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UAW-GM
Electrical Safe Work
Practices Document
(ESWP)
UAW-GM Electrical Safe Work Practices Document
Table of Contents
Section
1
Page
General...............................................................................................1
1.1
Scope...............................................................................................................1
1.2
Purpose ...........................................................................................................1
'H¿QLWLRQV..........................................................................................2
1RUPDWLYH5HIHUHQFHV ......................................................................9
3ULQFLSOHVDQG3ROLFLHV ...................................................................10
2EMHFWLYH .......................................................................................................10
5HVSRQVLELOLWLHV............................................................................................10
4.2.1
Management Responsibility ................................................................10
4.2.2
Personal Responsibility ....................................................................... 11
(OHFWULFDO6DIHW\3ULQFLSOHV ......................................................................... 11
4.3.1
Plan Every Job .................................................................................... 11
4.3.2
Anticipate Unexpected Events............................................................. 11
4.3.3
Use the Right Tool for the Job ............................................................. 11
4.3.4
Use Procedures as Tools ....................................................................12
4.3.5
Isolate the Equipment..........................................................................12
4.3.6
Identify the Hazards.............................................................................12
4.3.7
Eliminate or Minimize Hazards ............................................................12
4.3.8
Protect the Person...............................................................................12
4.3.9
Audit These Principles.........................................................................12
4.3.10
Evaluate Each Completed Job ............................................................13
4.3.11
Continuous Improvement ....................................................................13
3ROLFLHV..........................................................................................................13
4.4.1
As-Built Documentation Policy ............................................................13
4.4.2
Electrically Safe Work Condition .........................................................13
4.4.3
Safe Approach Distance......................................................................13
4.4.4
Test (and possibly ground) Before Touch ............................................14
4.4.5
Work On or Near Energized Equipment ..............................................14
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UAW-GM Electrical Safe Work Practices Document
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
Abandoned Lines, Wires, or Cables ....................................................14
Electrical Incidents...............................................................................14
Substation Equipment .........................................................................14
Insertion and Removal of Bus Plug-in Units ........................................15
Operation of Bus Plug-in Units ............................................................15
All Tasks Greater Than 8 cal/cm2.................................................................................................... 15
4XDOL¿FDWLRQRI3HUVRQQHO..............................................................16
2EMHFWLYH .......................................................................................................16
4XDOL¿FDWLRQV................................................................................................16
5.3
4XDOL¿HG ..............................................................................................16
8QTXDOL¿HG...........................................................................................16
5.2.3
Exceptions ...........................................................................................17
General ..........................................................................................................17
5.3.1
Personnel to be Trained ......................................................................17
5.3.2
On-The-Job Training............................................................................17
4XDOL¿FDWLRQ'RFXPHQWDWLRQ................................................................17
3ODQQLQJ(OHFWULFDO:RUN ................................................................18
2EMHFWLYH .......................................................................................................18
3URFHGXUH6HTXHQFH....................................................................................18
3ODQQLQJ(OHFWULFDO:RUN)ORZFKDUW)LJXUH..........................................19
3HUVRQDO3URWHFWLYH(TXLSPHQW33(5HTXLUHPHQWV .................20
2EMHFWLYH .......................................................................................................20
7.2
General ..........................................................................................................20
(TXLSPHQW/LVW .............................................................................................20
*HQHUDO(TXLSPHQW ......................................................................................21
33(,QVSHFWLRQDQG0DLQWHQDQFH ...............................................................22
7.5.1
Insulating Equipment ...........................................................................22
7.5.2
Flame Resistant Protective Equipment ...............................................23
7.5.3
Test Instruments and Equipment.........................................................23
(OHFWULFDO7HVWLQJ..........................................................................................23
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UAW-GM Electrical Safe Work Practices Document
6SHFL¿F(TXLSPHQW,QIRUPDWLRQ .................................................................24
7.7.1
Hand and Arm Protection ....................................................................24
7.7.2
Foot and Leg Protection ......................................................................24
7.7.3
Insulated Tools and Equipment ...........................................................24
7.7.4
Voltage Testing and Other Test Equipment .........................................24
7.7.5
Flame Resistant (FR) PPE ..................................................................25
7.7.6
Protective Shields and Barricades.......................................................25
7.7.7
Insulating Blankets and Mats...............................................................25
7.7.8
Personal Safety Grounding Equipment ...............................................25
3HUVRQDO6DIHW\*URXQGLQJ............................................................26
2EMHFWLYH .......................................................................................................26
8.2
General ..........................................................................................................26
8.2.1
When Personal Safety Grounds Are Needed......................................26
8.2.2
Selection of Grounding Sets................................................................26
8.2.2.1
Clamps ...........................................................................................26
8.2.2.2
Cables ............................................................................................27
8.2.3
Temporary Personal Safety Grounds Procedure.................................28
9ROWPHWHUDQG$PPHWHU8VH ..........................................................30
2EMHFWLYH .......................................................................................................30
3URFHGXUDO6HTXHQFH...................................................................................30
9.2.1
Meter Selection....................................................................................30
9.2.2
Using Electrical Test Equipment..........................................................30
Electrical Testing and Troubleshooting Checklist (Figure 4)................31
9.2.3
Obtaining a Voltage Measurement ......................................................32
9.2.3.1 Phantom Voltage Reading .............................................................32
9.2.4
Using a Volt-Ohm Meter (VOM) to Measure Resistance.....................33
9.2.5
Using a VOM to Measure Current .......................................................34
9.2.6
Effects of Meter Leads on Measurements...........................................34
9.2.7
Clamp-On Ammeter Selection.............................................................34
9.2.8
Obtaining a Current Reading with a Clamp-On Ammeter ...................35
9.2.9
Proper Use and Care of Metering Devices..........................................35
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UAW-GM Electrical Safe Work Practices Document
7URXEOHVKRRWLQJ(OHFWULFDO(TXLSPHQW .........................................36
2EMHFWLYH .......................................................................................................36
10.2
General ..........................................................................................................36
3URFHGXUH6HTXHQFH....................................................................................36
10.3.1
Know the System/Equipment ..............................................................36
10.3.2
Investigate the Symptoms ...................................................................36
10.3.3
List the Probable Causes ....................................................................37
10.3.4
Eliminate the Possibilities ....................................................................38
10.3.5
Discover the Root Cause(s) ................................................................39
5HHQHUJL]DWLRQ$IWHU3URWHFWLYH'HYLFH2SHUDWLRQ ..................................39
7HPSRUDU\0RGL¿FDWLRQRI&LUFXLWVRU3URJUDPV......................................39
%XV3OXJLQ8QLWV$QG%XVZD\......................................................40
2EMHFWLYH .......................................................................................................40
11.2 General ..........................................................................................................40
3URFHGXUDO6HTXHQFH...................................................................................40
11.3.1
Disconnect Switch and Stab Assembly Inspection..............................40
11.3.2
Power Distribution Busway Inspection ................................................41
11.3.3
Installation ...........................................................................................42
11.3.4
Unit Removal .......................................................................................43
&RQGXLWDQG:LUHZD\,QVWDOODWLRQ±:LUH3XOOLQJ .........................44
2EMHFWLYH .......................................................................................................44
3URFHGXUDO6HTXHQFH...................................................................................44
12.2.1
General Requirements ........................................................................44
12.2.2
50 to 150 Volts.....................................................................................44
12.2.3
151 to 750 Volts...................................................................................45
(OHFWULFDO(TXLSPHQW/DEHOLQJ±
8$:*0(OHFWULFDO+D]DUG:DUQLQJ/DEHOV .................................46
2EMHFWLYH .......................................................................................................46
13.2
General ..........................................................................................................46
/DEHOLQJ5HTXLUHPHQWVIRU(OHFWULFDO
+D]DUG:DUQLQJDQG'DQJHU/DEHOV...........................................................46
iv
13.3.1
Electrical Hazard Warning Label Required..........................................47
13.3.2
Electrical Hazard Warning Label Not Required ...................................47
UAW-GM Electrical Safe Work Practices Document
13.3.3
13.3.4
13.3.5
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Arc Flash Hazard Calculation Not Required........................................48
Equipment with Nominal Voltage of Less Than 50 Volts .....................48
Label Application Table........................................................................48
$QQH[$1RUPDWLYH6DIH$SSURDFK'LVWDQFHV ....................... $
$
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*HQHUDO ........................................................................................................ $
6KRFN+D]DUG.............................................................................................. $
A.2.1
A.2.2
A.2.3
Limited Approach Boundary .............................................................. A-2
Restricted Approach Boundary.......................................................... A-3
Prohibited Approach Boundary.......................................................... A-3
$ $UF)ODVK+D]DUG ........................................................................................ $
A.3.1
Background / Description .................................................................. A-4
A.3.2
Hazard Assessment .......................................................................... A-4
A.3.3
Current Limiting Protective Devices .................................................. A-4
A.3.4
Conventional Circuit Breakers ........................................................... A-4
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UAW-GM Electrical Safe Work Practices Document
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UAW-GM Electrical Safe Work Practices Document
1 — General
1.1
Scope
The following document pertains to all electrical work performed at General Motors facilities
1.2
Purpose
The purpose of this document is to provide consistent information for the safe performance of
electrical work. This information is based in part on the following documents:
•
National Fire Protection Association (NFPA) 70E Standard for Electrical Safety in the
Workplace, 2004 Edition.
•
OSHA Regulations, Standard 29 CFR 1910.
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UAW-GM Electrical Safe Work Practices Document
³'HÀQLWLRQV
Approve - Review job requirements and planning documents, and if appropriate, authorize
that actual task(s) can be performed. Requires signature of approver.
Authorized – One who has been given authority or formally sanctioned to perform a task.
Arc Blast – The concussive force generated by an Arc Flash.
Arc Flash Boundary – This boundary marks the distance of an approach limit from which a
SHUVRQFRXOGUHFHLYHDVHFRQGGHJUHHEXUQLIDQHOHFWULFDOÀDVKZHUHWRRFFXUDQGWKH\ZHUH
not wearing ArcFlash PPE. This is a calculation based on time, distance, and available incident
energy.
Arc Flash Hazard – A dangerous condition associated with the rapid release of energy in the
form of heat and light that suddenly and violently changes material(s) into a vapor as a result
of an electrical arc from phase to phase or phase to ground.
Barehanded Work – A technique of performing work on exposed energized conductors or
circuit parts, after the worker has been raised to the potential of the energized conductor or
circuit part. %DUHKDQGHGZRUNLVQRWDFFHSWDEOHDW*HQHUDO0RWRUV
Barricade – A physical obstruction such as tapes, cones, or A-frame type wood or metal
structures intended to provide warning about and to limit access to a hazardous area.
Barricades are generally only installed temporarily.
Barrier – A physical obstruction which is intended to prevent contact with exposed energized
electrical conductors or circuit parts. Barriers may be installed temporarily or permanently.
Bonding – The permanent joining of metallic parts to form an electrically conductive path that
will ensure continuity and the capacity to conduct safely any current likely to be imposed. A
bond need not be a weld to be considered a permanent connection.
Buddy – Person assigned to accompany another person on a particular job and is instructed
RQKRZWRJLYH¿UVWDLGLQWKHHYHQWRIDQDFFLGHQW)RUHOHFWULFDOZRUNWKLVSHUVRQPXVWEH
TXDOL¿HGLQDFFRUGDQFHZLWK*HQHUDO0RWRUV(OHFWULFDO6DIH:RUN3URFHGXUH
Clamp-On Ammeter – A metering device that can be utilized for measuring AC or DC
FXUUHQWÀRZLQJLQDFLUFXLWZLWKRXWKDYLQJWRLQWHUUXSWRUEHLQVHULHVZLWKWKHFLUFXLW7KLVLV
accomplished via magnetic coupling between the circuit conductor and a split/clamp-on current
transformer integral to the meter.
Close out Inspection – Inspection to be performed on equipment prior to release for operation
which ensures that all tools, foreign objects, or other improper materials have been removed.
Conductive – Any material suitable for carrying electric current.
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UAW-GM Electrical Safe Work Practices Document
Corrective Maintenace – Any task past the point of testing and troubleshooting or that
involves using a tool other than a piece of test equipment.
De-energized – Having been disconnected from all sources of voltage and/or electrical
charge, resulting in zero volts to ground on the conductors.
Electrical Circuit Conductors – Components (including wire, bus and terminals) which are
intended to be in the normal current carrying path of the electrical system.
Electrical Energy State –
De-energized – Having been disconnected from all sources of voltage and/or electrical
charge, resulting in zero volts to ground on the conductors..
Energized – Electrically connected to a source of voltage or electrical charge so as to have
conductors elevated above ground potential.
Potentially Energized Equipment – Any equipment or component that is physically
connected to a power source.
Electrical Hazard±$FRQGLWLRQZKHUHHQHUJL]HGFRQGXFWRUVH[LVWDERYH9$&RU'&DQG
ZKHUHLQDGYHUWHQWRUXQLQWHQWLRQDOFRQWDFWRUHTXLSPHQWIDLOXUHPD\UHVXOWLQVKRFNDUFÀDVK
burn, thermal burn, or blast.
Electrical Incident – An event resulting in equipment damage or potential of injury to
employees brought about by either personnel action or electrical equipment failure. An
electrical incident has the potential to result in injury from:
•
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•
(OHFWULFDOVKRFNLI!YROWV
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5HÀH[DFWLRQWRDQHOHFWULFVKRFN
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Arc blast
Electrical Safety – Recognizing hazards associated with the use of electrical energy and
taking precautions so that hazards do not cause injury or death.
Energized Electrical Work Permit – The Energized Electrical Work Permit includes all of
the elements that NFPA 70E requires for any work where the equipment can not be placed
into an “Electrically Safe Work Condition” due to increased or additional hazard or infeasibility
per NFPA 70E 2004 -130.1 The Energized Electrical Work Permit requires a higher level of
authorization than a Written Job Permit due to the increased hazards. See Required form in
Annex D.
Electrically Non-hazardous Task – A task which involves equipment energized at a voltage
OHVVWKDQYROWV$&RU'&ZKHUHWKHUHZLOOEHQRLQFUHDVHGH[SRVXUHWRHOHFWULFDOEXUQVRUWR
explosion due to electric arcs.
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UAW-GM Electrical Safe Work Practices Document
Electrically Safe Working Condition – A state in which a conductor or circuit part has been
disconnected from energized parts, locked/tagged in accordance with established standards,
tested to ensure the absence of voltage, and if necessary grounded.
Enclosure – The case or housing of apparatus, or the fence or walls surrounding an
installation to prevent personnel from accidentally contacting energized parts or to protect the
equipment from physical damage.
Energized – Electrically connected to or having a source of voltage.
Equipment±$JHQHUDOWHUPLQFOXGLQJPDWHULDO¿WWLQJVGHYLFHVDSSOLDQFHVOXPLQDLUHV
¿[WXUHVDSSDUDWXVDQGWKHOLNHXVHGDVDSDUWRIRULQFRQQHFWLRQZLWKDQHOHFWULFDO
installation.
Gloves (Low Voltage) – 1000 volt rated rubber gloves conforming to Class 0, ASTM D120
UHTXLUHPHQWV$OVR&ODVVJORYHVUDWHG9XWLOL]HGLQ*HQHUDO0RWRUVIRUORZYROWDJH
work. All gloves are to be used with leather protectors.
Gloves (Medium Voltage) – 17,000 volt rated rubber gloves conforming to Class 2, ASTM
D120 requirements. These are only to be used with leather protectors.
Ground – A conducting connection, whether intentional or accidental, between an electrical
circuit and the earth or some conducting body that serves in place of the earth.
Grounded – Connected to earth or some external conducting body that serves in place of the
earth. This connection may be intentional or accidental.
Grounded Conductor – A system or circuit conductor that is intentionally grounded. This is
usually a current carrying conductor and is also called the neutral or power return.
Grounding Conductor, Equipment or Equipment Grounding Conductor – That conductor
used to connect the noncurrent-carrying metal parts of equipment, raceways, and other
enclosures to the system grounded conductor and/or the grounding electrode conductor at
the service equipment or at the source of a separately derived system. This conductor is also
called the “green” wire and must not be used to carry load current. The color green may not be
used on any other conductor.
Grounding Electrode±7KDWFRQGXFWRUWKDWVSHFL¿FDOO\PDNHVFRQWDFWZLWKWKHHDUWKIRU
grounding a power system.
Grounding Electrode Conductor – A conductor used to connect the grounding electrode
to the equipment grounding conductor and/or to the grounded conductor of the circuit at the
service equipment or at the source of the separately derived system.
Grounding jumper or Grounding strap – A strap of wire used to connect equipment housings
to the equipment grounding conductor.
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UAW-GM Electrical Safe Work Practices Document
Hot Work (Working On) – Working on means coming in contact with exposed energized
electrical conductors or circuit parts with the hands, feet, or other body parts, with tools,
probes, or with test equipment, regardless of the personal protective equipment a person is
wearing. This is the same as being inside the Prohibited Approach Boundary.
Incoming Supply – All conductors, cables, or rigid buswork that introduce power to a piece
of equipment. This includes the primary or alternate supplies, temporary supply, or interlock
control wiring.
Insulated – Separated from other conducting surfaces by a dielectric (including air space)
offering a high resistance to the passage of current. Note: When any object is said to be
insulated, it is understood to be insulated for the conditions to which it is normally subjected.
Otherwise, it should be treated as uninsulated.
Isolated – This is a much abused word in electronics. It can mean lifted from ground or earth,
separated by a transformer, use of a shielded transformer, separation by distance, separated
by special circuits, and so forth. An isolated circuit may or may not have a conductive path to
another circuit.
Limited Approach Boundary – An approach limit at a distance from an exposed live part
ZLWKLQZKLFKDVKRFNKD]DUGH[LVWV7KLVERXQGDU\LVWKHGLVWDQFHDWZKLFKDQXQTXDOL¿HG
SHUVRQPXVWVWD\EDFNXQOHVVHVFRUWHGE\DTXDOL¿HGSHUVRQ6HH$QQH[$IRUIXUWKHU
H[SODQDWLRQRIXQTXDOL¿HGSHUVRQVFURVVLQJOLPLWHGDSSURDFKERXQGDULHV
Live Parts – Energized conductive components or circuit parts.
