contractors	p. 31
Lockout-Tagout Training	p. 31
Procedural Reviews	p. 32
Voltage-Measurement Techniques	p. 32
Purpose	p. 32
Instrument Selection	p. 32
Instrument Condition	p. 33
Three-Step Measurement Process	p. 34
What to Measure	p. 34
How to Measure	p. 36
Placement of Safety Grounds	p. 37
Safety Grounding Principles	p. 37
Safety Grounding Location	p. 38
Application of Safety Grounds	p. 38
The Equipotential Zone	p. 43
Removal of Safety Grounds	p. 44
Control of Safety Grounds	p. 44
Flash Hazard Calculations and Approach Distances	p. 46
Introduction	p. 46
Approach Distance Definitions	p. 46
Determining Shock Hazard Approach Distances	p. 46
Calculating the Flash Hazard Minimum Approach Distance (Flash Protection Boundary)	p. 49
Calculating the Required Level of Arc Protection (Flash Hazard Calculations)	p. 51
Introduction	p. 51
The Lee Method	p. 52
Methods Outlined in NFPA 70E	p. 52
IEEE Standard Std 1584-2002	p. 53
Software Solutions	p. 55
Required PPE for Crossing the Flash Hazard Boundary	p. 55
A Simplified Approach to the Selection of Protective Clothing	p. 56
Barriers and Warning Signs	p. 56
Illumination	p. 61
Conductive Clothing and Materials	p. 61
Confined Work Spaces	p. 62
Tools and Test Equipment	p. 62
General	p. 62
Authorized Users	p. 62
Visual Inspections	p. 63
Electrical Tests	p. 63
Wet and Hazardous Environments	p. 63
Field Marking of Potential Hazards	p. 65
The One-Minute Safety Audit	p. 65
References	p. 66
Chapter 4 Grounding of Electrical Systems and Equipment	p. 1
Introduction	p. 1
Electric Shock Hazard	p. 1
General Requirements for Grounding and Bonding	p. 2
Definitions	p. 2
Grounding of Electrical Systems	p. 3
Grounding of Electrical Equipment	p. 6
Bonding of Electrically Conductive Materials and Other Equipment	p. 6
Performance of Fault Path	p. 8
Arrangement to Prevent Objectionable Current	p. 8
Alterations to Stop Objectionable Current	p. 8
Temporary Currents Not Classified as Objectionable Current	p. 8
Connection of Grounding and Bonding Equipment	p. 8
Protection of Ground Clamps and Fittings	p. 9
Clean Surfaces	p. 9
System Grounding	p. 9
Purposes of System Grounding	p. 9
Grounding Service-Supplied Alternating-Current Systems	p. 9
Conductors to Be Grounded-Alternating-Current Systems	p. 11
Main Bonding Jumper	p. 11
Grounding Electrode System	p. 12
Grounding Electrode System Resistance	p. 14
Grounding Electrode Conductor	p. 14
Grounding Conductor Connection to Electrodes	p. 16
Bonding	p. 18
Equipment Grounding	p. 19
Equipment to Be Grounded	p. 19
Grounding Cord- and Plug-Connected Equipment	p. 19
Equipment Grounding Conductors	p. 21
Sizing Equipment Grounding Conductors	p. 22
Use of Grounded Circuit Conductor for Grounding Equipment	p. 22
Ferroresonance	p. 25
Summary	p. 27
Chapter 5 Electrical Maintenance and Its Relationship to Safety	p. 1
Introduction	p. 1
The Safety-Related Case for Electrical Maintenance	p. 1
Overview	p. 1
Regulatory	p. 2
Relationship of Improperly Maintained Electrical Equipment to the Hazards of Electricity	p. 2
Hazards Associated with Electrical Maintenance	p. 3
The Economic Case for Electrical Maintenance	p. 3
Reliability Centered Maintenance (RCM)	p. 4
What is Reliability Centered Maintenance?	p. 5
A Brief History of RCM	p. 5
RCM in the Industrial and Utility Arena	p. 5
The Primary RCM Principles	p. 6
Failure	p. 8
Maintenance Actions in an RCM Program	p. 8
