NREL’s
Electrical Safety Culture
Revitalization
Sal Sferrazza
July 2014
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
NREL’s
Electrical Safety Culture
Revitalization
NREL’s
Electrical Safety Culture
Revitalization
January 2013
Electrical safety is a challenge at NREL
– custom built equipment and systems (unlisted)
– Difficult to choose applicable design standards for R&D equipment
– changes in work, equipment, environment
– Many visitors users and students each year
– Subcontractors
- Organizational Structure and Culture
- Tendency for R&D community to rely on facilities and safety
organizations for electrical safety expertise
NREL’s
Electrical Safety
Organizational Changes
NREL NEEDS MORE INVOLVEMENT IN ELECTRICAL SAFETY ACROSS
THE ORGANIZATION
–
Electrical Safety Panel Charter
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Modified
DOE and Line Management is represented
AHJ Authority clarified with DOE
Created ESO and Advisors, selected by the AHJ/Charter
Electrical Safety Officers (ESOs) and Advisors are key panel members and have
been selected
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The ESO has a strong working background in the electrical field. (e.g. scientist, EE,
electrician, electronics technician, lineman)
NREL Electrical Safety Organizational Structure
Lab Director
Senior
Manager
Champion
National Center
for
Photovoltaics
Transportation
& Hydrogen
Systems
Chemical &
Materials
Sciences
National Renewable Energy Laboratory
Buildings and
Thermal Systems
AHJ
Electrical
Safety Panel
Biosciences
Site Operations
National Wind
Technology
Center
Environmental
Health and
Safety
Power Systems
Engineering
National
Bioenergy
Center
Innovation for Our Energy Future
ESO Training
“train more, to fewer employees, and allow even fewer
employees to do the work”
Extensive Training Program Initiated for ESOs and Advisors
– 5 Specialized Courses in the last 2 months of fiscal year 2013, 17 days of
training at a cost of $100,000
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National Electric Code for Lab Workers
NFPA 70E Electrical Safety in the Workplace
Specialized Officer training for Lab Workers
National Electric Code Inspector Class (ICC Inspector Certification prep class)
Medium Voltage Power Systems
– 2014 Training:
• SEMI S22 Safety Guidelines for the Electrical Design of Semiconductor
Manufacturing Equipment & EN 60204-33 Safety of Machinery – Requirements
for Semiconductor Fabrication Equipment
• NFPA 79 Electrical Standard for Industrial Equipment
• Additional Medium Voltage Training for Electricians (certification is goal)
NREL’s
Electrical Safety
Engaging R&D
Electrical Inspection Process Improvements
– Working with Officers to id equipment for inspection
– Additions to the Electrical Safety Lab Level Procedures
– Working on simple electrical tests to aid in approving equipment per NFPA
79 , Chapter 18
–
Earthing Continuity Test ,ground impedance tests, Dialectic Tests, Residual
voltage
Encourage Research in Electrical Safety
–Encourage them to be the Expert
–Hazard identification & control of lab electrical hazards (DC, RF, stored
energy etc.)
–Third Party Certifications
•1/3 of ESOs are ICC certified inspectors now
Qualification Cards
NREL’s
Electrical Safety Culture
Engaging R&D
Engaged in Electrical Inspection /Process Improvements
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Selected document control software(FileMaker Pro) : Document/Form Control
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LOTO Form
Excavation Permit
Electrical Safe Work Permit
INSPECTION FORM
Arc Flash Reports
PRO: FileMaker Pro is a record keeping database / compliance tool
CON: More administrative overhead
NREL’s
Electrical Safety Culture
Engaging Facilities
PPE : Everyday wear
– We have recently adopted everyday wear for those engaged in
daily electrical construction work.
Mandated electricians to be third party certified to do
construction inspections
– Facilities electricians are accepting and grateful for the
opportunity
– All NREL electricians are licensed and ICC certified electrical
inspectors
– Formal NFPA 70E training for mechanical technicians
10
Other Improvements
Policy Updates
Electrical Safety Policy Updates
– R&D hazards
• Shock boundary thresholds for special R& D hazards
– DOE Handbook
– Practical
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Electrical Hazard Classification Adopted
Classify according to waveform
and source
60 Hz
1.x
DC
2.x
capacitors
3.x
batteries
4.x
RF
subRF
3 kHz - 100 MHz
1 Hz – 3 kHz
5.x
6.x
inductors
7.x
General Categories
National Renewable Energy Laboratory
Innovation for Our Energy Future
Other Significant
Electrical Improvements
PM Program for Electrical Equipment
–
Year 1 of the PM program has started
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Budgeted $500,000 or $125,000 per year, 4 year cycle
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Priorities Set
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#1 Equipment that poses the greatest arc flash hazard
#2 Oldest equipment first
– Hiring a full time employee to manage NREL’s electrical preventative
maintenance program
Electrical Safety Challenges
Administration for Electrical Safety
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Permit Library
Equipment Labeling
Inspection
PPE Program
Engineering Support
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Arc Flash Analysis
Hazard Analysis
Inspections
Real Time Configuration Management / Equipment Alignment
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How do we keep R&D engaged in
Electrical Safety Program?
Qualification and Training
– Recognition of Hazards
– Methods to Control Hazards
Engineering Controls
– Equipment Approval Program
Administrative Controls
– Work Control
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Two person rule
Permits
PPE
Qualification and Training
BUDGET PROVIDED TO ESOs
Recommended Additional Electrical Training
• UL 508
o Safety Standard for Industrial Control Equipment
• NFPA 790 & 791
o Standard for Competency of Third-Party Field Evaluation Bodies
o Recommended Practice and Procedures for Unlabeled Equipment Evaluation
• Third Party Medium Voltage Certification
• Third Party Electrical Testing Certification
National Renewable Energy Laboratory
Innovation for Our Energy Future
NREL’s
Electrical Safety Culture
Revitalization Observations
– There is a benefit of having the latest understanding of NFPA
70E and other codes and standards
– Sold the idea to management
– Managing the expectations
– Costs, but requires more discipline than cost
– Audits & inspections
– It is long term plan
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Questions?
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