Live-Line Tool Work -–A technique of performing work on exposed energized conductors or
circuit parts where the worker utilizes insulated live-line tools, rated for the voltage involved to
provide insulation of the person from the energized part on which work is to be performed.
Main Bonding Jumper or Bonding Jumper, Main – The connection between the grounded
circuit and the equipment grounding conductor at the service. This connection is the key to
electrical safety and thus this conductor is given a special name.
Neutral Conductor – The grounded conductor used to bring power to a facility or to a load.
This phrase is usually used to describe the grounded conductor in three-phase power.
Non-contact Voltage Tester – A device designed to indicate voltage by sensing the magnetic
DQGRUHOHFWULF¿HOGHPLWWHGE\HQHUJL]HGFRQGXFWRUV
Non-Resident Expert±$SHUVRQTXDOL¿HGWRPDNHHQJLQHHULQJDQGVDIHW\MXGJPHQWV
regarding issues in question, and who is not in the chain of command of the organization
needing assistance; provides expertise and educated opinions.
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UAW-GM Electrical Safe Work Practices Document
Prohibited Approach Boundary – An approach limit at a distance from an exposed live
part within which work is considered the same as making contact with the live part. To be
HQWHUHGRQO\E\TXDOL¿HGSHUVRQVUHTXLULQJVDPHSURWHFWLRQDVLILQGLUHFWFRQWDFWZLWKOLYH
part. Crossing the Prohibited Approach Boundary with any held object ( i.e., meter probes,
screwdrivers) is considered making contact. See Annex A for further explanation of crossing
prohibited approach boundaries.
Proximity Work (Working Near) – Working near is any activity inside the Limited Approach
Boundary of exposed energized electrical conductors or circuit parts that are not put into an
electrically safe work condition.
4XDOL¿HG*HQHUDO0RWRUV±0HHWVWKH³26+$([SDQGHG´GH¿QLWLRQDQG
•
Is thoroughly familiar with the General Motors Safe Electrical Work Procedures, and
•
Intends to implement the General Motors Safe Electrical Work Procedures in the work
place.
4XDOL¿HG26+$([SDQGHG±$TXDOL¿HGSHUVRQVKDOOEHWUDLQHGDQGNQRZOHGJHDEOHRI
WKHFRQVWUXFWLRQDQGRSHUDWLRQRIHTXLSPHQWRUDVSHFL¿FZRUNPHWKRGDQGVKDOOEHWUDLQHG
to recognize and avoid the electrical hazards that may be present with respect to that
equipment or work method. Such persons shall also be familiar with the proper use of special
precautionary techniques, personal protective equipment, insulating and shielding materials,
DQGLQVXODWHGWRROVDQGWHVWHTXLSPHQW$SHUVRQPD\EHFRQVLGHUHGTXDOL¿HGZLWKUHVSHFWWR
FHUWDLQHTXLSPHQWDQGPHWKRGVEXWVWLOOEHXQTXDOL¿HGIRURWKHUV6XFKSHUVRQVSHUPLWWHGWR
work within the limited approach boundary of exposed energized conductors and circuit parts
shall at a minimum be additionally trained in the following:
(a)
The skills and techniques necessary to distinguish exposed energized parts from other
parts of electric equipment,
(b)
The skills and techniques necessary to determine the nominal voltage of exposed
energized parts, and
F 7KHDSSURDFKGLVWDQFHVVSHFL¿HGLQ$SSHQGL[%DQGWKHFRUUHVSRQGLQJYROWDJHVWR
ZKLFKWKHTXDOL¿HGSHUVRQZLOOEHH[SRVHG
(d)
The decision making process necessary to determine the degree and extent of the
hazard and the personal protective equipment and job planning necessary to safely
SHUIRUPWKHWDVNDVGH¿QHGLQ3URFHGXUH
Rated Voltage – A meter rating which indicates the highest voltage that a meter may contact
without risking insulation failure and meter failure/destruction (and potentially personal injury).
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UAW-GM Electrical Safe Work Practices Document
Restricted Approach Boundary – An approach limit at a distance from an exposed live
part within which there is an increased risk of shock. This boundary must be entered only by
TXDOL¿HGSHUVRQVUHTXLUHGWRXVHVKRFNSURWHFWLRQWHFKQLTXHVDQGHTXLSPHQW(PSOR\HHV
must also have a documented plan. See Annex A for further explanation of crossing restricted
approach boundaries.
Review – Review job requirements and planning sheet, looking for errors in logic and
procedures, and working with the planner to modify. Requires the signature of the reviewer.
Scope of Work – A description of the work to be accomplished, including the physical
boundaries of the work.
Separately Derived System – A new or separate power source such as the secondary of a
transformer or the output of a motor generator set.
Shock Hazard±$GDQJHURXVFRQGLWLRQDVVRFLDWHGZLWKWKHÀRZRIFXUUHQWWKURXJKDSHUVRQ¶V
body caused by contact or approach to exposed electrical conductors or circuit parts nearer
than the minimum air insulation distance.
Solenoid Tester – A voltage tester utilized as an indicator of the approximate voltage between
two points of concern. There is typically a very approximate analog scale indicator, along with
an indicator in the end of the device that serves as an “energized”--“non-energized” gage. This
GHYLFHLVXVHIXOGXULQJWURXEOHVKRRWLQJZKHUHH[DFWYROWDJHYDOXHVDUHQ¶WQHFHVVDU\
Step Potential – A potential difference over the surface of the earth which can cause current
ÀRZIURPIRRWWRIRRWWKURXJKWKHERG\7KLVFRQGLWLRQLVPRVWFRPPRQO\FDXVHGE\DQHDUE\
lightning strike or a large local ground fault.
Touch Potential±$SRWHQWLDOGLIIHUHQFHZKLFKFDQFDXVHFXUUHQWÀRZIURPKDQGWRKDQGRU
hand-to-foot through the body.
Tic Tracer – A trademarked brand name for a non – contact voltage tester.
Troubleshooting – the logical analysis of symptoms to determine the cause of a failure.
8QTXDOL¿HG±$SHUVRQQRWPHHWLQJWKHTXDOL¿FDWLRQVHVWDEOLVKHGLQ&KDSWHUZKLFKLQFOXGHV
WKH26+$H[SDQGHGDQGWKH*HQHUDO0RWRUVDGGLWLRQDOTXDOL¿FDWLRQV
Voltage Sensing – A task intended solely to sense for the presence or absence of voltage.
Voltage Testing – A task intended solely to measure or sense voltage.
Voltmeter – An instrument utilized to determine the voltage difference between two points by
contacting each of two probe leads on the points in question. An analog or digital display is
utilized to indicate the value of the voltage. This type of meter will also include a limited ability
to measure current, as well as the ability to measure resistance (ohms). Also known by the
term VOM, or volt-ohm meter. DVOM represents a digital volt-ohm meter.
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UAW-GM Electrical Safe Work Practices Document
Wiggy – A trademarked brand name for a Solenoid Tester.
Working Near (Live Parts) – Any activity inside a Limited Approach Boundary.
Working On (Live Parts) – Coming into contact with live parts with the hands, feet, or other
body parts, with tools, probes, or other test equipment, regardless of the personal protective
equipment a person is wearing.
Written Work Instructions – A documented site procedure for commonly performed routine
tasks. These documents can be added to a database and distributed for people to reference.
Written Work Instructions must be reviewed with authorized persons annually. See sample
form in Annex C.
Written Job Permit ±$GRFXPHQWHGWDVNVSHFL¿FSODQUHTXLUHGIRUHOHFWULFDOO\KD]DUGRXV
ZRUNYROWVRUJUHDWHURQKD]DUGVWKDWDUHODEHOHGDWFDOFP2 or less . This is generally a
non-routine task involving assessing, adjusting, or aligning. This permit is documented and
reviewed by authorized management each time it is needed. See Required form in Annex D.
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UAW-GM Electrical Safe Work Practices Document
3 — Normative References
The following normative references contain provisions that, through reference in this text,
constitute provisions of this standard. The editions indicated were valid at the time of
publication. All normative documents are subject to revision and the most recent editions of the
normative standards indicated below shall apply.
•
•
•
•
•
•
•
•
NFPA 70E,Standard for Electrical Safety in the Workplace 2004 Edition.
IEEE 902-1998,IEEE Maintenance, Operation, and Safety of Industrial and Commercial
Power Systems.
OSHA 29 CFR 1910.269,SubPart “R” - Special Industries.
OSHA 29 CFR 1910.301, SubPart “S” - Electrical, General
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NEMA Standard BU 1-2002 for Busways
9
UAW-GM Electrical Safe Work Practices Document
4 — Principles and Policies
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This Electrical Safe Work Practices document describes the philosophy, policies, and required
procedures in support of electrical safety for General Motors Corporation. It is recognized that
local ordinances and conditions may require additions or supplements to this document.
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priority in everything that we do. Management must provide the time and funds necessary
to insure that each employee exposed to electrical hazards is provided with the proper
instruction and tools in order to perform their job safely. Each supervisor must set an example
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UHÀHFWHGLQWKHFRQGXFWRIWKRVHWKDWKHRUVKHVXSHUYLVHV(DFKVXSHUYLVRUVKRXOGHPSRZHU
the people under his or her direction to be proactive in continuously improving their own safety
and the safety of others. Engineering personnel are responsible to give technical direction
when necessary to guide the activities of the supervisor and the employees performing the
work.
Although it is clearly understood that every employee is responsible for himself/herself, it does
not negate the responsibilities of management to properly educate every member of the crew/
team on the task to be performed for the day. Each member shall be kept up to date with the
appropriate level of technical skills that are required to perform the functions of the job to be
completed.
Every employee performing work that exposes them to electrical hazards shall be provided
ZLWKWKHDSSURSULDWHVDIHW\LQVWUXFWLRQVIRUWKHVSHFL¿FWDVN0DQDJHPHQWPXVWLQVXUHWKDW
there is no misunderstanding of what to do if there is an injury as a result of electric shock,
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•
•
•
•
•
10
Location of the Nearest Telephone
Plant Emergency phone numbers.
Plant Security phone numbers.
Medical Department phone numbers.
Location of Nearest Fire Alarm.
UAW-GM Electrical Safe Work Practices Document
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(DFKSHUVRQLVUHVSRQVLEOHIRUKLVRUKHURZQVDIHW\(DFKSHUVRQ¶VDFWLRQVFDQLPSDFWWKH
safety of others. Each person is expected to understand, and use applicable safety procedures
as tools to guide all tasks. If a person feels that they are uncomfortable with the procedures,
methods, or the training presented to them, they should contact their supervisor and safety
UHSUHVHQWDWLYHIRUIXUWKHUFODUL¿FDWLRQRUDGYLFH
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The following principles provide a process that, when followed, can help ensure the safe
accomplishment of any electrical work and should be utilized as a means to communicate
essential information.
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Any time a task requires an employee to cross the Restricted Approach Boundary, you must
have a Written Work Instruction, Written Job Plan, Energized Electrical Work Permit or Safe
Operating Practice (SOP).
Plan all jobs, regardless of their size. Proper planning is the cornerstone of safely completing
any electrical work. Break down each job into small manageable tasks. If you perceive that the
tasks are complicated or critical, write down the steps necessary to complete them so that you
ZRQ¶WIRUJHW$XWKRUL]HGPDQDJHPHQWLVWRGLVFXVVWKHSODQZLWKWKRVHZKRZLOOEHSHUIRUPLQJ
the tasks. Then, make sure that the persons who are affected are aware of the general plan
RIDFWLRQ:KHQDSSURSULDWHVDIHW\DQGHPHUJHQF\SHUVRQQHOVKDOODOVREHQRWL¿HG,IWKH
FRQGLWLRQVRIWKHMRERUWDVNVFKDQJHRULI\RX¿QGVRPHWKLQJXQH[SHFWHGVWRSWKHZRUN
and re-plan the tasks with authorized management (remember always take two for safety).
For more information on planning electrical work, see General Motors Electrical Safe Work
Procedure 6.0, Planning Electrical Work.
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Before undertaking any task, ask “What if...?” and decide upon contingency plans in the event
WKDWVRPHWKLQJJRHVZURQJ'RQ¶WFRQ¿QH\RXUWKLQNLQJWRHOHFWULFDOHQHUJ\,QVWHDGFRQVLGHU
the overall environment such as what will happen if someone walking by happens to trip while
you are performing the task.
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,GHQWLI\WKHSURSHUWRROIRUWKHMREDQGGRQ¶WSHUIRUPWKHWDVNXQWLO\RXKDYHWKHULJKWWRRODW
hand. Using the proper fuse pullers or the right voltage tester can help ensure your safety. Find
out if the tasks you have planned require special tools.
11
UAW-GM Electrical Safe Work Practices Document
8VH3URFHGXUHVDV7RROV
Procedures provide a roadmap for accomplishing a job safely. Procedures prompt you to ask
the right questions. They are tools that help you plan your work; and, like tools, they should be
properly maintained.
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Isolate electrical equipment, both physically and electrically, to reduce the possibilities for
damage or injury. Isolation can mean performing hazardous energy control lockout, providing
insulating barriers, and/or barricades.
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Identify all potential hazards associated with a task, and consider each of them separately.
+D]DUGVDUHQRWDOZD\VHDVLO\LGHQWL¿HG,I\RXDUHQRWVXUH\RXKDYHLGHQWL¿HGDOORIWKH
hazards, ask for help. Remember that potential hazards are not always electrical.
(OLPLQDWHRU0LQLPL]H(OHFWULFDO+D]DUGV
As stated by the General Motors Hierarchy of Health and Safety controls process, elimination
or substitution are the most preferred methods for risk management. The preferred approach
to working on or near equipment is to put the equipment in an electrically safe work condition.
When this is not possible, minimize the hazards by up-grading your plan, isolating the
equipment, limiting the time of exposure, installing safety grounds, choosing scaffolds instead
of ladders, or by using insulating barriers or barricades.
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Use appropriate personal protective equipment (PPE) for each potential hazard, based on
the hazard assessment. Even if you apply all of the previous principles and appropriate
HQJLQHHULQJFRQVLGHUDWLRQV33(PD\EHQHFHVVDU\DVWKH¿QDOSURWHFWLRQDJDLQVWLQMXU\)RU
more information see Chapter 7, “Electrical PPE.”
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H[SRVXUHWRKD]DUGV'RWKH\UHÀHFWWKHQHZYDOXHVSURIHVVHGE\\RXDQGWKHRUJDQL]DWLRQ"
Learning continues outside of the classroom. Keep your eyes and ears open to evaluate work
as it progresses. Make use of additional written references.
12
UAW-GM Electrical Safe Work Practices Document
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7KHZRUNLVQRWWREHFRQVLGHUHGFRPSOHWHXQWLOLW¶VVFRSHKDVEHHQUHYLHZHGWRLQFOXGHEXW
not limited to, the following points:
1. Lessons learned.
2. Proper submittal of red-lined drawings, if necessary. Identify on existing prints the
differences found and/or changes made.
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equipment.
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Each person must recognize that the practices of the past do not insure future safety. A
SDUWLFXODUPDQQHULQZKLFKZHJRDERXWSHUIRUPLQJDWDVNLVQRWVDIHPHUHO\EHFDXVH³ZH¶YH
always done it that way.” As technological advances give us a better understanding of the work
that we do, we must improve our standards, practices and procedures.
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installations. Single-line diagrams, schematics, underground drawings, and all other necessary
system documentation must all be up-to-date so that proper planning can take place. In
addition, up-to-date drawings can help identify potential hazards. Inaccurate drawings can
compromise the safe execution of an electrical task, no matter how well planned the task might
be. Engineering shall maintain all drawings in an up-to-date condition. As-built changes shall
EHUHFRUGHGDQG¿OHFRSLHVDSSURSULDWHO\XSGDWHG
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employee may be exposed shall be put into an electrically safe work condition before an
employee works on or near them. Exceptions to this shall follow Section 6 - Planning Electrical
Work.
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Safe work practices shall be used to protect employees from injury while they are working
ZLWKLQVSHFL¿FGLVWDQFHVIURPFLUFXLWSDUWVZKLFKDUHRUPD\EHFRPHHQHUJL]HG7KHVSHFL¿F
safe work practices shall be determined by the level of hazards to which the employee may
be exposed. These distances are shown on the Electrical Hazard Warning Label. Refer to
Annex A for determination of these distances if not shown on an Electrical Hazard Warning
Label.
13
UAW-GM Electrical Safe Work Practices Document
7HVWDQG3RVVLEO\*URXQG%HIRUH7RXFK
All terminals, conductors, or other exposed components of electrical circuitry which could
be contacted (purposely or accidentally) are to be treated as energized until they have been
isolated, tested for the absence of voltage using approved test equipment, and locked out per
DSSURYHGSURFHGXUHV&RQVXOW&KDSWHU9ROWDJH7HVWLQJDQG$QQH[%6SHFL¿FDWLRQVIRU
Voltage Test Equipment) for reference information. If the conductor at issue is of a nominal
V\VWHPYROWDJHRIJUHDWHUWKDQ9XVHWHPSRUDU\SHUVRQDOVDIHW\JURXQGVLQDFFRUGDQFH
with Procedure 8.2.3.
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Live parts to which an employee might be exposed shall be put into an electrically safe work
condition before an employee works on or near them, unless it can be demonstrated that
deenergizing introduces additional or increased hazards or is infeasible due to equipment
GHVLJQRURSHUDWLRQDOOLPLWDWLRQV(QHUJL]HGSDUWVWKDWRSHUDWHDWOHVVWKDQYROWVWRJURXQG
shall not be required to be deenergized if there will be no increased exposure to electrical
burns or to explosion due to electric arcs. If situations arise that require work to be performed
on or near energized electrical equipment planning and authorization are to be in accordance
with Section 6, Planning Electrical Work.
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Electrical lines, wires, and cables that are removed from service or not connected should be
removed. If they cannot be removed, individual conductors must be taped and then tagged
to indicate the location of the other end. Underground wiring that has been abandoned in
place must be maintained on drawings for reference. Wiring installed to provide power during
construction must be removed when it is no longer required.
