NREL’s Electrical Safety Culture Revitalization

1. NREL’s Electrical Safety CultureRevitalization Sal Sferrazza July 2014

2. NREL’s Electrical Safety CultureRevitalization

3. NREL’s Electrical Safety CultureRevitalization January 2013

4. Electrical safety is a challenge at NREL • custom built equipment and systems (unlisted) • Difficult to choose applicable design standards for R&D equipment • changes in work, equipment, environment • Many visitors users and students each year • Subcontractors • Organizational Structure and Culture • Tendency for R&D community to rely on facilities and safety organizations for electrical safety expertise

5. NREL’s Electrical Safety Organizational Changes • NREL NEEDS MORE INVOLVEMENT IN ELECTRICAL SAFETY ACROSS THE ORGANIZATION • Electrical Safety Panel Charter • Modified • DOE and Line Management is represented • AHJ Authority clarified with DOE • Created ESO and Advisors, selected by the AHJ/Charter • Electrical Safety Officers (ESOs) and Advisors are key panel members and have been selected • The ESO has a strong working background in the electrical field. (e.g. scientist, EE, electrician, electronics technician, lineman)

6. NREL Electrical Safety Organizational Structure

7. ESO Training“train more, to fewer employees, and allow even fewer employees to do the work” • Extensive Training Program Initiated for ESOs and Advisors • 5 Specialized Courses in the last 2 months of fiscal year 2013, 17 days of training at a cost of $100,000 • National Electric Code for Lab Workers • NFPA 70E Electrical Safety in the Workplace • Specialized Officer training for Lab Workers • National Electric Code Inspector Class (ICC Inspector Certification prep class) • Medium Voltage Power Systems • 2014 Training: • SEMI S22 Safety Guidelines for the Electrical Design of Semiconductor Manufacturing Equipment & EN 60204-33 Safety of Machinery – Requirements for Semiconductor Fabrication Equipment • NFPA 79 Electrical Standard for Industrial Equipment • Additional Medium Voltage Training for Electricians (certification is goal)

8. NREL’s Electrical Safety Engaging R&D • Electrical Inspection Process Improvements • Working with Officers to id equipment for inspection • Additions to the Electrical Safety Lab Level Procedures • Working on simple electrical tests to aid in approving equipment per NFPA 79 , Chapter 18 • Earthing Continuity Test ,ground impedance tests, Dialectic Tests, Residual voltage • Encourage Research in Electrical Safety • Encourage them to be the Expert • Hazard identification & control of lab electrical hazards (DC, RF, stored energy etc.) • Third Party Certifications • 1/3 of ESOs are ICC certified inspectors now • Qualification Cards

9. NREL’s Electrical Safety CultureEngaging R&D • Engaged in Electrical Inspection /Process Improvements • Selected document control software(FileMaker Pro) : Document/Form Control • LOTO Form • Excavation Permit • Electrical Safe Work Permit • INSPECTION FORM • Arc Flash Reports PRO: FileMaker Pro is a record keeping database / compliance tool CON: More administrative overhead

10. NREL’s Electrical Safety CultureEngaging Facilities • PPE : Everyday wear • We have recently adopted everyday wear for those engaged in daily electrical construction work. • Mandated electricians to be third party certified to do construction inspections • Facilities electricians are accepting and grateful for the opportunity • All NREL electricians are licensed and ICC certified electrical inspectors • Formal NFPA 70E training for mechanical technicians

11. Other ImprovementsPolicy Updates • Electrical Safety Policy Updates • R&D hazards • Shock boundary thresholds for special R& D hazards • DOE Handbook • Practical

12. Electrical Hazard Classification Adopted Classify according to waveform and source inductors 60 Hz capacitors DC batteries subRF 1 Hz – 3 kHz RF 3 kHz - 100 MHz 1.x 2.x 3.x 4.x 5.x 6.x 7.x General Categories

13. Other Significant Electrical Improvements • PM Program for Electrical Equipment • Year 1 of the PM program has started • Budgeted $500,000 or $125,000 per year, 4 year cycle • Priorities Set • #1 Equipment that poses the greatest arc flash hazard • #2 Oldest equipment first • Hiring a full time employee to manage NREL’s electrical preventative maintenance program

14. Electrical Safety Challenges • Administration for Electrical Safety • Permit Library • Equipment Labeling • Inspection • PPE Program • Engineering Support • Arc Flash Analysis • Hazard Analysis • Inspections • Real Time Configuration Management / Equipment Alignment

15. How do we keep R&D engaged in Electrical Safety Program? • Qualification and Training • Recognition of Hazards • Methods to Control Hazards • Engineering Controls • Equipment Approval Program • Administrative Controls • Work Control • Two person rule • Permits • PPE • Qualification and Training • BUDGET PROVIDED TO ESOs

16. Recommended Additional Electrical Training • UL 508 • Safety Standard for Industrial Control Equipment • NFPA 790 & 791 • Standard for Competency of Third-Party Field Evaluation Bodies • Recommended Practice and Procedures for Unlabeled Equipment Evaluation • Third Party Medium Voltage Certification • Third Party Electrical Testing Certification

17. NREL’s Electrical Safety CultureRevitalization Observations • There is a benefit of having the latest understanding of NFPA 70E and other codes and standards • Sold the idea to management • Managing the expectations • Costs, but requires more discipline than cost • Audits & inspections • It is long term plan

18. Questions?