Electrical Safety Program Baytown Site, Texas Houston Business Round Table

1. Electrical Safety Program Baytown Site, Texas Houston Business Round Table OSHA Best Practice

2. The program is designed for all personnel who work in an environment influenced by the presence of energized electrical equipment and empowers those personnel to work safely on the electrical equipment. The focus of the program is directed toward the general features of a set of principles and controls that when practiced on a regular basis will lead people into the awareness and discipline to safely perform electrical work. The program has been progressively implemented in three world scale Chemical facilities in both the USA and Canada and received a IEEE prize paper award at the 1986 PCIC Petroleum Industry Technical Conference. The program recently recognized by OSHA as a best practice.

3. Electrical Safety Statistics • OSHA requirements • The development of Electrical Safety in North America • The development of one users Electrical Safety Program • The Electrical Safety Program Standard and Procedures • Designing the potential electrical hazard out of the equipment. • Empowerment

4. Nonfatal Electrical Incidents, Industry Sector Versus Nature of Injury (U.S data) 1992-2002 [Source: Cawly and Homce, Trends in Electrical Injury, 1992-2002 PCIC-IEEE-2006-38] Total=47,406 (N=18,360) (N=29,046)

6. Edison took electricity out of the lab with the first commercially practical light bulb. Patented 1880

7. 1900 1920 1940 1960 1980 OSHA-1970 NESC - 1913 NIOSH-1970 NFPA 70E-1979 NEC - 1897 Burn Center-1980 Development of Electrical Safe Work Practices 1879 IEC - 1904 First commercially practical incandescent light bulb. Milestones in the First 100 Years

8. Development of Electrical Safe Work Practices Yellow Book - 1998 Elect Hot Work Safety Program by JMG/LBMc - 1987 NFPA 70E-1995 1980 1990 2000 NESF-1994 1st IEEE-IAS-ESW in Dallas 1992 Arc-Resistant Swgr. - 1997 NFPA 70E-1988 ASTM F-1506 - 1998 Subpart S-1989 Lee’s Paper - 1982 Workshop. SE Asia - 1998 PCIC Safety Subcom.-1990 Incident energy consensus - 2000 DuPont Safety Workshop, Chantilly -1991 Milestones in the Past 28 Years

9. Development of Electrical Safe Work Practices 15th Annual IEEE-IAS-ESW in Dallas 2000 2004 2008 OSHA VPP BEST PRACTICE NFPA 70E-2004 NFPA 70E - 2000 IEEE 1584-2002 $3.2MM Contributions Rec’d for AFH Testing IEEE/NFPA Collaborative Effort on AFH Issues Milestones in the Past 8 Years

10. Development in Electrical Safety OSHA & NFPA-70E • Occupational Safety & Health Administration • OSHA 29 CFR 1910.119 Process Safety Management • OSHA 29 CFR 1910.137 Electrical Protective Equipment • OSHA 29 CFR 1910.145 Specification for Accident Prevention & Tags • OSHA 29 CFR 1910.147 The Control of Hazardous Energy (LO/TO) • OSHA 29 CFR 1910.254 Subpart Q – Welding, Cutting and Brazing • OSHA 29 CFR 1910.269 Subpart R- Generation,& Distribution • OSHA 29 CFR 1910.301 Subpart S thru 1910.399 - Utilization • OSHA 29 CFR 1926.400 Subpart K thru 1926.499 - • OSHA 29 CFR 1926.950 Subpart V- Construction

11. OSHA Mandates for Electrical Safety • Electrical equipment installed safe per recognized installation and inspection is considered to be safe until: • Deterioration occurs • Unsafe acts are performed • Carelessness takes place • OSHA directs that electrical equipment be de-energized before working on or near exposed electrical conductors or circuit parts

12. OSHA Mandates for Electrical Safety • OSHA recognizes a few situations where it is infeasible to deenergize the electrical equipment while performing some tasks in proximity of “live” parts: • Performing diagnostics and testing (startup or troubleshooting) of electric circuits that can only be performed with the circuit energized • Work on circuits that form an integral part of a continuous process that would otherwise have to be completely shut down in order to permit work on one circuit or piece of equipment • If deenergizing the electrical power could present a greater hazard than the potential hazard of working on or near exposed energized electrical conductors or circuit parts.