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All electrical incidents shall be reported to supervision. Anyone receiving any type of an
electrical shock must report to the Medical Department/First Aid for evaluation. Workers can
learn from electrical incidents. Insights gained during the incident investigation will help revise
current policies and procedures in order to reduce the likelihood of future injuries.
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The manual opening, closing, and racking of all substation power circuit breakers other than
Arc-Resistant Switchgear-type equipment shall not be done without the use of appropriate
PPE. This shall be a minimum of the standard 40 cal/cm2DUFÀDVKVXLWDQGKRRGJORYHVDQG
hearing protection. This task should follow the steps in Chapter 6 – Planning Electrical Work.
$Q\ZRUNRIWKLVQDWXUHDOVRUHTXLUHVWKHXVHRIDTXDOL¿HGEXGG\DVDUHVFXHULQFDVHRIDQ
incident. This buddy should exit the substation before any switch or transfer is made as to
minimize hazard exposure.
14
UAW-GM Electrical Safe Work Practices Document
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,WLVWKH&RPSDQ\¶VSROLF\WKDWDOOLQVHUWLRQDQGUHPRYDOVRIEXVSOXJLQXQLWVVKDOOEH
completed with the busway in an electrically safe work condition.
Further, it is recognized that events or conditions may arise that make it infeasible or present
a greater hazard to de-energize the busway before insertion or removal of a plug-in unit. In
such cases follow Section 6 – Planning Electrical Work and Section 11 – Bus Plug-in Units and
Busway.
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Opening and closing of bus plug-in units should be done using a hook stick with non-metallic
pole and all other appropriate PPE from the maximum feasible distance possible to minimize
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All tasks that require the use of a 40 cal/cm2ÀDVKVXLWPXVWKDYHDVHFRQGHOHFWULFLDQDVVLJQHG
observing the task at a distance. In addition, the pre-task plan for this task must include an
HPHUJHQF\UHVSRQVHSODQLQFOXGLQJSURYLVLRQIRU¿UVWDLGDQG&35VHUYLFHV
15
UAW-GM Electrical Safe Work Practices Document
³4XDOLÀFDWLRQRI3HUVRQQHO
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This procedure describes the requirements and procedures necessary to qualify personnel
with regard to electrical safety.
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regarding the knowledge and the intention to use the procedures listed in this document.
Additional consideration was given to accommodate enhancements from the National
Fire Protection Association (NFPA) 70E Standard for Electrical Safety in the Workplace.
)XUWKHUPRUHTXDOL¿FDWLRQLVDWDVNEDVHGWHUP,QRWKHUZRUGVDQHPSOR\HHPLJKWEHTXDOL¿HG
WRSHUIRUPDSDUWLFXODUW\SHRIMREDQGQRWEHTXDOL¿HGWRSHUIRUPVRPHRWKHUWDVN'HWDLOVIRU
TXDOL¿FDWLRQVIRUVXEVWDWLRQZRUNPD\EHIRXQGLQWKH(OHFWULFDO3RZHU(TXLSPHQW0DLQWHQDQFH
Manual (EMM-1).
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DVGH¿QHGE\WKH(OHFWULFDO+D]DUG:DUQLQJ/DEHORU$QQH[$7KHGHVLJQDWHG3HUVRQ
In-Charge of the work space where the electrical hazard exists shall cooperate with the
GHVLJQDWHG3HUVRQ,Q&KDUJHRIWKHXQTXDOL¿HGSHUVRQVWRHQVXUHWKDWDOOZRUNFDQEHGRQH
VDIHO\7KLVVKRXOGLQFOXGHDGYLVLQJWKHXQTXDOL¿HGSHUVRQVRIWKHHOHFWULFDOKD]DUGDQG
warning them to stay outside of the Limited Approach Boundary and the Arc Flash Hazard
Boundary.
:KHQWKHUHLVDQHHGIRUDQXQTXDOL¿HGSHUVRQVWRFURVVWKH/LPLWHG$SSURDFK%RXQGDU\
RUWKH$UF)ODVK+D]DUG%RXQGDU\WRSHUIRUPDPLQRUWDVNRUORRNDWHTXLSPHQWDTXDOL¿HG
SHUVRQVKDOODGYLVHWKHPRIWKHSRVVLEOHKD]DUGVDQGHQVXUHWKDWWKHXQTXDOL¿HGSHUVRQV
LVDUHVDIHJXDUGHG8QGHUQRFLUFXPVWDQFHVVKDOOVXFKXQTXDOL¿HGSHUVRQVEHSHUPLWWHG
WRFURVVWKH$UF)ODVK%RXQGDU\XQOHVVWKH\DUHZHDULQJ)5FORWKLQJUDWHGIRUWKHDUFÀDVK
KD]DUGWKH\PD\EHH[SRVHGWR8QGHUQRFLUFXPVWDQFHVVKDOOVXFKXQTXDOL¿HGSHUVRQVEH
SHUPLWWHGWRFURVVWKH5HVWULFWHG$SSURDFK%RXQGDU\8QTXDOL¿HGSHUVRQVVKDOOEHWUDLQHGLQ
DQGEHIDPLOLDUZLWKDQ\RIWKHHOHFWULFDOVDIHW\UHODWHGSUDFWLFHVZKLFKPD\QRWEHVSHFL¿FDOO\
addressed in this document, but are necessary for their safety.
16
UAW-GM Electrical Safe Work Practices Document
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$QHPSOR\HHPD\EHFRQVLGHUHGWREHDTXDOL¿HGSHUVRQIRUWKHSHUIRUPDQFHRIVSHFL¿FGXWLHV
given that all of the following criteria are met:
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2. The employee has demonstrated an ability to perform duties safely at his or her level of
training.
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observing the duties being executed.
5.3
General
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The following personnel shall be trained in safety related work practices and procedural
requirements as necessary to provide protection from electrical hazards associated with their
respective job or task assignments:
•
•
•
•
•
All electricians
All electrical technicians
All supervisors of electricians and/or electrical technicians
All electrical engineers involved in the electrical area
All personnel contracted to General Motors who meet the preceding descriptions
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On-the-job training shall be held for the above groups:
•
Shortly after major changes to equipment or procedures
•
Periodically through regular safety contacts by supervisors with employees
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•
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job training
•
•
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Safety contact records (Safety Talks)
17
UAW-GM Electrical Safe Work Practices Document
6 — Planning Electrical Work
2EMHFWLYH
This procedure establishes the guidelines to be utilized when planning the safe execution
of electrical work. These policies and practices shall be used for all electrical work to be
performed at General Motors.
3URFHGXUH6HTXHQFH
'H¿QHWKHVFRSHRIWKHZRUNLQFOXGLQJWKHSK\VLFDOERXQGDULHVDQGVDIHDSSURDFK
GLVWDQFHVRIWKHZRUNDVRXWOLQHGLQ$QQH[$DQGWKHSDQHO¶V(OHFWULFDO+D]DUG:DUQLQJ
/DEHO$OVRGH¿QHDOORIWKHKD]DUGV/LVWSRWHQWLDOHQHUJ\KD]DUGVVXFKDVJUDYLW\DVZHOO
as electrical hazards.
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3. Where necessary, determine when the equipment may be secured by completing a
Request for Machine Maintenance Access/Shutdown for the affected equipment. See
sample form in Annex C.
4. Where authorized management is required to approve electrical work, the supervisor in
FKDUJHVKDOOEHUHVSRQVLEOHIRUHQVXULQJWKDWDMREEULH¿QJZLWKWKHZRUNHUVLQYROYHGKDV
been held before the start of the work. Where necessary, hold a project pre-meeting to
discuss job purpose, safety, personnel, equipment, and contingency plans. The formality
and structure of these meetings shall match the level of complexity and risk that the job
poses.
(PSOR\HHVVKDOOEHLQVWUXFWHGWREHDOHUWDWDOOWLPHVGXULQJWKHMREDQGUHPLQGHGRIDQ\
MREVSHFL¿FKD]DUGVWKDWPLJKWH[LVW$Q\FKDQJHVWRDQDXWKRUL]HGPDQDJHPHQWSURFHGXUH
require employees to stop work and notify their supervisor. Remember to always “Take 2
for Safety”.
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EULH¿QJVKDOOPDWFKWKHOHYHORIFRPSOH[LW\RIWKHMRE
7. Complex tasks involving multiple crews, multiple shifts, multiple energy sources, multiple
locations, multiple employers, unique disconnecting means, complex or unique switching
sequences shall require a documented plan.
18
UAW-GM Electrical Safe Work Practices Document
Figure 1: Planning Electrical Work Flowchart
The purpose of this table is to determine the documentation process and level of
management approval required for electrical work. It considers ONLY the electrical
KD]DUGVDVVRFLDWHGZLWKDVSHFL¿FWDVN(OHFWULFDOZRUNRQHTXLSPHQWOHVVWKDQYROWVWR
JURXQGLVFODVVL¿HGDVQRQKD]DUGRXV
1RWH –––– Written Work Instructions – A documented site procedure for commonly performed routine tasks. These
documents can be added to a database and distributed for people to reference. Written Work Instructions must
be reviewed with authorized persons annually. See sample form in Annex C.
1RWH –––– :ULWWHQ-RE3HUPLW±$GRFXPHQWHGWDVNVSHFL¿FSODQUHTXLUHGIRUHOHFWULFDOO\KD]DUGRXVZRUNYROWVRUJUHDWHU
on hazards that are labeled 8 cal/cm2 or less. This is generally a non-routine task involving assessing, adjusting,
or aligning. This permit is documented and reviewed by authorized management each time it is needed. See
required form in Annex D.
1RWH –––– The Energized Electrical Work Permit includes all of the elements that NFPA 70E requires for any work where
the equipment can not be placed into an “Electrically Safe Work Condition” due to increased or additional hazard
or infeasibility per NFPA 70E 2004 -130.1 The Energized Electrical Work Permit requires a higher level of
authorization than a Written Job Permit due to the increased hazards. See required form in Annex D.
1RWH –––– ,QDGHTXDWHORFNRXWIRUP6236DIH2SHUDWLQJ3URFHGXUH±$VSHFL¿FZULWWHQSURFHGXUHWKDWPXVWEHIROORZHG
to reduce risk when it is determined that a particular task must be performed while equipment is energized. An
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forms. If the hazard is greater than 8 cal/cm2 then an Energized Electrical Work Permit is also required.
19
UAW-GM Electrical Safe Work Practices Document
7 — Personal Protective Equipment
(PPE) Requirements
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7KLVSURFHGXUHGH¿QHVWKHSHUVRQDODQGRWKHUSURWHFWLYHHTXLSPHQW33(QHFHVVDU\WR
protect personnel from electrical hazards. Further, this chapter discusses the maintenance and
the care of that PPE.
7.2
General
Safety related work practices shall be used to safeguard employees from injury while they
DUHZRUNLQJZLWKLQVSHFL¿FGLVWDQFHVIURPHOHFWULFDOFLUFXLWSDUWVZKLFKDUHRUPD\EHFRPH
HQHUJL]HG7KHVSHFL¿FVDIHW\UHODWHGZRUNSUDFWLFHVKDOOEHGRFXPHQWHG7KH33(UHTXLUHG
for each task shall be documented on the Electrical Hazard Warning Label. Even if all safe
work practices and the appropriate engineering considerations are applied, PPE may be
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When determined by an evaluation of the degree of hazard and exposure, employees shall
wear protective equipment for the head, face, neck, chin, eyes, ears, body, and extremities.
This equipment may be worn alone or combined with normal apparel. When deemed
QHFHVVDU\E\DÀDVKKD]DUGDVVHVVPHQWÀDPHUHVLVWDQWDSSDUHOVKDOOEHZRUQ(YHQZLWK
ÀDPHUHVLVWDQWSURWHFWLYHDSSDUHOWKHHQHUJ\WKDWFDQSRWHQWLDOO\EHUHOHDVHGE\DUFÀDVKLV
VXI¿FLHQWWRPHOWVRPHV\QWKHWLFPDWHULDOVVXFKDVSRO\HVWHU7KHUHIRUHLWLVUHFRPPHQGHG
WKDWDOOSHUVRQQHOZKRVHSULPDU\MREIXQFWLRQLVHOHFWULFDOZRUNZHDURQO\QDWXUDO¿EHUFORWKLQJ
to work.
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Personal safety and protective equipment include, but are not limited to, the following items:
•
•
•
•
•
•
•
•
•
•
•
20
Safety Glasses
FR Protective Clothing
Voltage Class Rated Gloves with Leather Protectors
Voltage Testers and Hot Sticks
Flash Protection Face Shield
FR Fall Protection Equipment
Hard Hat (Class E)
Insulated Tools
Hook Sticks
Insulating Sleeves
Insulating Blankets and Mats
UAW-GM Electrical Safe Work Practices Document
•
•
•
•
•
•
•
Protective Barriers
External Circuit Breaker Rack-Out Devices
Disconnects / Isolation Devices
Portable Lighting Units
Safety Grounding Equipment
Dielectric and Insulating Footwear
40 cal Flash Suit (Nomex®RURWKHUFRPSDUDEOH¿UHUHVLVWDQWIDEULF
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Safety glasses with side shields are required at all times when doing any work around
energized equipment. Earplugs shall be worn if required by the Electrical Hazard Warning
Label or the policy of the individual location. If hearing protection is deemed necessary and
verbal communication is vital between workers on a particular job, an alternate communication
method shall be established to ensure safe completion of the job task.
,WHPV127WREHZRUQ
Conductive articles of jewelry and clothing, such as watch bands, bracelets, rings, necklaces,
metallized aprons, cloth with conductive thread, metal headgear, or unrestrained metal frame
glasses, shall not be worn where they present an electrical contact hazard with exposed
energized conductors or circuit parts. These items may be allowed if they are properly
insulated by covering, wrapping, or some other method which make them non-conductive.
&RQGXFWLYH0DWHULDOV7RROVDQG(TXLSPHQW%HLQJ+DQGOHG
Conductive materials, tools, and other equipment that are in contact with any part of an
HPSOR\HH¶VERG\VKDOOEHKDQGOHGLQDPDQQHUWKDWZLOOSUHYHQWDFFLGHQWDOFRQWDFWZLWK
exposed energized electrical conductors or circuit parts. Examples of these types of materials
include, but are not limited to, the following items:
•
•
•
•
•
•
•
•
•
•
•
•
Ducts
Pipes
Tubes
Conductive Hoses/Ropes
Metal-Lined Rules, Scales, Tape Measures
Keys
Metal Flashlights
Pulling Lines
Metal Scaffold Parts
Structural Members
Bull Floats
Chains
21
UAW-GM Electrical Safe Work Practices Document
33(,QVSHFWLRQDQG0DLQWHQDQFH
,QVXODWLQJ(TXLSPHQW
,QVXODWLQJHTXLSPHQWVKDOOEHLQVSHFWHGIRUGDPDJHEHIRUHHDFKGD\¶VXVHDQGLPPHGLDWHO\
following any incident that can reasonably be suspected of having caused damage to it.
Insulating gloves shall be given an air test, along with the inspection. Figure2 1 outlines the
process to complete the air test:
Figure 2: Insulating Glove “Air Test”
1. HOLD THE
GLOVE WITH
THUMBS AND
FOREFINGERS AS
ILLUSTRATED.
2. TWIRL THE GLOVE 3. TRAP THE AIR BY 4. HOLD THE GLOVE
TO THE FACE
AROUND QUICKLY
SQUEEZING THE
TO FILL WITH AIR
GAUNTLET WITH
TO DETECT AIR
ONE HAND. USE
LEAKAGE OR
HOLD IT TO THE
THE OTHER HAND
EAR AND LISTEN
TO SQUEEZE THE
PALM, FINGERS,
FOR ESCAPING
AND THUMB IN
AIR.
LOOKING FOR
WEAKNESSES
AND DEFECTS.
Insulating equipment found to have defects that might affect its insulating properties shall be
removed from service and returned for testing.
Insulating equipment with any of the following defects shall not be used:
•
•
•
•
•
22
Holes, Tears, Cut, or Puncture
Ozone Deterioration
Mechanical stress into a series of interlocking cracks
Embedded Foreign Objects
Texture Deterioration (i.e., swelling, softening, hardening,)
UAW-GM Electrical Safe Work Practices Document
)ODPH5HVLVWDQW3URWHFWLYH(TXLSPHQW
)ODPH5HVLVWDQW3URWHFWLYH(TXLSPHQWVKDOOEHLQVSHFWHGIRUGDPDJHEHIRUHHDFKGD\¶VXVH
and immediately following any incident that can reasonably be suspected of having caused
damage to it. Flame resistant equipment found to have defects that might affect its barrier
properties shall be removed from service and replaced. The equipment shall be kept clean
and dry. Follow all recommended maintenance and inspection recommendations from the
manufacturer. Employees shall care for the equipment as though their life depends on it.
7KHIROORZLQJDUHH[DPSOHVRIGHIHFWVWKDWDUHXQDFFHSWDEOHLQÀDPHUHVLVWDQWSURWHFWLYH
equipment:
•
•
•
Holes, Tears, Punctures, Cuts
Embedded Foreign Objects
Texture Deterioration (i.e., swelling, softening, hardening)
7HVW,QVWUXPHQWVDQG(TXLSPHQW
All test equipment and components shall be visually inspected prior to use for obvious defects.
If any defect is found that could endanger employees, the instrument shall be removed
from service until it is repaired. Furthermore, if voltage test equipment is being used for the
purpose of determining whether a circuit is de-energized, the equipment should be checked
on a “known live” circuit before and after checking the circuit in question in order to verify the
reading on the circuit in question.
