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Integrated Safety Management and Electrical Equipment Inspection at the APS June 14, 2010

Integrated Safety Management and Electrical Equipment Inspection at the APS June 14, 2010. Boris Deriy, APS Electrical Safety Committee Chair Ju Wang, Power Systems Group Leader. Why has Argonne adopted ISM?.

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Integrated Safety Management and Electrical Equipment Inspection at the APS June 14, 2010

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  1. Integrated Safety Management and Electrical Equipment Inspection at the APSJune 14, 2010 Boris Deriy, APS Electrical Safety Committee Chair Ju Wang, Power Systems Group Leader

  2. Why has Argonne adopted ISM? Argonne's Integrated Safety Management (ISM) program Formal approach to integrate safety into all aspects of the work process in the Lab ISM based on seven principles and five core functions B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010 2 ISM program provides an organized process for people to plan, perform, assess and improve the safe conduct of work at all levels. DOE mandates ISM within our prime contract ISM provides a framework for compliance with other regulatory requirements

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

  4. Five ISM Core Functions Everyone assigned for a job has to ask himself B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  5. Analyzing Hazards Example (Booster Magnet PS)Arc Flash Calculation, Stored Energy Warning This is an example of how ISM works based on LOTO Procedure for Booster Dipole. Every piece of equipment at the APS is provided with a label containing information based on Arc Flash Calculations -- what hazards present, the Arc Flash Boundaries, PPE required... B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  6. Implementing Controls Example (Booster Magnet PS)Warning Signs, Panel Meters, Power Alert UAP-100, LOTO Procedure B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  7. An Example of Clear Roles and Responsibilities (Test&Measurement Authorization Form) Division Director Responsibilities • Appoints qualified electrical workers • Approves conversion of task-specific one-time-use to extended-duration T&M Authorizations Group Leader Responsibilities (For CATs: CAT Director ) • Assures that the energized test & measurements can be justified • Assures that the work can be done safely and that persons listed are authorized and qualified to perform the work. ESH Coordinator Responsibilities • Assures that the proper safety approval process has been followed. APS Electrical Safety Committee Member Responsibilities • Approves and/or performs the hazard analysis. • Approves and/or defines PPE and safe working practices for the task to be performed. • Self-certifies that they are qualified to address electrical safety issues with the work for which the authorization is requested. Authorized Worker Responsibilities • Participates in pre-job briefing • Complies with criteria on the T&M Authorization. • Understands the safety envelope of work before starting, and stops work if conditions change beyond the original scope or safety envelope. • Performs work according to established APS safe working practices. B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  8. Unlisted electrical equipment approval program at the APS By 2005, two independent safety issues obviously grew up: • For almost 15 years of operation APS accumulated hundreds of pieces of equipment facing aging and obsolescence. Some of them did not match with newer standard safety requirements. • With extensive growing of users’ programs, the APS beamlines became flooded with non-standard equipment brought by users for experiments. There was no trained personnel at beamlines to help users to set up non-APS equipment which compromised safe operation. OSHA requires that electrical equipment must either be listed by an NRTL, or approved by the local AHJ. To meet these requirements ANL initiated an unlisted electrical equipment approval program performed by Designated Electrical Equipment Inspectors (DEEI). B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  9. DEEI Program – Why we needed it An example of equipment brought to APS by a user for a beamline experiment B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  10. DEEI Program – Why we needed it Same equipment -- modified, inspected and allowed for experiment B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  11. Designated Electrical Equipment Inspectors (DEEI) Training Program The training program was initiated in 2005. Now we have more than 90 inspectors trained (33 at the APS) • Review of Electrical Basics • Codes and Standards • NEC • Code Violations • DOE Handbook • Managing Electrical Hazards • NRTL by OSHA Program included: • Approval by UL • Hazard Classification • Unlisted Equipment Approval • Administrative Controls • Lessons Learned • Practical Electrical Safety including Argonne Tour • NFPA 70E for R&D B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  12. What Needs Inspection? Equipment not needing inspection, one or more of the following: • NRTL listed, not modified, and used per mfgr’s instructions • Equipment considered non-hazardous • Prototype (i.e. equipment under construction) equipment for < 3 months • Equipment not being used All other electrical equipment requires inspection and inventorying B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  13. Argonne Recognized Reputable Manufacturers (8/31/2009) allows to perform “light” inspection B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  14. Guidelines for Equipment Approval Suitability for installationand Grounding • Some potential considerations of suitability for installation and use are as follows: • Operation, considering environmental conditions • Temperature, humidity, air pressure, radiation, outdoor/indoor, etc. • Normal and abnormal use, considering duty cycle, average and peak power, etc. • Properly sized and installed equipment grounding (chassis grounding) • Equipment design that includes consideration of the available short circuit and ground fault current • Properly sized and installed over-current protection (fuses or circuit breakers) • Separation of high- and low-voltage components, especially where high voltage could escape along a hidden fault path B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  15. Guidelines for Equipment Approval Mechanical strength and Preventing from Arc Flash Mechanical strength and durability considerations : • Enclosure should: • Prevent damage to internal components during use and transportation • Contain arching, heating, and explosion • Prevent injury to personnel from hazardous energized parts • Prevent damage to internal components from environmental conditions • Workmanship—unused openings effectively closed • Integrity of electrical equipment and connections • Any item that would adversely affect the safe operation or mechanical strength of the equipment, such as damaged, corroded, or overheated parts B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  16. Guidelines for Equipment ApprovalWiring and Insulation • Wire bending and connection space includes the consideration of assembly and potential repair : • The protection of conductors and their insulation against damage by over-bending, over crowding, • location near moving parts in equipment, and at termination points. • The integrity of insulation ensures that the system: • Prevents the escape/transfer of electrical energy to other conductors and to personnel; • Is free from short circuits or potential short circuits; • Uses listed conductors where possible; and • Is free from grounds other than those required or permitted by National Electrical Code. B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  17. Guidelines for Equipment Approval Other factors contributing to the practical safeguarding of personnel • Reviewing non-electrical hazards (X-rays, UV and IR, RF fields, excessive noise ). • Preventing electric shock, burn, or reflex hazards by eliminating personnel contact with live parts of equipment operating at 50 volts or more. • Establishing a procedure of energy removal, e.g., disconnection, LOTO, removal of stored energy, for both normal/emergency shutdown. • Use listed or recognized components where possible. • Consider the loss of electrical power, automatic removal of stored energy, the use of interlocks on enclosures and other systems. B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  18. Unlisted Electrical Equipment Approval Form B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  19. Purchased Equipment should be listed by an NRTL (Nationally Recognized Testing Laboratory) The following are the NRTLs for electrical equipment recognized by OSHA B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  20. Approval and Rejection Labels B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  21. Electrical Equipment Inspection Discoveries One fuse per 6 supplies Abandoned live wire Spliced Ground Wire Cracked Insulation B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  22. Lab-wide Unlisted Electrical Equipment Database B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

  23. APS Electrical Equipment Inspection Status B.Deriy, J.Wang, 2nd Workshop on POCPA, June 14-17, 2010

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

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