Impact of RCM on a Facilities Life Cycle	p. 9
Conclusion	p. 10
The Eight Step Maintenance Program	p. 10
Introduction	p. 11
Step 1 Plan	p. 11
Step 2 Inspect	p. 11
Step 3 Clean	p. 12
Step 4 Tighten	p. 12
Step 5 Lubricate	p. 12
Step 6 Test	p. 13
Step 7 Record	p. 13
Step 8 Evaluate	p. 13
Frequency of Maintenance	p. 14
Determining Testing Intervals	p. 14
Summary	p. 14
Maintenance Requirements for Specific Equipment and Locations	p. 14
General Maintenance Requirements	p. 14
Substations, Switchgear, Panel Boards, Motor Control Centers, and Disconnect Switches	p. 15
Fuse Maintenance Requirements	p. 16
Molded-Case Circuit Breakers	p. 16
Low-Voltage Power Circuit Breakers	p. 18
Medium Voltage Circuit Breakers	p. 20
Protective Relays	p. 21
Rotating Equipment	p. 23
Portable Electric Tools and Equipment	p. 23
Personal Safety and Protective Equipment	p. 24
Conclusion	p. 24
References	p. 24
Chapter 6 Regulatory and Legal Safety Requirements and Standards	p. 1
Introduction	p. 1
The Regulatory Bodies	p. 1
The American National Standards Institute (ANSI)	p. 1
The Institute of Electrical and Electronic Engineers (IEEE)	p. 3
National Fire Protection Association (NFPA)	p. 3
American Society for Testing and Materials (ASTM)	p. 4
American Society of Safety Engineers (ASSE)	p. 5
The Occupational Safety and Health Administration (OSHA)	p. 6
Other Electrical Safety Organizations	p. 12
The National Electrical Safety Code (NESC)-ANSI C-2	p. 12
General Description	p. 12
Industries and Facilities Covered	p. 13
Technical/Safety Items Covered	p. 13
The National Electrical Code (NEC)-ANSI/NFPA 70	p. 14
General Description	p. 14
Industries and Facilities Covered	p. 15
Technical and Safety Items Included	p. 15
Electrical Equipment Maintenance-ANSI/NFPA 70B	p. 15
General Description	p. 15
Industries and Facilities Covered	p. 16
Technical and Safety Items Covered	p. 16
Standard for Electrical Safety in the Workplace-ANSI/NFPA 70E	p. 16
General Description	p. 16
Industries and Facilities Covered	p. 17
Technical Safety Items Covered	p. 18
The American Society for Testing and Materials (ASTM) Standards	p. 19
Occupational Safety and Health Administration (OSHA) Standards	p. 19
Overview	p. 19
General Industry	p. 19
Construction Industry	p. 22
Chapter 7 Accident Prevention, Accident Investigation, Rescue, and First Aid	p. 1
Accident Prevention	p. 1
Individual Responsibility	p. 1
Installation Safety	p. 1
Power System Studies	p. 3
First Aid	p. 7
General First Aid	p. 8
Resuscitation (Artificial Respiration)	p. 12
Heart-Lung Resuscitation	p. 12
Rescue Techniques	p. 14
General Rescue Procedures	p. 14
Elevated Rescue	p. 18
Confined-Space Rescue	p. 30
Ground-Level Rescue	p. 31
Accident Investigation	p. 37
Purpose	p. 37
General Rules	p. 38
Data Gathering	p. 38
Accident Analysis	p. 40
Chapter 8 Medical Aspects of Electrical Trauma	p. 1
Introduction	p. 1
Statistical Survey	p. 1
Non-Occupational Electrical Trauma	p. 4
Fatality and Injury Related Costs	p. 4
Electrical Events	p. 6
Electrocution and Electrical Fatalities	p. 7
Medical Aspects	p. 8
Non-Electrical Effects in Electrical Events	p. 10
Stabilization and Initial Evaluation	p. 13
Medical and Surgical Intervention	p. 14
Rehabilitation Focus and Return to Work Planning	p. 16
Reentry to Employment Settings	p. 16
Plateau in Recovery	p. 16
References	p. 18
Chapter 9 Low-Voltage Safety Synopsis	p. 1