(OHFWULFDO7HVWLQJ
Electrical (insulating) protective equipment shall be subjected to periodic electrical tests. The
test voltage to be used in the tests, as well as the interval between the tests, is dictated by
OSHA. Table 1 that follows shows the testing intervals for different insulating materials and
other electrical equipment:
Table 1: Electrical Equipment Testing Intervals
EQUIPMENT
TESTING INTERVAL
Insulating Blankets
%HIRUH¿UVWLVVXHDQGHYHU\PRQWKVWKHUHDIWHU
Insulating gloves / sleeves
%HIRUH¿UVWLVVXHDQGHYHU\PRQWKVWKHUHDIWHU
Insulated Hot Sticks / Insulated
Hook Sticks
Annually
Voltage test indicators
Regular intervals to validate data obtained
Safety Grounds
As dictated by conditions of use
23
UAW-GM Electrical Safe Work Practices Document
6SHFL¿F(TXLSPHQW,QIRUPDWLRQ
+DQGDQG$UP3URWHFWLRQ
As stated in the NFPA 70E standard, “Insulating rubber gloves with leather protectors and
insulating rubber sleeves shall be used as required where there is a danger of hand and
arm injury from electric shock or burns due to contact with exposed, energized electrical
conductors or circuit parts. Appropriate hand and arm protection shall be worn where there is
SRVVLEOHH[SRVXUHWRDUFÀDVKEXUQV´3URWHFWLYHJORYHVVKDOOEHZRUQRYHULQVXODWLQJJORYHV
The only exception would be Class 00 under limited use conditions where the task involves
VPDOOHTXLSPHQWDQGSDUWVPDQLSXODWLRQZKLFKUHTXLUHXQXVXDOO\KLJK¿QJHUGH[WHULW\7KLV
PD\EHGRQHRQDRQHWLPHXVHZLWKJORYHYROWDJHGHUDWHGWRYROWVDQGDQDSSURSULDWH
documented plan. Gloves used without leather protection must be sent for insulation testing
DQGUHXVHFHUWL¿FDWLRQDIWHUDVLQJOHXVHZLWKRXWOHDWKHUSURWHFWRUV6HH&KDSWHU±3ODQQLQJ
Electrical Work.
)RRWDQG/HJ3URWHFWLRQ
Industrial safety footwear protection such as steel toe cap and steel shanks are allowed for
employees who work on or near exposed, energized electrical conductors or circuit parts.
Insulated soles are not to be considered as primary personal protection against step and touch
potential.
,QVXODWHG7RROVDQG(TXLSPHQW
These tools are to protect against accidental contact with an energized conductor to provide
a second level of protection. Employees shall use suitably insulated tools and/or handling
equipment when working inside the Restricted Approach Boundary of exposed energized
electrical conductors or circuit parts where it could be reasonably anticipated that the tools or
handling equipment may make accidental contact with the energized conductor or circuit part.
Insulated tools shall be protected from damage to the insulating material. Only nonconductive
ropes and hand lines shall be used near exposed energized parts.
9ROWDJH7HVWLQJDQG2WKHU7HVW(TXLSPHQW
“Test instruments and their accessories shall be voltage rated for the circuits and equipment
to which they will be connected and shall be suitable for the environment in which they will
be used.” Further, they must meet the minimum criteria set forth in Annex B (Test Equipment
6SHFL¿FDWLRQV
24
UAW-GM Electrical Safe Work Practices Document
)ODPH5HVLVWDQW)533(
(PSOR\HHVVKDOOZHDUDSSURSULDWH)5FORWKLQJZKHQHYHUZRUNLQJLQVLGHRIWKHÀDVKSURWHFWLRQ
boundary as determined by the Electrical Hazard Warning Label. Refer to Annex A for table of
)ODVK3URWHFWLRQ%RXQGDU\LIDVLWHVSHFL¿FÀDVKKD]DUGDVVHVVPHQWKDVQRWEHHQSHUIRUPHG
Resident GM hourly and salary personnel assigned to perform electrical work on a daily basis
are required to wear FR clothing on a daily basis. Engineering personnel are required to wear
SODQWVSHFL¿HG)5FORWKLQJZKHQZRUNLQJRQWKHSODQWÀRRUDQGLQYROYHGLQHOHFWULFDOZRUN
8cal/cm2 clothing is required as daily wear unless a local clothing control policy has been
approved by the UAW-GM Center for Human Resources, Health and Safety Department. In
such cases local policies and posted Electrical Hazard Warning Labels shall be followed. See
Annex E for further explanation of taking local control of your facilities FR clothing PPE.
3URWHFWLYH6KLHOGVDQG%DUULFDGHV
Insulated protective barriers can be installed to separate live conductors and parts from
personnel performing maintenance or inspection. Employees shall use protective shields,
protective barriers, or suitably insulated materials to protect themselves from exposure to
electrical hazards when they are working within the Limited Approach Boundary. Work-site
barricades shall also be used when necessary in order to ensure the safety of the workers and
those that might cross the Arc Flash or the Limited Approach Boundary. Work site barricades
may be physical in nature such as cones, tape or rope or may be a second person used as a
spotter.
,QVXODWLQJ%ODQNHWVDQG0DWV
Insulating blankets and mats are to be used only as a supplemental protection for employees.
They are not to be used as the sole means of protection. Insulating blankets and mats must be
stored in suitable containers or in compartments of trucks which are used solely for the storage
of such protective equipment.
3HUVRQDO6DIHW\*URXQGLQJ(TXLSPHQW
7HPSRUDU\SURWHFWLYHJURXQGLQJHTXLSPHQWVKDOOEHUHTXLUHGWRPHHWWKHVSHFL¿FIDXOWGXW\RI
the electrical system for which it will be utilized. The fault duty may be obtained from the site
Short Circuit Study, if necessary. After de-energization, grounding cables are to be connected
from the station (earth) ground to each of the three phases (also to the neutral or grounded
phase if used). This method of grounding will minimize the voltage drop across the work plane
and help facilitate the operation of the circuit overcurrent protection device upon accidental reenergization. The cable sets shall be inspected for cuts in the protective sheath and damage
to the conductors. Clamps and connectors strain relief devices shall be checked for tightness.
6HH6HFWLRQIRUVSHFL¿FLQIRUPDWLRQUHJDUGLQJSHUVRQDOVDIHW\JURXQGLQJHTXLSPHQW
25
UAW-GM Electrical Safe Work Practices Document
8 — Personal Safety Grounding
2EMHFWLYH
This procedure describes the requirements for utilization of Personal Safety Grounds.
8.2
General
Based upon a hazard assessment, employees of General Motors are required to install
temporary Personal Safety Grounds in accordance with Table 2 prior to working on electrical
conductors that could potentially be inadvertently or accidentally re-energized.
:KHQ3HUVRQDO6DIHW\*URXQGV$UH1HHGHG
Employees working on or around exposed, de-energized electrical conductors that could
potentially be inadvertently or accidentally re-energized shall be protected from the associated
KD]DUGVRIHOHFWULFVKRFNDQGDUFÀDVKEXUQV6RPHH[DPSOHVRIDFFLGHQWDORULQDGYHUWHQWUH
energization are:
•
•
•
•
Induced voltages
Lightning strikes
Failures that allow an energized circuit to come in contact with a de-energized circuit
Switching errors
The installation of Personal Safety Grounds will create an equipotential zone in which all
exposed conductors that the employee(s) could possibly contact are at the same voltage
OHYHO7KLVSURFHGXUHWKXVHOLPLQDWHVWKHSRVVLELOLW\RIFXUUHQWÀRZWKURXJKDSHUVRQEHFDXVH
there is no potential difference between the parts of his or her body that are in contact with
WKHFRQGXFWRUV7KHVDIHW\JURXQGVZLOODOVRIDFLOLWDWHWKHHI¿FLHQWRSHUDWLRQRIWKHV\VWHP
protective devices.
6HOHFWLRQRI*URXQGLQJ6HWV
The criteria set forth in this section establishes the technical requirements for personal safety
ground sets. Each facility shall contact a supplier of personal safety ground sets in order to
have an evaluation completed by a representative of the supply unit. This evaluation will result
in a recommendation of the appropriately rated ground sets for the various applications at each
facility.
&ODPSV
The clamps that are used to connect to the phase conductors and the grounding conductor
VKDOOKDYHDGHTXDWHPHFKDQLFDOFDSDFLW\WR¿WDQGHOHFWULFDOFDSDFLW\WRFDUU\WKHPD[LPXP
available fault current.
26
UAW-GM Electrical Safe Work Practices Document
&DEOHV
The cables used in Personal Safety Ground sets shall meet the following criteria:
•
The interface between the cable ends and the clamps must have the capacity to carry
the maximum available fault current.
•
7KHFDEOHPXVWEHRIVXI¿FLHQWDPSDFLW\WRZLWKVWDQGWKHPD[LPXPDYDLODEOHIDXOW
FXUUHQW6HH7DEOHIRUWKH$6706WDQGDUG6SHFL¿FDWLRQVIRU7HPSRUDU\*URXQGLQJ
Systems.
•
The cable must have clear insulation so to mechanically protect the conductors and
facilitate inspection.
Table 2: Grounding Cable and Jumper Ratings
Withstand Rating
(Symmetrical)
kA RMS @ 60 Hz
Ultimate Capacity** (Symmetrical)
kA RMS @ 60 Hz
Cable Size,
AWG (Copper)
F\FOHV
30 cycles
6 cycles
F\FOHV
30 cycles
60 cycles
Continuous
Current
Rating
A RMS
@ 60 Hz
#2
1/0
2/0
3/0
4/0
NFPLO
NFPLO
21
27
36
43
74
10
20
30
39
29
47
74
94
120
18
30
37
47
60
70
98
13
21
26
33
42
49
69
9
14
18
23
29
49
200
300
400
Withstand and ultimate short circuit properties are based on performance with surges
not exceeding 20% asymmetry factor.
** Ultimate capacity represents a calculated symmetrical current which the cable or jumper is capable
RIFRQGXFWLQJIRUWKHVSHFL¿HGWLPH
These currents are based upon the fusing (melting) current-time values for copper at 40°C.
Reference: ASTM Standard F855-1990, pg. 14
27
UAW-GM Electrical Safe Work Practices Document
7HPSRUDU\3HUVRQDO6DIHW\*URXQGV3URFHGXUH
Before attempting to install temporary grounds on any piece of equipment, the conductors
WREHJURXQGHGPXVWEHGHHQHUJL]HGDQGYHUL¿HGGHHQHUJL]HGZLWKWKHDSSURSULDWHWHVW
equipment. Verify the equipment is de-energized in accordance with Section 9.
The following precautions should be observed when installing temporary grounds:
1. Establish a written procedure to follow when installing temporary grounds. The
procedure shall include the type of safety ground set to be used and where they are to
be applied.
2. Never use chains or other devices that are not designed for this purpose.
3. Visually verify the equipment to be grounded is locked out.
4. Wear the PPE appropriate for the voltage class.
9HULI\]HURYROWDJHRQWKHFRQGXFWRUZKHUHWKHWHPSRUDU\JURXQGVDUHWREHSODFHG
following the recommended procedure in Section 9.
6. Ensure the connection points for the grounding cluster are cleaned before installing
them.
7KHJURXQGFOXVWHUVKRXOGEHDWWDFKHG¿UVWWRDJRRGVWDWLRQRUVZLWFKJHDUJURXQGLQJ
conductor.
8. Attach the ground cluster as close as possible to the actual work location.
9. Equipment that has temporary grounds installed should always be marked as such to
ensure that it is not re-energized until the temporary grounds are removed.
10. No equipment can provide complete protection from a lightning strike. Temporary
grounds cannot offer adequate protection for personnel to ensure complete protection.
Strong consideration should be given to delaying the work if lightning storms are in the
area.
11. Use the procedure developed for installation of the temporary grounds as a reference
when removing the temporary grounds after the work is complete. This will reduce the
possibility of accidentally energizing the circuit with a temporary ground still in place.
While performing the work, it is recommended that anytime an employee working on the
FLUFXLWOHDYHVWKHZRUNORFDWLRQWKHHPSOR\HHYHUL¿HVWKDWWKHHTXLSPHQWLVVWLOOORFNHGRXWDQG
grounds still in place before continuing with the work.
28
UAW-GM Electrical Safe Work Practices Document
When the work is complete, remove tools and equipment from the work area, replace any
safety guards and barriers, and inspect all areas where the work was performed to verify that
no tools or equipment has been left in the work area. Many electrical incidents have occurred
where tools or other equipment were left on or near exposed conductors upon re-energization
of the circuit.
When removing temporary grounds, remove in the reverse order of installation, equipment
¿UVWDQGJURXQGODVW$OZD\VZHDUWKHDSSURSULDWHSURWHFWLYHHTXLSPHQWZKHQUHPRYLQJWKH
grounds. It is extremely important that a tracking system be used as a control to ensure that
temporary grounds be removed prior to clearing lockouts and re-energizing equipment.
Before re-energizing the circuit, use a Megger to verify that the circuit is clear of phase to
phase and phase to ground conditions. Figure 3 shows the procedure for installing and
removing personal safety grounds.
Figure 3: Procedure for Installing and Removing Personal Safety Grounds
,QVWDOODWLRQ
5HPRYDO
#1
Use the appropriate PPE
#1
Use the appropriate PPE.
#2
Verify that the equipment is deenergized.
#2
Remove ground cluster attachments
from the equipment.
#3
Attach ground cluster to a good station
or switchgear grounding conductor.
#3
Remove ground cluster from station or
switchgear grounding conductor.
#4
Attach ground cluster as close as
possible to actual work location on the
equipment.
&RPPHQFHWKHZRUNRULQVSHFWLRQ
29
UAW-GM Electrical Safe Work Practices Document
9 — Voltmeter and Ammeter Use
2EMHFWLYH
This procedure explains the proper selection and use of voltmeters and clamp-on ammeters on
energized circuits.
3URFHGXUDO6HTXHQFH
0HWHU6HOHFWLRQ
The circuit must be evaluated to determine the maximum voltage that could be anticipated at
the test points to be utilized in the circuit. It is important to note whether this value represents
possible failure conditions as well as every day situations, as some equipment failure modes
cause much higher voltages to be present than otherwise would be. Having determined this
value, obtain a meter with an AC and DC rating higher than the highest expected voltage in
the circuit. Additionally, all of the test instruments used to perform voltage testing, voltage
PHDVXUHPHQWDQGFXUUHQWPHDVXUHPHQWPXVWPHHWWKHPLQLPXPVSHFL¿FDWLRQVVHWIRUWKLQ
$QQH[%5HIHUWRWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQVIRUXVHWRGHWHUPLQHVXLWDELOLW\
8VLQJ(OHFWULFDO7HVW(TXLSPHQW
Utilize Figure 4 as a checklist to perform the process of voltage testing (testing for the
presence or absence of voltage):
30
UAW-GM Electrical Safe Work Practices Document
Figure 4: Electrical Testing & Troubleshooting Checklist
Ordered Procedure
1.
Review schematics and wiring diagrams.
2.
Remove or properly secure all metal or conductive objects which might make contact
with energized conductors (i.e., watches, rings ,tools, etc.)
3.
Insure adequate lighting.
(VWDEOLVKVDIHZRUNERXQGDULHVHTXDOWRRUJUHDWHUWKDQWKRVHGH¿QHGE\WKH$UF
Flash and Shock Hazard boundaries listed on the Electrical Hazard Warning Label.
:HDUDSSURSULDWH33(DVUHTXLUHGDQGOLVWHGRQ(OHFWULFDO+D]DUG:DUQLQJ/DEHO
6.
Inspect physical integrity of test equipment and test leads to be used.
7.
Secure door / cover in the open position. Insulate exposed energized parts, where
possible.
8
Verify the tester setting ( i.e., proper voltage setting or amperage setting) prior to use.
9.
Secure the meter in an appropriate location and manner so that it can easily be
read. If provisions do not exist for securing the meter, utilize a properly protected and
TXDOL¿HGEXGG\WRKROGWKHPHWHU
10. Check the meter on a known live circuit and then obtain the voltage measurement or
amperage measurement of concern in accordance with Chapter 9.
11
Check the continued operation of the tester by checking it again on a known live
circuit (known as the live-dead-live test).
12. After identifying the problem, lock the equipment out prior to making the repairs.
13. Perform a closeout inspection to insure that all parts,equipment ,and tools have been
removed before the circuit is returned to normal operation.
14. Close and secure door / cover. Notify affected personnel.
Note: Always follow manufacturer’s recommendations for proper use and care of test
equipment.
31
UAW-GM Electrical Safe Work Practices Document
2EWDLQLQJD9ROWDJH0HDVXUHPHQW
The preceding checklist can be used as a guide to performing the process of voltage
measurement (obtaining an actual measured value of voltage). The following additional
guidelines are to be followed when taking a voltage measurement:
•
If the meter is auto ranging (digital), set the meter buttons or dial to indicate voltage AC
or DC, depending on which is being measured.
•
If the meter is not auto ranging, set the buttons or dial to the highest voltage of the
meter and to AC or DC as appropriate.
•
Secure the meter where it can easily be seen while performing the testing. If provisions
GRQRWH[LVWIRUVHFXULQJWKHPHWHUXWLOL]HDSURSHUO\SURWHFWHGDQGTXDOL¿HGEXGG\WR
hold the meter. The black lead should be connected to the “Com.” terminal on the meter,
and the red probe to the “Volts” terminal.
•
Hold onto the insulated portion of the red and black probes. If one of the circuit
FRQGXFWRUVLQWKHWHVWFLUFXLWLVJURXQGHGSXWWKHEODFNOHDGRQWKLVFRQGXFWRU¿UVW,IWKH
circuit is a DC circuit, put the black lead on the conductor anticipated to be at the lower
voltage of the two. Next put the red probe on the other conductor. NOTE: if the meter
GHÀHFWVKDUGWRWKHOHIW'&FLUFXLWDQDORJPHWHULPPHGLDWHO\UHPRYHWKHOHDGVDQG
repeat the procedure reversing the black and red leads.
•
Attempt to read the meter. On an auto-ranging meter, the display should indicate the
voltage of the circuit and may be read directly. On other meters, reduce the meter scale
from the highest scale down to a scale which causes the meter to indicate in the upper
third of its scale (best accuracy) and then note the reading. Carefully remove the leads
IURPWKHFLUFXLWZKHQ¿QLVKHG
•
If the meter is being used to test for the presence or absence of voltage, the meter must
now be tested on a known energized circuit to insure that it is still functioning properly
(Live, Dead, Live Test).
3KDQWRP9ROWDJH5HDGLQJV
Due to the high impedance of measuring instruments, a voltage reading may be detected
on open conductors where there is no physical electrical connection to a voltage source.
Conductors that are installed in close proximity to one another, and are capacitively coupled
to each other, can cause this A.C. voltage reading. Such a reading could be 2 or 3 volts, or
it may be as high as the voltage on the adjacent conductors. This is what is referred to as a
“phantom” or “ghost” voltage. Since the “phantom” voltage is a physical phenomenon involving
very small values of capacitance, it cannot energize a load or cause physiological damage
to a person. In order to help minimize the likelihood of reaching a wrong conclusion from this
phenomenon, It is recommend that a follow up measurement be taken with a low impedance
meter in place of a high impedance measuring device for testing on open conductors where
there is no physical electrical connection and you suspect “phantom” voltage. Care must be
32
UAW-GM Electrical Safe Work Practices Document
taken to be sure that the voltage reading truly is a phantom voltage and not a result of a cable
defect or improper installation, which may result in a shock hazard.
8VLQJD9ROW2KP0HWHU920WR0HDVXUH5HVLVWDQFH
The resistance measurement is accomplished in the meter by supplying an internally
generated low voltage to the meter leads and the circuit connected to them, and by measuring
WKHFXUUHQWZKLFKÀRZVLQWKHFLUFXLW8WLOL]LQJ2KP¶V/DZ9 ,[5WKHUHVLVWDQFHFDQEH
calculated by the meter. The steps to be followed are:
•
The circuit to be tested should be de-energized and have all residual voltage and
electric charge removed.
•
Untangle the leads, as this can affect the readings if the value of resistance is fairly low.
•
On an analog meter or manual digital meter:
– Put the meter on the highest resistance scale. Touch the ends of the leads together.
The meter should indicate zero ohms. If not, there should be a zero adjustment
knob, which can be turned in order to zero the meter (analog meter).
– Once the meter is zeroed, put the leads across the circuit to be measured. If the
PHWHUGHÀHFWVLQWRWKHXSSHUWKLUGRIWKHVFDOHUHDGWKHYDOXH,IWKHPHWHULQGLFDWHV
IXOOVFDOHWKHUHDGLQJLVFRQVLGHUHGWREHLQ¿QLW\RUJUHDWHUWKDQWKHIXOOVFDOHYDOXH
– If the meter is not in the upper third of scale, lower the meter scale one range, rezero the meter, and repeat the reading. Continue this process until a scale is found
where a proper reading can be taken. If the meter reads zero, even on the lowest
meter range, then within the precision constraints of the meter, the reading is
continuity.
– 127(: Most analog meters will be damaged if voltage is applied to the leads when
the meter is in the resistance measurement mode. To protect the meter, most
PDQXIDFWXUHU¶VIXVHWKHPHWHUDJDLQVWWKLVSRVVLELOLW\ZLWKWKHIXVHEHLQJLQVLGH
the meter case. If this fuse is blown, the meter could indicate zero voltage on a live
circuit -- emphasizing the need to check the meter against a known live circuit before
and after when testing for voltage presence. (Live-Dead-Live Test).
•
On an auto-ranging digital meter:
– Put the meter in the resistance measuring position. Untangle the leads and touch
the ends of the leads together. The meter should indicate very close to zero ohms
(a few milliohms may be indicated, as the leads do not have zero resistance). If not,
try a different set of leads and/or check the connections of the leads to the meter. If
WKLVVWLOOGRHVQRW¿[WKHSUREOHPUHSODFHWKHEDWWHU\LQWKHPHWHUDQGFKHFNDJDLQ
The meter needs to be repaired or calibrated if the problem persists. Use another
instrument.
33
UAW-GM Electrical Safe Work Practices Document
– Put the leads across the circuit to be measured. The meter should automatically
scale the reading and directly display the value of resistance.
– Note that most of the digital meters in use today are internally protected from
contacting a voltage source when in the resistance measurement mode, as long as
WKHDSSOLHGYROWDJHLVZLWKLQWKHPHWHU¶VUDWHGYROWDJH(YHQVRWKHPHWHUVKRXOGVWLOO
be checked against a known live source when being used to test for the presence or
absence of voltage.
8VLQJD920WR0HDVXUH&XUUHQW
0RVW920¶VKDYHDOLPLWHGDELOLW\WRPHDVXUHFXUUHQWXVXDOO\LQPLOOLDPSVPDNHVXUHQRW
WRH[FHHGWKHPHWHU¶VUDWLQJ,QRUGHUWRGRVRWKHPHWHUOHDGVPXVWEHLQVHULHVZLWKWKH
path of the current -- thereby requiring that the circuit be de-energized and locked out before
proceeding with insertion of the meter leads in the circuit. When the circuit is locked out, the
meter should be secured in an accessible location, the black lead plugged into COM on the
meter, the red lead plugged into AMPS/current on the meter, and the meter leads installed in
a secure manner in series with the circuit. It is important that the leads not be removed while
under current carrying conditions.
•
Put the meter into the ammeter mode. Re-energize the circuit. Follow the same steps
for ranging the meter as used in voltage or resistance testing, depending on the type of
meter used.
•
De-energize and lock out the circuit, and remove the meter from the circuit.
(IIHFWVRI0HWHU/HDGVRQ0HDVXUHPHQWV
Meter leads do not have zero resistance. However, for most resistance measurements, the
leads are a very tiny percentage of the resistance of the device being measured, and therefore
can be ignored. It is possible though, to impact the reading when attempting to measure a very
small value -- especially with a digital meter. In this situation, the best alternative is to use a
meter especially designed to measure low range resistances. If one is not available, however,
the meter leads can be shorted and the reading noted, with this value being subtracted from
the total reading seen when measuring the item of interest.
&ODPS2Q$PPHWHU6HOHFWLRQ
7KH¿UVWLVVXHLQVHOHFWLQJDFODPSRQDPPHWHULVGHFLGLQJZKHWKHUH[DFWFXUUHQWVDUHUHTXLUHG
RUZKHWKHUDSSUR[LPDWHLQGLFDWLRQVDUHVXI¿FLHQW1HHGRIRQO\DSSUR[LPDWHYDOXHVFRXOGSRLQW
to the use of an analog device, while greater accuracy points to digital equipment. Next, the
FLUFXLWPXVWEHHYDOXDWHGWRGHWHUPLQHWKHPD[LPXPFXUUHQWÀRZWKDWFRXOGEHDQWLFLSDWHG
the maximum voltage the clamp-on portion of the meter could be subjected to (especially of
concern in bare conductor measurements), as well as the maximum conductor diameter to be
clamped around. Having determined these values, obtain a meter with physical characteristics
DQGHOHFWULFDOUDWLQJVVXI¿FLHQWIRUWKHFLUFXLWLQTXHVWLRQ
34
UAW-GM Electrical Safe Work Practices Document
2EWDLQLQJD&XUUHQW5HDGLQJZLWKD&ODPS2Q$PPHWHU
After obtaining a proper meter, it is turned on (if digital) and then :
•
If the meter is auto-ranging (digital), set the meter buttons or dial to indicate AC or DC,
depending on which is being measured.
•
If the meter is not auto ranging, set the buttons or dial to the highest current range of the
meter and to AC or DC as appropriate.
•
Using voltage rated gloves and protectors, and other personal protective equipment
as required by the Electrical Hazard Warning Label, clamp the meter over the circuit
conductor of interest, being careful to keep as much of your body as possible away from
electrical exposure.
•
Allow the clamp to spring shut securely, and center the conductor in the opening. 1RWH
WKDWDVFXUUHQWÀRZLQFUHDVHVHOHFWURPDJQHWLFIRUFHVLQFUHDVHFDXVLQJYLEUDWLRQWKDW
will be felt in the hands, and noise which will be heard. Additionally, these conditions
PD\FDXVHWKHFODPSWREHPRUHGLI¿FXOWWRRSHQIRUUHPRYDO,WLVLPSRUWDQWWREH
prepared for these conditions.
•
Once clamped on, read the value of current directly on the display. If your meter is
not auto ranging, lower the range until the meter is indicating in the upper third of the
selected range. This gives greatest accuracy.
•
2QFHWKHUHDGLQJLV¿QLVKHGRSHQWKHFODPSUHPRYHWKHPHWHUDQGPRYHDZD\IURP
the energized conductors.
3URSHU8VHDQG&DUHRI0HWHULQJ'HYLFHV
Meters should be properly stored when not in use. They should be kept in a cool dry location,
and kept from undue physical shock. If they are expected to be stored for a long period of time,
remove any batteries before storage. If the meter needs cleaning, wipe clean with a dry cloth,
or one very slightly dampened with water. Do not use solvents or harsh chemicals.
Meter leads should be loosely coiled (to prevent premature cracking and breaking) and
stored with the meter. If meter leads need cleaning, try wiping with a clean dry cloth. If this is
LQVXI¿FLHQWWRFOHDQWKHOHDGVWU\XVLQJDVPDOODPRXQWRIVROYHQWVXFKDVHOHFWULFDOFRQWDFW
cleaner. If this is still unsuccessful, replace the leads.
35
UAW-GM Electrical Safe Work Practices Document
10 — Troubleshooting Electrical
Equipment
2EMHFWLYH
7KLVSURFHGXUHGH¿QHVKRZWRDSSO\WKHVWHSVRIHIIHFWLYHWURXEOHVKRRWLQJWRHOHFWULFDO
equipment.
10.2 General
$VLQGLFDWHGLQWKHGH¿QLWLRQVVHFWLRQWURXEOHVKRRWLQJLVWKHPHDQVE\ZKLFKQRQRSHUDWLQJ
equipment is safely restored to service in the least possible time. The troubleshooting process
is a systematic and logical approach in searching out and eliminating the problem(s). Often
times, problems observed are just symptoms of the root cause and can lead the troubleshooter
down the wrong path
3URFHGXUH6HTXHQFH
7KHUHDUH¿YHEDVLFVWHSVWRWURXEOHVKRRWLQJDVGLVFXVVHGEHORZ
.QRZWKH6\VWHP(TXLSPHQW
:LWKRXWNQRZOHGJHRIKRZHTXLSPHQWLVVXSSRVHGWRRSHUDWHQRRQHFDQHI¿FLHQWO\DQGVDIHO\
troubleshoot a problem. It is the system knowledge that allows us to know what the normal
operating condition is and the symptoms for the most common failures. By understanding
DV\VWHP¶VRSHUDWLRQSURSHUVDIHW\SUHFDXWLRQVDQGXWLOL]LQJWKHSURSHUSHUVRQDOSURWHFWLYH
equipment, downtime will be minimized.
,QYHVWLJDWHWKH6\PSWRPV
The next step in a logical approach is to determine that there is, in fact, a problem.
•
Ask an operator, if possible, what happened.
•
Try to arrive at the machine or equipment in its “failed” state (e.g., before operators
attempt to set it back up).
•
Check to ensure equipment is lined up for normal operation. Have circuit breakers
tripped? Is power lost? Is equipment in the “home” position?
•
Analyze the performance of the equipment to ensure it actually has a failure and is not
just reacting to an external condition. Ask if anything different is being done than normal.
(i.e., new part run, recent overhaul, etc.)
•
Try to determine if performance appears degraded or total equipment failure has
occurred.
36
UAW-GM Electrical Safe Work Practices Document
•
Know the equipment; recognize the symptoms of an impending failure.
•
7U\WREHDVVSHFL¿FDVSRVVLEOHLQGH¿QLQJWKHSUREOHP
•
Check and take note of engineered failure mode indicators (i.e., overloads and trip
ÀDJV
•
1RWHYDULDWLRQVIURPVSHFL¿HGUHDGLQJVHYHQLIWKH\DUHVWLOOZLWKLQWKHWROHUDQFHEDQG
•
Attempt to determine if the variations have developed slowly (i.e., drift) or occurred
VXGGHQO\DWDVSHFL¿FWLPHRUGDWH
/LVWWKH3UREDEOH&DXVHV
Utilizing the information gathered, list (either on paper or mentally) the probable causes of the
problem. Most often, the problem can be categorized into one or more of the following:
•
The Power Supply: Whether the problem is partial or total loss of input voltage, or
ZKHWKHUDVSHFL¿FDUHDVXFKDVFRQWUROSRZHUKDVEHHQORVWREYLRXVV\PSWRPVXVXDOO\
occur - such as no movement at any location, no lights on the panel, etc. This is usually
a fairly easy problem to validate by voltage testing at appropriate test points.
•
The Load Control: The load of concern might be a valve, motor, variable speed drive,
lighting, etc., but will usually have power switched to it by some form of load controller.
([DPSOHVLQFOXGHPRWRURUOLJKWLQJFRQWUDFWRUV3/&¶VYDULDEOHVSHHGGULYHXQLWVHWF,W
is also possible that the load controller could operate another energy type for controlling
the load - for instance, an electrically operated valve is switched on and off by the
controller to turn pneumatic pressure on and off to an air motor. Typical symptoms
LQFOXGHSRZHUEHLQJSUHVHQWEXWWKDWWKHORDGZRQ¶WRSHUDWHXQOHVVWKHFRQWUROOHULV
bypassed.
•
The Load Itself: If the load itself is exhibiting a problem, it will usually be an intermittent
problem, such as an overload. Or the problem could be something more instantaneous
and catastrophic such as a device failure. Often, protective devices will operate and
possibly provide a clue as to the type and nature of the problem. Trying to manually
move or operate the load, or bypassing the controlling devices will still not cause the
load to operate properly.
•
The Input Devices: These items include position sensing equipment, safety switches,
input push buttons and switches, PLC information, and other types of input devices. If
power exists and bypassing the control device and/or its control signals allows the load
to function normally, the problem lies either with an input device or the system logic. The
one-line diagram of the system should help in utilizing the symptoms to narrow down
the number of devices that could be at fault. After this determination is made, a series
of voltage tests at appropriate points will systematically eliminate the operating devices
and point out the failed one.
37
UAW-GM Electrical Safe Work Practices Document
•
The System Logic,WLVRIWHQGLI¿FXOWWRVHSDUDWHWKHLQSXWGHYLFHVDQGWKHV\VWHP
logic because they are usually intimately entangled with each other. This is especially
true of non-PLC type logic systems, as the discrete relays and other components that
make up the logic circuit will not act as though proper logic exists if an input device
fails. Therefore, some systems will require troubleshooting the input devices and logic
in parallel. In a PLC or other electronic systems, however, a single area of logic will
not normally change (fail) unless an OUTSIDE PARTY has made such a change. The
persons in the area of the equipment (such as the operator or maintenance personnel)
should be queried very diligently to determine if this might be the case. It is reasonable
for the troubleshooter to assume that the logic on a PLC is all right if the machine had
EHHQUXQQLQJSUHYLRXVO\DQGLIWKH3/&LWVHOIKDVQ¶WIDLOHG8QNQRZQUHFHQWFKDQJHVLQ
PLC logic can lead to a troubleshooter following dead ends, and frustrate the process
while lengthening the machine downtime.
(OLPLQDWHWKH3RVVLELOLWLHV
Using the list of probable causes determined in the previous step, isolate and/or eliminate
causes from the list. This may include performing various equipment tests.
•
Use the test equipment properly.
•
Use drawings/diagrams to plan test points and sequences.
•
Know approximately what value to expect before taking a reading, both for test
equipment safety and to limit confusion about results obtained.
•
If an incorrect reading is obtained, verify both the reading and the test equipment setup.
•
If possible, compare test readings with the equipment normal values (i.e., baseline data)
rather than general data values found in service manuals. This requires record keeping
over time.
•
Only take measurements that will prove a condition or aid in drawing a logical
conclusion. Be systematic.
•
Repeat sequence until the problem is found.
•
Repair the problem, and validate that the equipment has been returned to proper
operation.
38
UAW-GM Electrical Safe Work Practices Document
'LVFRYHUWKH5RRW&DXVHV
Many times the cause of a problem goes deeper than just what appeared to happen to the
XVHU,QRUGHUWRGULYHRXWXQH[SHFWHGGRZQWLPHDQGIDLOXUHVLWLVHVVHQWLDOWR¿QGWKHXOWLPDWH
cause for the failure and eliminate it. For example, the equipment quits operating, and by
WURXEOHVKRRWLQJWKHSUREOHPZH¿QGDWKDWDZLUHOHDGRQDODUJHPRWRULQWKHV\VWHPKDV
EXUQWRSHQ:H¿[LWDQGLWUXQV¿QH%XWZK\GLGWKHOHDGEXUQ"$QGKRZORQJZLOOLWEHXQWLO
it happens again? Could it hurt someone if it happened in a particular way? What will it cost
if it happens again in the middle of a production run? These are all questions worth asking
DQGZRUWK¿QGLQJWKHDQVZHUVWR,WFRXOGEHWKDWWKHPRWRUOHDGVSOLFHER[LVQRWVHDOHGZHOO
and that water from the roof drips on it when it rains, eventually causing the lead to fail? Most
LPSRUWDQWO\ZHPXVWNHHSDVNLQJZK\ZK\ZK\ZK\ZK\ZK\XQWLOZHFDQ¶WDQVZHULWDQ\
more. At that point we will have discovered our root cause(s) and can attempt to deal with the
problem in such a way that effectively eliminates it forever. This is the step most commonly
left out of the process, allowing operating costs to be driven up and disruptions to be common
place.
5HHQHUJL]DWLRQ$IWHU3URWHFWLYH'HYLFH2SHUDWLRQ
Re-energization of a circuit or system with an uncorrected problem can lead to equipment
GDPDJHDQGVHULRXVLQMXU\,IWKHV\VWHP¶VSURWHFWLYHGHYLFHVRSHUDWHGGXHWRDIDXOWFRQGLWLRQ
(short circuit), some investigation is necessary to determine the probable cause. Testing of the
circuit should be completed, if possible. According to OSHA Regulation 1910.334(b)(2), manual
re-energization must not be attempted until it has been determined that it is safe to do so.
Immediate re-energization is only permitted when the cause of the operation of the protective
device was initiated by a known overload condition.