Introduction	p. 1
Low-Voltage Equipment	p. 1
Extension Cords	p. 2
Plug- and Cord-Connected Equipment	p. 3
Current Transformers	p. 5
Grounding Low-Voltage Systems	p. 5
What Is a Ground?	p. 5
Bonding Versus Grounding	p. 6
Voltage Hazards	p. 6
System Grounds	p. 8
Equipment Grounds	p. 11
Ground Fault Circuit Interrupters	p. 14
Safety Equipment	p. 14
Overview	p. 14
Hard Hats	p. 14
Eye Protection	p. 15
Arc Protection	p. 18
Rubber Insulating Equipment	p. 18
Voltage-Testing Devices	p. 18
Safety Procedures	p. 20
General	p. 20
Approach Distances	p. 20
Voltage Measurement	p. 20
Locking and Tagging	p. 21
Closing Protective Devices After Operation	p. 21
Electrical Safety Around Electronic Circuits	p. 21
The Nature of the Hazard	p. 21
Special Safety Precautions	p. 22
Stationary Battery Safety	p. 23
Introduction	p. 23
Basic Battery Construction	p. 24
Safety Hazards of Stationary Batteries	p. 25
Battery Safety Procedures	p. 25
Chapter 10 Medium- and High-Voltage Safety Synopsis	p. 1
Introduction	p. 1
High-Voltage Equipment	p. 1
Current Transformers	p. 1
Grounding Systems of Over 1000 V	p. 3
What Is a Ground?	p. 3
Bonding Versus Grounding	p. 4
Voltage Hazards	p. 5
System Grounds	p. 5
Equipment Grounds	p. 7
Safety Equipment	p. 7
Overview	p. 7
Hard Hats	p. 8
Eye Protection	p. 8
Arc Protection	p. 9
Rubber Insulating Equipment	p. 9
Voltage-Testing Devices	p. 9
Safety Procedures	p. 12
General	p. 12
Approach Distances	p. 12
Voltage Measurement	p. 13
Locking and Tagging	p. 13
Closing Protective Devices After Operation	p. 13
Chapter 11 Human Factors in Electrical Safety	p. 1
Introduction	p. 1
Background	p. 1
Power Systems and Human Factors	p. 3
Visualization	p. 4
Cognitive Ergonomics	p. 4
Summary	p. 8
References	p. 8
Chapter 12 Safety Management and Organizational Structure	p. 1
Introduction	p. 1
Electrical Safety Program Structure	p. 1
Electrical Safety Program Development	p. 2
The Company Electrical Safety Team	p. 2
Company Safety Policy	p. 4
Assessing the Need	p. 4
Problems and Solutions	p. 4
Program Implementation	p. 5
Examples	p. 5
Company Safety Procedures	p. 7
Results Assessment	p. 7
Employee Electrical Safety Teams	p. 8
Reason	p. 8
Method	p. 8
Safety Meetings	p. 9
Who Attends	p. 9
What Material Should Be Covered	p. 9
When Meetings Should Be Held	p. 10
Where Meetings Should Be Held	p. 10
How Long Meetings Should Be	p. 10
Evaluation of Safety Meetings	p. 10
Outage Reports	p. 11
Safety Audits	p. 11
Description	p. 11
Purposes	p. 12
Procedure	p. 12
The Audit Team	p. 14
Audit Tools	p. 14
Follow-Up	p. 14
Internal versus External Audits	p. 14
Chapter 13 Safety Training Methods and Systems	p. 1
Introduction	p. 1
Safety Training Definitions	p. 1
Training Myths	p. 2
Conclusion	p. 3
Elements of a Good Training Program	p. 3
Classroom Training	p. 3
On-the-Job Training (OJT)	p. 5
Self-training	p. 6
Conclusion	p. 6
On-the-Job Training	p. 6
Setup	p. 6
Implementation	p. 8
Evaluation	p. 8
Conclusion	p. 9
Training Consultants and Vendors	p. 9
Canned Programs and Materials	p. 9
Tailored Programs	p. 10
Training Analysis	p. 10
Evaluating Training Vendors and Consultants	p. 11
Conclusion	p. 11
Training Program Setup-A Step-By-Step Method	p. 12
Introduction	p. 12
Background	p. 12
A Plan	p. 14
Analyze	p. 14
Design	p. 16
Develop	p. 17
Implementation	p. 18
Evaluation	p. 18

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