7HPSRUDU\0RGL¿FDWLRQRI&LUFXLWVRU3URJUDPV
During the course of troubleshooting, “jumpers” or software changes are tools that are
sometimes used to eliminate an individual device, contact, or portion of a circuit as a possible
cause. While these changes are in effect, the machine or system may not operate as expected
and may result in unexpected electrical hazards or machine motion. After the problem is
located and repaired, these changes should be removed. If the change is to remain temporarily
(i.e., until the end of the shift or weekend) and the system or machine returned to operation, a
locally devised approval procedure must be followed. If a safety circuit is involved the safety
department shall review the changes.
39
UAW-GM Electrical Safe Work Practices Document
11 — Bus Plug-in Units
and Busways
2EMHFWLYH
This procedure establishes the installation and removal practices for bus plug-in units and
similar equipment utilized on 600V class electrical distribution busway.
11.2 General
,WLVWKHFRPSDQ\¶VSROLF\WKDWDOOEXVSOXJLQXQLWLQVHUWLRQVDQGUHPRYDOVVKDOOEH
FRPSOHWHGZLWKWKHEXVZD\LQDQHOHFWULFDOO\VDIHZRUNFRQGLWLRQIn some circumstances,
de-energizing a busway could present additional hazards to life safety or may be infeasible
(i.e., a continuous process where interruption would have catastrophic results.) Therefore,
if an insertion or removal must be completed with the busway energized, a Hazard Risk
Assessment as described in Chapter 6 must be completed and all of the following additional
criteria PXVW be met:
1. Plug-in unit rating is 200 A or less.
3OXJLQXQLW¿QJHUVRQO\HQWHURQHSOXJLQRSHQLQJLQWKHEXVZD\
3. The disconnect switch or circuit breaker on the plug-in unit is in the “open” or “off”
SRVLWLRQҘ
4. The following safe work practices from this chapter are adhered to.
7KHSHUVRQVGRLQJWKHLQVWDOODWLRQUHPRYDORULQWKHLPPHGLDWHYLFLQLW\DUHZHDULQJIXOO
DUFÀDVKSURWHFWLYHHTXLSPHQWIRUWKHKHDGKDQGVDUPVWRUVRDQGOHJV
3URFHGXUDO6HTXHQFH
'LVFRQQHFW6ZLWFKDQG6WDE$VVHPEO\,QVSHFWLRQ
Units shall be inspected prior to installation. The inspection shall include the following:
•
Check to ensure that the plug-in unit is compatible with the busway.
•
Check to ensure that line shields are in place.
•
Check for loose or broken hardware and terminals.
•
Check the line stabs and ground stab for alignment and damage.
•
Check for broken, cracked, or missing insulators and phase barriers.
40
UAW-GM Electrical Safe Work Practices Document
•
Check the mechanisms of all electrical and mechanical interlocks and padlocking
means for proper operation. Assure that the door interlock is functioning properly.
•
Operate the switch several times to make sure that all mechanisms operate freely and
are in working order.
•
Check the fuseholder and fuse clips for signs of damage, overheating, or any other
abnormal condition.
•
Clean switch frame, insulators and line contacts where necessary according to
manufacturers recommendations.
•
Megger test the plug-in device phase to phase, and phase to ground. Plug in unit shall
Megger at least 10 megohms with 1000 VDC applied. This test should be performed
with the switch in the open position and then repeated with the switch in the closed
position.
3RZHU'LVWULEXWLRQ%XVZD\,QVSHFWLRQ
9HULI\WKHEXVZD\WREHXVHGDQGLWVLGHQWL¿FDWLRQPDUNLQJV9HULI\WKHVRXUFHVWKDWIHHGWKH
busway. Always verify one line diagrams for the potential for back feed from double ended
IHHGVRUIURP7LHEUHDNHUV$OOEXVZD\VDUHWREHFRQVLGHUHGHQHUJL]HGXQWLOLWLVYHUL¿HGWKDWLW
is locked out and should be approached with the proper precautions.
If the bus is to be de-energized, the feeder circuit breaker shall be locked out.
NOTE: Loop fed busway must be similarly isolated from both ends.
Before any bus plug-in unit installation or removal, the power distribution busway shall be
visually checked for any loose components, hardware, foreign objects, or any other abnormal
conditions. Appropriately rated PPE and insulated tools shall be used while performing this
inspection. In addition, before installation, the busway must be inspected to including the
following:
•
With the plug-in opening cover closed, clean off busway enclosure in the area where
the plug-in device is to be installed. Use dry, clean rags and avoid the use of cleaning
agents.
•
Open plug-in opening cover and visually inspect for any abnormal condition, foreign
objects, or other improper materials.
•
If abnormal conditions of the plug-in device or the busway are found the installation
VKDOOEHVWRSSHGDQGDXWKRUL]HGPDQDJHPHQWZLOOEHQRWL¿HG
41
UAW-GM Electrical Safe Work Practices Document
,QVWDOODWLRQ
After completing the inspection of the plug-in device and power distribution busway, the plug-in
unit shall be installed as follows:
1. 5HYLHZPDQXIDFWXUHU¶VLQVWDOODWLRQLQVWUXFWLRQVEHIRUHSURFHHGLQJWRHQVXUHFRPSOLDQFH
2. Persons installing plug-in units shall place themselves in a secure position to avoid
falling, stumbling, slipping, or inadvertently moving into an unsafe condition. Never
stand in front of the busplug.
3. Assure that the plug-in unit disconnect is open with fuses removed and the door is
closed and latched.
4. $OLJQGHYLFHÀDQJHVDQGVWDEVDQGSXVKWKHXQLW¿UPO\RQWRWKHEXVZD\6HFXUHWKHXQLW
to the busway. The unit shall be installed to the busway by normal manual force only. On
larger plugs, the plug assist shall not be used to force the plug-in unit onto the busway.
&$87,21,IWKHUHLVDQ\GLI¿FXOW\LQLQVWDOOLQJWKHSOXJLQXQLWLWVKDOOEHUHPRYHG
DQGLQVSHFWHGWRGHWHUPLQHWKHSUREOHP1HFHVVDU\UHSDLUVVKDOOEHPDGHRUWKH
SOXJLQXQLWUHSODFHG
Install device mounting bolts or clamps as applicable.
6. At this time, if the busway was de-energized to install the plug-in unit, the busway may
be re-energized.
7. Open the door and verify that the load side of the switch (line side of fuse clips, all three
poles) is de-energized.
8. Close and latch the plug-in unit door
9. If possible, operate the plug-in unit switch to the “on” position from a remote location
using a “hook stick.” Personnel shall not stand directly in front of unit while operating the
switch.
10. Re-open the door and verify 480 VAC on all three phases at the line side of the fuse
clips.
11. Close and latch the plug-in unit door.
12. If possible, operate the plug-in unit switch to the off position from a remote location
using a “hook stick.”
13. Proceed to connect the load side equipment to be served.
14. After equipment connection is completed, the fuses shall be inserted and the door
closed and latched. At this time the switch may be closed from a remote location using a
“hook stick” to operate the switch.
42
UAW-GM Electrical Safe Work Practices Document
1RWH If there is a question or concern about the safety of the installation at any point,
employee shall consult technical assistance from his/her supervisor and/or engineering.
8QLW5HPRYDO
-XVWL¿FDWLRQIRULQIHDVLELOLW\RULQFUHDVHGKD]DUGVIRUWKHWDVNRIUHPRYDORIEXVSOXJVIURP
energized bus way should be given careful consideration. In most cases the removal can be
delayed until a shut down of the bus can be scheduled. In the rare occasions where a bus plug
must be removed from energized bus the following is the procedure;
Units shall be inspected prior to removal. The inspection shall include the following:
1. 5HYLHZPDQXIDFWXUHU¶VUHPRYDOLQVWUXFWLRQVEHIRUHSURFHHGLQJWRHQVXUHFRPSOLDQFH
2. Persons removing devices shall place themselves in a secure position to avoid falling,
stumbling, slipping, or inadvertently moving into an unsafe condition.
3. Open the device disconnect
4. Verify load side of switch (line side of fuse clips, all three poles) is de-energized.
Remove fuses.
6. Proceed to disconnect the load side equipment being served.
a. Disconnect all wires in the bus plug
b. Cut all wires in bus plug back to the point at which they enter the plug-in unit
enclosure
c. Do not remove any load without also removing the associated conduit and wiring.
The plug-in unit switch shall be open and locked out until such conduit and wiring is
completely removed.
7. ,IWKHSOXJLQXQLWLWVHOILVWRUHPDLQRQWKHEXVZD\³LQVWRUDJH´¿OODEDQGRQHGFRQGXLW
holes with the appropriate device(s).
8. Remove device mounting bolts or clamps as applicable.
9. Remove unit from bus. The plug-in shall be removed from the busway by normal
manual force only. No power assist devices shall be used to force the plug-in unit away
from the busway.
10. Install the busway plug-in opening access cover.
11. The busway may now be re-energized.
43
UAW-GM Electrical Safe Work Practices Document
12 — Conduit and Wireway Installation –
Wire Pulling
2EMHFWLYH
This procedure establishes the guidelines to be utilized when pulling wire in conduit and
wireway installations. Policies and practices shall be utilized for all electrical work performed at
General Motors.
3URFHGXUDO6HTXHQFH
*HQHUDO5HTXLUHPHQWV
•
All jobs, including emergencies, require approval in accordance with General Motors
Electrical Safe Work Procedure 6.0, Planning Electrical Work. Authorization must be
obtained before beginning work.
•
Follow all applicable Safe Work Rules. If there is doubt about what rules exist or their
LQWHUSUHWDWLRQRULIPRUHLQIRUPDWLRQLVQHHGHGVWRSZRUNDQGFRQWDFWDTXDOL¿HG
supervisor or Subject Matter Expert before proceeding with job.
•
All electrical conductors, including those that are insulated, shall be treated as energized
until proven otherwise. All terminals, conductors and other exposed components of the
electrical circuitry which could be contacted (purposely or accidentally) by body parts,
tools or equipment must be tested for presence of voltage using an approved voltage
tester before the job begins.
•
Always utilize the proper PPE for the job.
•
&$87,21+$=$5'627+(57+$1(/(&75,&$/6+2&.0$<(;,67 Protective
measures may be necessitated by other potential hazards. There may be the possibility
of electrical burns, severe electrical arcing, or explosions resulting from arcing in a
FODVVL¿HGDUHD$OOZRUNRQHQHUJL]HGV\VWHPVDWDQ\YROWDJHVKDOOEHHYDOXDWHGIRU
VXFKSRVVLELOLWLHV
WR9ROWV
If necessary, it is permitted to install or remove conductors in a raceway containing energized
conductors as long as all of the following conditions are met:
•
There are no exposed energized conductors.
•
The system nominal voltage to ground of all the conductors in the raceway or enclosure
LVYROWVRUOHVV
44
UAW-GM Electrical Safe Work Practices Document
•
The overcurrent protective devices at the source of all energized conductors are not
greater than 20 amps.
•
A person is observing at each end of the pull or feed. ( 2 person job)
Appropriately rated insulating gloves are worn by all workers involved.
•
All conductors being installed or removed have been effectively insulated
•
2QO\QRQFRQGXFWLYH¿VKWDSHVRUSXOOLQJGHYLFHVDUHXVHG
WR9ROWV
Pulling or feeding of wire in raceways other than cable trays containing energized conductors
ZLWKDV\VWHPQRPLQDOYROWDJHWRJURXQGRYHUYROWVLVQRWSHUPLWWHG
Installing or removing wire or cable in cable trays containing energized conductors is permitted
as long as all of the following conditions are met;
•
Cable tray contains only insulated conductors with a system nominal voltage to ground
RIYROWVRUOHVV
•
Handling of wire or cable must be done in such a way that there is a minimum
disturbance of existing conductors.
•
Appropriately rated insulating gloves with leather protectors are worn by all workers
involved.
45
UAW-GM Electrical Safe Work Practices Document
13 — Electrical Equipment Labeling –
UAW-GM Electrical Hazard
Warning Labels
2EMHFWLYH
This procedure establishes the guidelines for determining (1) when an Electrical Hazard
Warning Label is required; (2) if required, what information must be provided on the label; and
ZKHQDQ$UF)ODVK&DOFXODWLRQLVUHTXLUHGXVLQJWKH,(((FDOFXODWRU
13.2 General
(OHFWULFDOHTXLSPHQWDVGH¿QHGLQWKH1DWLRQDO(OHFWULFDO&RGH1(&$UWLFOHVKDOOEH
¿HOGPDUNHGWRZDUQTXDOL¿HGSHUVRQVRIWKHSRWHQWLDORIDQDUFÀDVKKD]DUG,QDGGLWLRQWRWKLV
warning the UAW-GM ESWP program also requires the following information on the Electrical
Hazard Warning Label;
•
Arc Flash Hazard Boundary
•
Incident Energy available at 18 inches (may be 24 inches in substation gear)
•
Shock Hazard Exposure based on voltage for;
– Limited approach boundary
– Restricted approach boundary
– Prohibited approach boundary
•
Minimum PPE Requirements
/DEHOLQJ5HTXLUHPHQWVIRU(OHFWULFDO+D]DUG:DUQLQJDQG
'DQJHU/DEHOV
Switchboards, panelboards, industrial control panels, and motor control centers that are likely
WRUHTXLUHH[DPLQDWLRQDGMXVWPHQWVHUYLFLQJRUPDLQWHQDQFHZKLOHHQHUJL]HGVKDOOEH¿HOG
PDUNHGWRZDUQTXDOL¿HGSHUVRQVRISRWHQWLDOHOHFWULFDUFÀDVKKD]DUGV7KHPDUNLQJVKDOO
EHORFDWHGVRDVWREHFOHDUO\YLVLEOHWRTXDOL¿HGSHUVRQVEHIRUHH[DPLQDWLRQDGMXVWPHQW
servicing, or maintenance of the equipment. (NFPA 70E Article 400.11 and NEC Article 110.16)
,Q*0WKH¿HOGPDUNLQJUHTXLUHGDERYHLVDFFRPSOLVKHGE\DODEHOUHIHUUHGWRDVWKH(OHFWULFDO
Hazard Warning Label.
46
UAW-GM Electrical Safe Work Practices Document
(OHFWULFDO+D]DUG:DUQLQJ/DEHO5HTXLUHG
Typical equipment requiring an Electrical Hazard Warning Label includes the following:
•
Switchgear
•
Bus plug-in units
•
Disconnect switches
•
Motor control panels including VFD & servo control
•
Power distribution panels
•
3URFHVVRUSDQHOVRSHUDWLQJDW9RUPRUH
•
,SDQHOVRSHUDWLQJDW9RUPRUH
•
2SHUDWRUFRQWUROSDQHOVLQFOXGLQJ+0,VRSHUDWLQJDW9RUPRUH
•
277/240/208/120V receptacle & lighting circuit breaker panels
•
Terminal boxes likely to require examination while energized
1RWH Reference “(OHFWULFDO+D]DUG:DUQLQJ/DEHO$SSOLFDWLRQ7DEOH” for further
information.
(OHFWULFDO+D]DUG:DUQLQJ/DEHO1275HTXLUHG
Typical equipment that may not require an Electrical Hazard Warning Label includes the
following:
•
480V busway - feeder type (not serviced while energized)
•
480V busway - plug-in type (labels are on bus plug-in units)
•
Enclosed transformers (not serviced while energized)
•
Junction boxes or motor termination boxes with taped splices (not likely to require
examination while energized)
Pull boxes (not likely to require examination while energized)
Terminal boxes that are not likely to require examination while energized (due to their
physical location, function, application, etc.)
•
•
•
Light switches (not a switchboard, panelboard, industrial control panel, or motor control
center)
•
(QGGHYLFHVVXFKDVUHFHSWDFOHVOLJKW¿[WXUHVHWFQRWDVZLWFKERDUGSDQHOERDUG
industrial control panel, or motor control center)
1RWH Reference “(OHFWULFDO+D]DUG:DUQLQJ/DEHO$SSOLFDWLRQ7DEOH” for further
information.
47
UAW-GM Electrical Safe Work Practices Document
$UF)ODVK+D]DUG&DOFXODWLRQ1275HTXLUHG
$QDUFÀDVKKD]DUGFDOFXODWLRQ,((($UF)ODVK&DOFXODWRULVQRWUHTXLUHGIRUHTXLSPHQW
RSHUDWLQJEHWZHHQYROWVWROHVVWKDQYROWVQRPLQDOXQOHVVLWLQYROYHVDWOHDVWRQH
kVA or larger low impedance transformer in its immediate power supply. An Electrical Hazard
:DUQLQJ/DEHOVSHFLI\LQJDQDUFÀDVKLQFLGHQWHQHUJ\RIOHVVWKDQFDOFPVKRXOGEH
placed on equipment in this category.
(TXLSPHQWZLWK1RPLQDO9ROWDJHRI/HVV7KDQ9ROWV
Equipment likely to required examination, adjustment, servicing, or maintenance while
HQHUJL]HGDQGRSHUDWLQJDWOHVVWKDQYROWVVKRXOGEHODEHOHGZLWKDSUHSULQWHG9ROWV
Electrical Hazard Warning Label.
/DEHO$SSOLFDWLRQ7DEOH
Electrical Hazard Warning Label Application Table
Electrical Equipment Examples
YROWVRUJUHDWHUXQOHVV
RWKHUZLVHVSHFL¿HG
Does
Not
Require
Label
Requires
6SHFL¿F
Calculation
Requires
Label
Medium Voltage Switchgear
x
x
Each compartment* front and rear
Medium Voltage 9E Tap Box
x
x
For IR inspection
Substation Primary Switch
x
x
Substation Transformer
Substation 480V Switchgear
x
x
Plug-in Busway
Busway Tap Boxes
Busway Bus Plugs
Panelboard (for power distribution compartmentalized)
Process Power Distribution Panel (single
main disconnect for process equipment)
Each compartment* front and rear
x
Feeder Busway
480V Equipment Fed Directly From Plugin Busway Via Bus Plug
Each compartment* front and rear.
Rational: No servicing while energized.
x
No label on busway, but will have label on
bus plugs.
x
Rational: No servicing while energized.
x
x
Calculation based on worst case
exposure.
x
x
One label on the main protective device
disconnect bucket* and one for each of
the remaining buckets.
x
x
x
x
One label on the main protective device
disconnect bucket* and one for each of
the remaining buckets.
x
x
([DPSOHVDUHD¿UHSXPSVWDPSLQJ
transfer press, etc.
x
x
Any equipment fed directly from a bus
SOXJUHTXLUHVDVSHFL¿FDUFÀDVKKD]DUG
calculation.
(Continued on next page)
48
Rational: No servicing while energized.
x
Motor Control Center
Equipment Directly Fed From Substation
LV Power Circuit Breaker
Comment
One label per panel.
UAW-GM Electrical Safe Work Practices Document
Electrical Hazard Warning Label Application Table (continued)
Electrical Equipment Examples
YROWVRUJUHDWHUXQOHVV
RWKHUZLVHVSHFL¿HG
Requires
6SHFL¿F
Calculation
Requires
Label
Does
Not
Require
Label
480V Equipment Not Directly Fed From
Busway
480V Control Panel
480V Equipment Within a Packaged Unit
(such as an Air Handling Unit)
480/277V Lighting Panels Fed From
Distribution Transformer
x
See
”Comment”
for
exception
x
“Example is a local disconnect for an
exhaust fan or a hydraulic motor.
([FHSWLRQ'RHVQRWUHTXLUHVSHFL¿FDUF
ÀDVKKD]DUGFDOFXODWLRQLIWKHXSVWUHDP
disconnecting means is 1.2 cal/cm2 or
less and the impedance between the
disconnect and the load (due to length
and/or size of conductors, transformers,
HWFLVQRWVLJQL¿FDQWHQRXJKWRLQFUHDVH
this hazard.”
x
x
Examples are machine tool control panels,
door control panels, etc.
x
x
Main disconnect and mini-load center
9FLUFXLWUHTXLUHVVSHFL¿FODEHO
x
x
Label applies only when the cover
is removed and exposes energized
conductors.
x
If distribution transformer is less than
N9$QRDUFÀDVKKD]DUGFDOFXODWLRQ
is required. Label applies only when the
cover is removed and exposes energized
conductors.
x
Label applies only when the cover
is removed and exposes energized
conductors.
x
Voltages of 240V or greater require a
VSHFL¿FDUFÀDVKKD]DUGFDOFXODWLRQ
regardless of the size of the distribution
transformer. Label applies only when the
cover is removed and exposes energized
conductors.
120/208V Receptacle Panels Fed From
N9$'LVWULEXWLRQ7UDQVIRUPHU
120/208V Receptacle Panels Fed
)URPN9$RU/DUJHU'LVWULEXWLRQ
Transformer
x
120/240V Receptacle Panels
x
120V Equipment That Does Not Require
Service, Examination, Adjustment, or
Maintenance While Energized.
x
Does not require a label if it is not
examined, adjusted, or serviced while
energized (implies no exposed parts).
,(((HPSHULFDOGDWDGHPRQVWUDWHV
WKDW9LVQRWVXI¿FLHQWWRVXVWDLQ
DQDUF1RDUFÀDVKKD]DUGFDOFXODWLRQ
required. Provide ‘green” pre-printed
label. This category includes disconnects
for both control panels and equipment to
be serviced. It is not necessary to label
receptacles, light switches, and other end
devices.
120V Equipment That Does Require
Service, Examination, Adjustment, or
Maintenance While Energized
x
277V Equipment That Does Not Require
Service, Examination, Adjustment, or
Maintenance While Energized.
Comment
x
Does not require a label if it is not
examined, adjusted or serviced while
energized (implies no exposed parts).
(Continued on next page)
49
UAW-GM Electrical Safe Work Practices Document
Electrical Hazard Warning Label Application Table (continued)
Electrical Equipment Examples
YROWVRUJUHDWHUXQOHVV
RWKHUZLVHVSHFL¿HG
Requires
6SHFL¿F
Calculation
Requires
Label
Does
Not
Require
Label
277V Equipment That Does Require
Service, Examination, Adjustment, or
Maintenance While Energized.
x
See
”Comment”
for
exception
“This category includes disconnects for
both control panels and equipment to be
serviced.
([FHSWLRQ'RHVQRWUHTXLUHVSHFL¿FDUF
ÀDVKKD]DUGFDOFXODWLRQLIWKHXSVWUHDP
disconnecting means is 1.2 cal/cm2 or
less and the impedance between the
disconnect and the load (due to length
and/or size of conductors, transformers,
HWFLVQRWVLJQL¿FDQWHQRXJKWRLQFUHDVH
this hazard.
It is not necessary to label receptacles,
light switches, and other end devices.”
x
Distribution Transformers
x
Does not require a label if it is not
examined, adjusted, or serviced while
energized (implies no exposed parts).
Requires tools to obtain access to live
parts
x
Does not require a label if it is not
examined, adjusted, or serviced while
energized (implies no exposed parts).
Requires tools to obtain access to live
parts
x
Does not require a label if it is not
examined, adjusted, or serviced while
energized (implies no exposed parts).
Motor Terminal Box
Junction Boxes or Pull Boxes - taped or
not likely to be serviced
Junction Boxes w/terminal strip or test
points
(TXLSPHQWRSHUDWLQJDWOHVVWKDQYROWV
that is likely to require examination or
servicing while energized
*
x
See
”Comment”
for
exception
x
x
Comment
([FHSWLRQ'RHVQRWUHTXLUHVSHFL¿FDUF
ÀDVKKD]DUGFDOFXODWLRQLIWKHXSVWUHDP
disconnecting means is 1.2 cal/cm2 or
less and the impedance between the
disconnect and the load (due to length
and/or size of conductors, transformers,
HWFLVQRWVLJQL¿FDQWHQRXJKWRLQFUHDVH
this hazard.
8VHSUHSULQWHG³/HVV7KDQ9ROW/DEHO´
- No Hazard
A compartment or bucket is a modular section of a panelboard or switchboard that has a
disconnecting means and is accessed by a single door or cover.
Additional information on the requirements for labels and the labeling process can be found in
the UAW-GM ESWP Implementation Guide.
50
UAW-GM Electrical Safe Work Practices Document
A — Annex A (Normative):
Safe Approach Distances
$ *HQHUDO
7KH6DIH$SSURDFK'LVWDQFHFULWHULDLVDWRROWRXVHZKHQGHWHUPLQLQJWKHVSHFL¿FVDIHW\
UHODWHGWRROVHTXLSPHQWDQGSURFHGXUHVWRXVHZKHQFRPSOHWLQJDVSHFL¿FWDVN7KHUHDUH
WZRVXEVHWVRIWKLVGLVWDQFH7KH¿UVWGHDOVZLWKVKRFNKD]DUGSURWHFWLRQDQGWKHRWKHULV
FRQFHUQHGZLWKDUFÀDVKSURWHFWLRQ
$ 6KRFN+D]DUG
Shock Hazard±$GDQJHURXVFRQGLWLRQDVVRFLDWHGZLWKWKHÀRZRIFXUUHQWWKURXJKDSHUVRQ¶V
body caused by contact or approach to exposed electrical conductors or circuit parts nearer
than the minimum air insulation distance
$QH[SRVHGHQHUJL]HGHOHFWULFDOFRQGXFWRUKDVDQDLUJDSZKLFKSURYLGHVVXI¿FLHQWO\KLJK
resistance to effectively insulate the voltage from other phase conductors and ground. The
voltage level is the main determinant of how large that air-gap must be. The Limited Approach
%RXQGDU\3URKLELWHG$SSURDFK%RXQGDU\DQG5HVWULFWHG$SSURDFK%RXQGDU\DUHLGHQWL¿HG
as levels of approach towards the exposed energized conductor where different levels of
precaution must be taken in order to protect against the hazard of electric shock by an
exposed, energized conductor. Each of these boundaries is determined by the voltage level
of the exposed energized conductor. In addition, the Limited Approach Boundary is depended
XSRQZKHWKHUWKHFRQGXFWRULV¿[HGRUPRYDEOH)LJXUHLOOXVWUDWHVWKHVKRFNKD]DUG
boundaries.
A-1
UAW-GM Electrical Safe Work Practices Document
Figure 5 : Shock Hazard Safe Approach Boundaries
$
/LPLWHG$SSURDFK%RXQGDU\
The following are the Limited Approach Boundary values to an exposed, energized electrical
FRQGXFWRU5HIHUHQFH7DEOHIRUWKH/LPLWHG$SSURDFK%RXQGDU\UHODWLYHWRD¿[HGRUPRYDEOH
exposed, energized conductor.
Table 3: Limited Approach Boundary Dimensions ( L )
Nominal System Voltage
(Phase to Phase)
From a
)L[HG
Limited
Conductor
Approach
Boundary
From a
Distance
0RYDEOH
Conductor
N
NN
¶´
¶´
¶´
¶´
¶´
¶´
¶´
¶´
,QVLGHRIWKH/LPLWHG$SSURDFK%RXQGDU\/WKHTXDOL¿HGHPSOR\HHLVUHVSRQVLEOHWRSODQ
for the requirements inside of this boundary and perform the work or inspection necessary. If
WKHFRQGXFWRUDWLVVXHLVPRUHWKDQ9WKHHPSOR\HHPXVWEHDFFRPSDQLHGE\DTXDOL¿HG
SDUWQHURU³EXGG\´8QTXDOL¿HGSHUVRQVVKDOOVWD\RXWVLGHRIWKH/LPLWHG$SSURDFK%RXQGDU\
:KHUHWKHUHLVDQHHGIRUDQXQTXDOL¿HGSHUVRQVWRFURVVWKH/LPLWHG$SSURDFK%RXQGDU\
A-2
UAW-GM Electrical Safe Work Practices Document
DTXDOL¿HGSHUVRQVKDOODGYLVHKLPRUKHURIWKHSRVVLEOHKD]DUGVDQGFRQWLQXRXVO\HVFRUWWKH
XQTXDOL¿HGSHUVRQVZKLOHLQVLGHWKH/LPLWHG$SSURDFK%RXQGDU\8QGHUQRFLUFXPVWDQFH
VKDOOWKHHVFRUWHGXQTXDOL¿HGSHUVRQVEHSHUPLWWHGWRFURVVWKH5HVWULFWHG$SSURDFK
Boundary.
$
5HVWULFWHG$SSURDFK%RXQGDU\
,QVLGHRIWKH5HVWULFWHG$SSURDFK%RXQGDU\WKHTXDOL¿HGHPSOR\HHIRUPXODWHVERXQGDU\
requirements based on the Electrical Hazard Warning Label and Chapter 6 – Planning
Electrical Work. The employee(s) must use a documented plan, insulated tools, and voltageUDWHGJORYHVDQGLQVWUXPHQWV8QGHUQRFLUFXPVWDQFHPD\DQXQTXDOL¿HGSHUVRQFURVVWKH
5HVWULFWHG$SSURDFK%RXQGDU\,IWKHFRQGXFWRUDWLVVXHLVPRUHWKDQ9WKHGRFXPHQWHG
SODQPXVWEHDSSURYHGE\DQRQUHVLGHQWH[SHUWDQGDTXDOL¿HGSDUWQHURU³EXGG\´PXVWEH
present.
The Restricted Approach boundary dimensions are listed in Table 4:
Table 4: Restricted Approach Boundary Dimensions ( R )
Nominal System Voltage
(Phase to Phase)
N
NN
Restricted Approach Boundary Dimension
Avoid
Contact
¶´
¶´
¶´
$
3URKLELWHG$SSURDFK%RXQGDU\
&URVVLQJWKH3URKLELWHG$SSURDFK%RXQGDU\ZLWKDQ\SDUWRI\RXUERG\LVFRQVLGHUHG
WKHVDPHDVPDNLQJFRQWDFWZLWKHQHUJL]HGFRQGXFWRUV Held objects, including meter
SUREHVDUHFRQVLGHUHGDQH[WHQVLRQRI\RXUERG\,QVLGHRIWKLVERXQGDU\WKHTXDOL¿HG
employee formulates boundary requirements based on the Electrical Hazard Warning Label
DQG6HFWLRQ±3ODQQLQJ(OHFWULFDO:RUN,IWKHFRQGXFWRUDWLVVXHLVPRUHWKDQ9DQRQ
UHVLGHQWH[SHUWPXVWDSSURYHWKHGRFXPHQWHGSODQ)XUWKHUWKHTXDOL¿HGSHUVRQVKDOO
1. Have specialized training in this type of work.
2. Have a documented plan conforming to the requirements of Section 6 – Planning
Electrical Work.
3. Perform a risk analysis as outlined in the NFPA 70E Standard.
4. :RUNZLWKDTXDOL¿HGSDUWQHU
Use PPE and insulating equipment rated for the voltage and energy level involved.
7KH3URKLELWHG$SSURDFK%RXQGDU\GLPHQVLRQVDUHDVIROORZVLQ7DEOH
A-3
UAW-GM Electrical Safe Work Practices Document
Table 5: Prohibited Approach Boundary Dimensions ( P )
Nominal System Voltage
(Phase to Phase)
N
NN
Prohibited Approach Boundary Dimension
Avoid
Contact
¶´
¶´
¶´
$ $UF)ODVK+D]DUG
$
%DFNJURXQG'HVFULSWLRQ
Flash Hazard – A dangerous condition associated with the release of energy caused by an arc
that suddenly and violently changes material(s) into a vapor.
:KHQDSRZHUV\VWHPIDXOWRFFXUVLHSKDVHWRSKDVHRUSKDVHWRJURXQGDQDUFÀDVK
occurs that releases a tremendous amount of energy in the form of light, heat, sound, and
UV radiation. As this energy is radiating out from the source of the fault, it can cause serious
injury to employees not wearing proper PPE when they are close to the source of the fault.
The Flash Protection Boundary establishes minimum criteria for protection from the hazards
RIDQDUFÀDVK0RVWRIWKHHQHUJ\IURPDQDUFÀDVKLVLQWKHIRUPRIKHDW7KHUHIRUHWKH
FRQVLGHUDWLRQVIRU33(UHTXLUHPHQWVFHQWHURQ¿UHSURWHFWLRQ6LQFHPDQ\IDFWRUVHQWHU
LQWRWKHHTXDWLRQVUHODWLYHWRWKHDPRXQWRIHQHUJ\UHOHDVHGIURPDSDUWLFXODUIDXOWWKHÀDVK
protection boundary conditions established in this section are categorized by the voltage levels
encountered and the type of upstream protective device that is utilized. This process yields
a “worst-case” scenario for energy level exposure from fault conditions. Any part of the body
that is inside of this boundary must be protected by FR protective equipment, or a material that
has equivalently performing FR properties based on the requirements of the Electrical Hazard
Warning Label.
$
+D]DUG$VVHVVPHQW
7RHVWDEOLVKDVLWHVSHFL¿FVHWRIFULWHULDDIRUPDOÀDVKKD]DUGDVVHVVPHQWPXVWEH
FRPSOHWHGXWLOL]LQJFXUUHQWVKRUWFLUFXLWGDWDIRUVSHFL¿FMREWDVNVWRPDNHDSURSHUHYDOXDWLRQ
RIWKHHQHUJ\OHYHOH[SRVXUHSRVVLELOLWLHVIURPDQDUFÀDVK7KLVKD]DUGDVVHVVPHQWVKRXOG
include:
•
What environment is the system operating in? (wet/dry, clean/dirty, etc...)
•
When was the protective devices last calibrated?
•
Is there any reason to believe that the system will not operate the way it was designed?
,(((DQG$QQH['RIWKH1)3$(6WDQGDUGHODERUDWHRQWKLVSURFHGXUHDQG
should be referenced as a guide in the evaluation process.
A-4
UAW-GM Electrical Safe Work Practices Document
B — Annex B (Normative):
6SHFLÀFDWLRQVIRU9ROWDJH
Testing Equipment
B.1
General
Testing for voltage is a common task performed by personnel very frequently within the
corporation. There have been instances where the equipment is not designed to perform
the task for which it was utilized. This practice can lead to the device being mis-read,
malfunctioning, or failing. In some instances, there have been accidents resulting in injury
from test equipment failure. In order to safeguard employees against using inadequate test
instruments, this Annex sets forth a minimum set of requirements to be used as criteria in the
selection of test equipment to be used within General Motors. Generally any meter being used
RQWKHÀRRUIRUYROWDJHUHDGLQJVLQRXULQGXVWULDOVHWWLQJPXVWKDYHDPLQLPXPUDWLQJRI&$7,,,
Please refer to Figure 6 to determine the correct Category Rating of meter based on the task
being performed.
Figure 6: Understanding Categories
Reprinted with permission from Fluke
B-1
UAW-GM Electrical Safe Work Practices Document
2YHUYROWDJH
&DWHJRU\
CAT IV
,QEULHI
([DPSOHV
Three-phase at
utility connection,
any outdoor
•
Refers to the “origin of installation”; i.e., where lowvoltage connection is made to utility power.
•
Electricity meters, primary overcurrent protection
equipment.
Outside and service entrance, service drop from
pole to building, run between meter and panel.
•
CAT III
Three-phase
CAT II
Distribution,
including
single-phase
commercial
lighting
Single-phase
receptacle
connected loads
•
Overhead line to detached building, underground
line to well pump.
•
(TXLSPHQW,Q¿[HGLQVWDOODWLRQVXFKDVVZLWFKJHDU
and polyphase motors.
•
Bus and feeder industrial plants.
•
Feeders and short branch circuits, distribution
panel devices.
•
Lighting systems to larger buildings.
•
Appliance outlets with short connections to service
entrance.
•
Appliance, portable tools, and other household and
similar loads.
•
Outlet and long branch circuits.
– Outlets at more than 10 meters (30 feet) from
CAT III source.
– Outlets at more than 20 meters (60 feet) from
CAT IV source.
CAT I
Electronic
•
Protected electronic equipment.
•
Equipment connected to (source) circuits in which
measures are taken to limit transient overvoltages
to an approximately low level.
Any high voltage, low-energy source derived from
a high-winding resistance transformer, such as the
high-voltage section of a copier.
•
B-2
UAW-GM Electrical Safe Work Practices Document
% 0XOWLPHWHUV
The following is the set of features that are required:
•
Rated for the voltage-level of the application.
•
A self-contained fault protection or limitation device, such as internal current limiting
fuses or probe current limiting resistors.
•
Voltage/Current path from the probes is not routed through the mode selector switch.
•
Conforms to National Consensus Standards (i.e., ANSI/ISA S82.02, UL 1244, MIL-T&7KLVUHTXLUHPHQWLQVXUHVWKDWWKHGHYLFHKDVWKLUGSDUW\FHUWL¿FDWLRQ
% 'LUHFW&RQWDFW9ROWDJH6HQVLQJ'HYLFHV
In addition to the set of criteria for multimeters, the following additional requirements shall
apply towards devices used solely for sensing for the presence (or absence) of voltage:
•
Single function, voltage only test device, or
•
Device must have automatic mode sensing feature that checks for voltage before
switching to other modes (i.e., resistance, continuity).
•
Fail-safe system to guard against accidental mis-connection of the test leads.
(permanently attached leads or only two connection points)
% 1RQ&RQWDFW9ROWDJH6HQVLQJ'HYLFHV
There are some applications in which direct contact voltage testers cannot be used to sense
voltage. In these circumstances, an inductive type, non contact voltage sensor can be utilized.
When deciding whether to use this type of test device, it is imperative to consider its limitations:
•
Sensitivity to frequency (cannot detect D.C. or low frequency voltages).
•
Sensitivity to the voltage level of the conductor.
•
Sensitivity to the orientation to and distance from the conductor.
•
Phase cancellation can occur if sensing a 3 phase multi-conductor cable.
•
Sensitivity to surrounding or nearby metal components (i.e., enclosures, armoring).
•
Sensitivity to temperature.
•
Sensitivity to the distance of the conductor being sensed to ground.
•
This type of voltage sensor may be used only to sense voltage, not measure it.
B-3
UAW-GM Electrical Safe Work Practices Document
B-4
UAW-GM Electrical Safe Work Practices Document
C — Annex C : Sample Forms
5HTXHVWIRU0DFKLQH0DLQWHQDQFH$FFHVV6KXWGRZQ
1.
2.
Site: __________________ Area: ________________ Project: _______________
Start
Expected
Planned start date: ______ Time: ________________ Duration:______________
3.
Weather Forecast for the Date(s) Above: _________________________________
_________________________________________________________________
4.
Description of work to be done:_________________________________________
_________________________________________________________________
_________________________________________________________________
7KHIROORZLQJLVUHTXHVWHGWREHVKXWGRZQ _______________________________
_________________________________________________________________
Until work is complete ____________________________________________
Temporarily while barriers are being placed ___________________________
6.
Will Production be able to run during the job (circle one)? Yes No
7.
The following contingency plans have been made in case the equipment being shut
GRZQFDQ¶WEHUHVWRUHGWRVHUYLFHDVSODQQHG
_________________________________________________________________
_________________________________________________________________
Persons to notify if contingency plans must be utilized:
Person:________________ Position:___________ Phone:______________
Person:________________ Position:___________ Phone:______________
8.
Shutdown Requested by: _____________________________________________
Dept/Title: ___________________________________Date:_____________
,WHPVEHFRPSOHWHGE\$XWKRUL]HG0DQDJHURIWKH$IIHFWHG$UHD
9.
Shutdown Is: † Granted
† Denied
10. If denied, the next available date for shutdown is? __________________________
11. Reason(s) for shutdown denial _________________________________________
_________________________________________________________________
_________________________________________________________________
12. Signature:_____________________
Dept:___________ Date:___________
C-1
UAW-GM Electrical Safe Work Practices Document
6DPSOH:ULWWHQ:RUN,QVWUXFWLRQ
Ordered Procedure
1.
Review schematics and wiring diagrams.
2.
Remove or properly secure all metal or conductive objects which might make contact
with energized conductors (i.e., watches, rings ,tools, etc.)
3.
Insure adequate lighting.
(VWDEOLVKVDIHZRUNERXQGDULHVHTXDOWRRUJUHDWHUWKDQWKRVHGH¿QHGE\WKH$UF
Flash and Shock Hazard boundaries listed on the Electrical Hazard Warning Label
:HDUDSSURSULDWH33(DVUHTXLUHGDQGOLVWHGRQ(OHFWULFDO+D]DUG:DUQLQJ/DEHO
6.
Inspect physical integrity of test equipment and test leads to be used.
7.
Secure door / cover in the open position. Insulate exposed energized parts, where
possible.
8.
Verify the tester setting ( i.e., proper voltage setting or amperage setting) prior to use.
9.
Secure the meter in an appropriate location and manner so that it can easily be
read. If provisions do not exist for securing the meter, utilize a properly protected and
TXDOL¿HGEXGG\WRKROGWKHPHWHU
10. Check the meter on a known live circuit and then obtain the voltage measurement or
amperage measurement of concern in accordance with Chapter 9 UAW-GM ESWP
Document.
11. Check the continued operation of the tester by checking it again on a known live
circuit (known as the live- dead-live test).
12. After identifying the problem, lock the equipment out prior to making the repairs.
13. Perform a closeout inspection to insure that all parts,equipment ,and tools have been
removed before the circuit is returned to normal operation.
14. Close and secure door / cover. Notify affected personnel.
Note: Always follow manufacturer’s recommendations for proper use and care of test
equipment.
C-2
UAW-GM Electrical Safe Work Practices Document
D — Annex D: Required Forms
:ULWWHQ-RE3HUPLW(OHFWULFDO+D]DUGRXV!YROWV7DVNV
RQ(TXLSPHQW/DEHOHGFDOFP2RU/HVV
To be completed by supervisor and person(s) doing the work.
Date: ______________________
Job Location: ______________________________ Job Assigned to:_____________________________
General description of work to be done: ____________________________________________________
____________________________________________________________________________________
Describe why it is necessary to perform this task with the equipment energized:
____________________________________________________________________________________
____________________________________________________________________________________
Using the information contained on the Hazard Assessment Label, identify the Arc Flash and the
Shock Hazard boundaries that will be crossed when performing the task:
Arc Flash Boundary: _______________________ Shock Hazard Boundary: _______________________
Based on the Hazard Assessment Label and the approach boundaries from above, list the
protective items which are required to perform the task:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
,VDTXDOL¿HGHOHFWULFDOEDFNXS%XGG\UHTXLUHG"
<HV
1R
Is communications equipment required?
Yes
No
'HVFULEHKRZQRQTXDOL¿HGRUDIIHFWHGSHUVRQQHOZLOO
be kept beyond the Arc and Limited Approach Boundaries: _____________________________________
List any other trades required to perform the task and the work they will be performing:
Trade: ________________________________
Task: _____________________________________
________________________________
_____________________________________
________________________________
_____________________________________
List additional hazards and concerns as well as precautions to be taken to protect exposed persons:
Hazard or Concern:
Precaution to be taken:
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
Continued on reverse side
D-1
UAW-GM Electrical Safe Work Practices Document
:ULWWHQ-RE3HUPLW(OHFWULFDO+D]DUGRXV!YROWV7DVNV
RQ(TXLSPHQW/DEHOHGFDORU/HVV
(Continued)
List the step-by-step outline of the work:
1
__________________________________
12
___________________________________
2
__________________________________
13
___________________________________
3
__________________________________
14
___________________________________
4
__________________________________ ___________________________________
__________________________________
16
___________________________________
6
__________________________________
17
___________________________________
7
__________________________________
18
___________________________________
8
__________________________________
19
___________________________________
9
__________________________________
20
___________________________________
10
__________________________________
21
___________________________________
11
__________________________________
22
___________________________________
Location of nearest phone: _____________________ Emergency Phone Number: __________________
6LJQDWXUHV5HTXLUHG
_____________________________________
Skilled Trades Supervisor
Date
_____________________________________
Skilled Trades Supervisor
Date
_____________________________________
Tradesperson
Date
_____________________________________
Tradesperson
Date
_____________________________________
Tradesperson
Date
_____________________________________
Tradesperson
Date
_____________________________________
Tradesperson
Date
_____________________________________
Tradesperson
Date
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Has all personal protective equipment been inspected and/or tested to insure its integrity?
D-2
Yes
No
UAW-GM Electrical Safe Work Practices Document
(QHUJL]HG(OHFWULFDO:RUN3HUPLW
3DUW,²:RUN5HTXHVW
(To be completed by the Electrical S.M.E. requesting the permit and attached to the Written Job Permit)
Site: ____________________________________ Area: ________________________
Work order/project #: ____________________________________________________
Planned start date: _________________ Time: ___________ Duration: _____________
Description of the work to be done: _________________________________________
______________________________________________________________________
Was the equipment requested to be shut down?
Was the shut down request denied?
† Yes
† Yes
† No
† No
Reason shut down was denied: ____________________________________________
The next available date for shutdown is: _____________________________________
______________________________________________________________________
(Signature)
(Title)
(Date)
3DUW,,²$SSURYDOWR3HUIRUPWKH:RUN:KLOH(OHFWULFDOO\(QHUJL]HG
(To be completed by operations)
-XVWL¿FDWLRQIRUOLYHZRUNUHTXHVW___________________________________________
______________________________________________________________________
______________________________________________________________________
/LYHZRUNRQWKLVHTXLSPHQWLV
______________________________________
(Signature, Plant Manager)
__________________
(Date)
† Approved
† Not Approved
______________________________________
(Signature, Safety Supervisor)
__________________
(Date)
† Approved
† Not Approved
______________________________________
(Signature, Maintenance/Engineering Manager)
__________________
(Date)
† Approved
† Not Approved
______________________________________
(Signature, Electrical Subject Matter Expert)
__________________
(Date)
† Approved
† Not Approved
Note: Once work is complete, forward this form to the site safety departments for review and
retention. Forms will be retained for a period of one year
D-3
UAW-GM Electrical Safe Work Practices Document
D-4
UAW-GM Electrical Safe Work Practices Document
E — Annex “E”: Taking Local Control of Your Facility’s
ESWP Clothing Requirement Program
7KHIROORZLQJLVDQRYHUYLHZRIWKHVWHSVQHHGHGWRWDNHORFDOFRQWURORI\RXUIDFLOLW\¶V)5
clothing PPE program.
Steps 1-7 of the process all will require supporting documentation to show that the
requirements have been meet.
It is suggested that all this information be placed into a notebook tabbed to correspond with the
bullet points as listed. The exception to this would be items 1.1 and 1.2. Submitting these items
RQD&'DQGLQVHUWLQJLWLQWRWKHQRWHERRNZRXOGEH¿QHDVWKH\FRXOGEHYHU\ODUJH¿OHV
This process will enable all parties to be able to quickly locate and review any part of the
ESWP program if needed.
Steps 8 and 9 take you through the process once the notebook has been completed.
Once the CHR has approved your facilities local FR PPE clothing program as written you can
then follow your own local policies as to what clothing is required and when it is required.
This local policy shall be reviewed by the Local Joint Heath and Safety Committee annually.
Additionally, the clothing policy must be reviewed when there is reason to believe that
protective measures taken under the policy may not adequately protect workers. Examples of
conditions that may require a review of the policy include an occurrence of an injury or a near
miss, employees observed violating the policy, or employee complaints concerning the policies
effectiveness. The review must occur immediately and action must be taken to correct any
GH¿FLHQFLHV
Any changes to the approved policy must be jointly approved by the Divisional Safety Manager
and the UAW International Rep.
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1.1 – Short Circuit and Coordination Study (Substation to Bus) is complete.
1.2 – Detailed Plant Floor Survey (Bus to Plant Floor) is complete.
1.3 –
Hazard Risk Assessment has be completed for all electrical panels.
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± $OOHOHFWULFDOSDQHOVKDYHEHHQODEHOHGIRUDUFÀDVKDQGHOHFWULFVKRFNKD]DUG
H[SRVXUHDVGH¿QHGLQ1)3$1(&
E-1
UAW-GM Electrical Safe Work Practices Document
2.2 – Processes are in place for the application of new or replacement labels when
HTXLSPHQWLVUHORFDWHGPRGL¿HGRULQVWDOOHGDIWHUWKHLQLWLDOSODQWÀRRUVXUYH\
and associated labeling are complete.
2.3 – All “Initial Survey” (Identify potential exposures to high incident energy on the
SODQWÀRRU±WKRVHJUHDWHUWKDQ&DWHJRU\#FDOFP2) labels have been
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(6:37UDLQLQJIRU$OO$IIHFWHG3HUVRQQHO
± $OOHPSOR\HHVZKRDUHH[SRVHGWRDUFÀDVKDQGHOHFWULFVKRFNKD]DUGV
(including supervision and engineering personnel) have been trained in ESWP.
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4.1 – Insulating Gloves with Leather Protectors have been issued.
± $QLQVXODWLQJJORYHWHVWLQJUHFHUWL¿FDWLRQSURJUDPLVLQSODFH
4.3 – Insulated Tools have been issued.
4.4 – Appropriate Test Equipment (CAT III Meters) have been issued.
± +LJK(QHUJ\)ODVK6XLWVDQG&ORWKLQJDUHDYDLODEOHVHH³&ORWKLQJ3URJUDP´
below.
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± 3URFHGXUHVDUHLQSODFHWRGHWHUPLQHDQGLPSOHPHQWWKHUHTXLUHPHQWVIRU
ESWP daily required uniform wear.
± (OHFWULFDOVXUYH\VKDYHEHHQFRQGXFWHGDQGWKHOHYHOVRIH[SRVXUHGHWHUPLQHG
and labeled.
± $SODQKDVEHHQGHYHORSHGWRSURYLGHWKHQHFHVVDU\33(IRUHDFKH[SRVXUH
level greater than the required daily wear including the type of PPE and location
of the PPE equipment required.
± 7KHLVVXHRIWUDQVIHUUHGHPSOR\HHVLHQHZHPSOR\HHRUDQHPSOR\HH
moving from a Category 0 exposure area into a Category 2 exposure area) is
addressed.
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6.1 – The Plant has developed written work instructions for Testing and Trouble
Shooting where power is required.
E-2
UAW-GM Electrical Safe Work Practices Document
± 623¶VDUHZULWWHQIRUDOO+D]DUG5LVN$VVHVVPHQWVUHTXLULQJ33(JUHDWHUWKDQ
the required daily wear.
± $OLVWRIDOOKD]DUGULVNDVVHVVPHQWVFODVVL¿HGDV³'$1*(5QR33(DYDLODEOH´
(Hazard greater than 40 cal/cm2KDVEHHQFRPSLOHGDQG623¶VKDYHEHHQ
written.
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7.1 – Processes are in place to address the engineering/technical issues associated
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electrical infrastructure.
7.2 – A process exists to maintain the accuracy of electrical diagrams and
schematics.
± 7KHLQVWDOODWLRQPRGL¿FDWLRQUHORFDWLRQRIHOHFWULFDOHTXLSPHQWPXVWLQFOXGH
DVDIHW\EX\RIIE\TXDOL¿HGSHUVRQQHOSULRUWRWKHHTXLSPHQWEHLQJSODFHGLQ
normal operation.
7.4 – Maintenance management processes are in place that eliminates the likelihood
of improper fuse or electrical components being installed or altered which could
alter Arc Flash or Electric Shock exposures.
± 3URSHUPDLQWHQDQFHDQGWHVWLQJRIVXEVWDWLRQSURWHFWLYHGHYLFHVVXFKDV
breakers and relays are being preformed per manufactures and GM standards
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7.6 – Electrical test equipment management processes are in place that ensures that
only proper test equipment is used.
± $Q(OHFWULFDO(QJLQHHUKDVEHHQLGHQWL¿HGDVWKHIDFLOLWLHV6XEMHFW0DWWHU([SHUW
(SME) and is available to provide engineering/technical support to the electrical
trades.
± $MRLQW(6:3LPSOHPHQWDWLRQWHDPKDVEHHQLGHQWL¿HGDQGPHHWVUHJXODUO\WR
address electrical safety and ESWP issues.
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The PSRB will assure an implementation plan is developed, monitor the plan, and provide
appropriate resources to complete the plan in an expeditious and timely manner. At the time of
FRPSOHWLRQRIWKHSURMHFWWKH365%ZLOOUHYLHZDQGFRQ¿UPWKH(6:3SURFHVVLVFRPSOHWHSHU
the national guidelines and will provide the appropriate documentation to the Divisional Safety
Manager.
E-3
UAW-GM Electrical Safe Work Practices Document
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The facility PSRB may make application to take local control of their PPE FR clothing program.
They may reassess the need to continue the requirement for Category 2 FR clothing as daily
wear based on the status of the hazard assessment after the facility has been 100% surveyed.
&DWHJRU\)5FORWKLQJPD\QRWEHUHTXLUHGZKHUHWKHDUFÀDVKKD]DUGKDVEHHQGHWHUPLQHG
to be Category 0 (less than 1.2 cal/cm2).
Following the approval, facilities need to ensure that affected personal are provided, through
a managed program, a minimum of Category 0 clothing which consists of long-sleeved non
PHOWLQJFRWWRQFORWKLQJFRYHUDOOVRUXQLIRUPZLWKDIDEULFZHLJKWRIDWOHDVWR]\G2. This
would then become the standard PPE clothing for affected personnel. Unique conditions may
DOVRH[LVWWKDWZRXOGUHTXLUH&DWHJRU\RU&DWHJRU\FORWKLQJVSHFL¿FWRDSDUWLFXODUMRERU
WDVNEDVHGRQKD]DUGULVNDVVHVVPHQW623¶VVKDOOEHLQSODFHWRDGGUHVVWKHVHKD]DUGV
The Divisional Safety Manager will coordinate the program review with the International Union
DQGRWKHUVXEMHFWPDWWHUH[SHUWVDVGHHPHGQHFHVVDU\DQGZLOODGYLVHWKH365%RIWKH¿QDO
resolution. It must be emphasized, that all facilities must require affected personnel to wear
as daily wear Category 2 clothing until all aspects of the reassessment have been achieved
and the facility has received approval from the Divisional Safety Manager and the UAW
International Health and Safety Representative.
E-4
Copyright © 2008
UAW-GM Center for Human Resources
All rights reserved.
No material in this book may be copied, reproduced, or used
in any way without permission.
Inventory Code: ES200BK