13. OSHA Recognition of NFPA 70E • OSHA is revising the general industry electrical installation standard found in Subpart S of 29 CFR Part 1910. In the Wednesday, February 14, 2007 OSHA Final Rule, “The agency has determined that electrical hazards in the workplace pose a significant risk of injury or death to employees and that the requirements in the revised standard, which draw heavily from the 2000 Edition of NFPA 70E and the 2002 Edition of the NFPA 70 are reasonably necessary to provide protection from these hazards.” This final rule became effective August 13, 2007. • “OSHA is responding to requests from stakeholders that the agency revise Subpart S so that it reflects the most recent editions of NFPA 70E and NFPA 70.”

14. NFPA 70E Standard for Electrical Safety • National Standard for Electrical Safety • Consensus document and presents basis for OSHA CFR Subpart S 1910.331-335 • Strategies • Electrical Safe Work Condition • Training • Planning the work • Protective Equipment • Preventative Maintenance • NEC • Fundamental principles of protection against • Electric shock • Thermal effects • Overcurrent • Fault currents • Overvoltage

15. The development spans 22 years • Electrical Safety Standard • Electrical Safety Principles • Controls • Responsibilities • Shock Hazard • Arc Flash Hazard • Definitions • Limits of Approach • General and Specific Electrical Work Procedures • Electrical Safety Working Group • Manage the Program • Select the electrical tools • Selects the electrical PPE • Develop general and specific Electrical Work Procedures • Training leading to Qualification

16. 1994 1985 1986 1991

17. 1995 2000

18. 2004

19. One Electrical Safety Program for the Site (multi business site) • Principles • Controls • Training to provide the awareness and discipline • Simple Program that empowers people to work safely through awareness and discipline

20. The Electrical Safety Program is not designed for hands on live line work. It is designed for an integrated electrical system in a 24 hour continuous Petro-Chemical facility where every alternative is investigated before electrical energized work is authorized. The majority of work performed in Baytown is: • Troubleshooting an energized circuit • Checking and testing for Isolation • Applying temporary grounds • Opening and closing Circuit breakers • Resetting Overload relays

21. Principles of the program The Electrical Safety Working Group uses the following principles to implement the Electrical Safety Program. Identify the Hazard Each job must identify and focus on the Electrical Shock and Electrical Arc Flash Hazard. Eliminate the Hazard (whenever possible) The energized electrical work and potentially hazardous switching will be reviewed to determine if the hazard can be removed by design or by establishing an electrically safe work condition. Control the Hazard When the electrical hazard cannot be eliminated by design or by establishing an electrically safe work condition, it will be controlled by qualified personnel using a well defined electrically safe work or electrical switching procedure.

22. Minimize the Severity of Potential Injuries The severity of injuries when a potential hazard gets out of control during the execution of energized electrical work or potentially hazardous switching will be minimized by: Wearing the correct personnel protective equipment Minimizing the number of personal potentially exposed to the hazard within the arc flash hazard boundary to only those persons necessary to perform the work. Maximize the ability to recover from an injury. The ability to recover from an injury is maximized by: • The use of a second qualified person for Class A and a standby person for class B, W, X and Y energized electrical work and electrical switching. Refer to S-056 Appendix “B”. • The use of radios to communicate the status of the work. • Standby personnel qualified in the use of CPR.

23. Electrical Safety Program (S-056 Site Procedure) • Electrical Safety Working Group • Authority for electrical safety at the site. • Selection of PPE • Selection of Live Line Tool’s • Electrical Work Procedures (EWP’s) • Electrical Switching Procedures (EWP’s) • Training leading to qualification • Restricting access of personnel into the Limited Approach Boundary • Arc Flash Hazard Analysis and Label’s

24. Classroom training • Two day class room. Training included “skits” performed by electrical supervisors and technicians on how and how not to perform electrical work. Actual equipment or equipment “mock ups” used. • Computer based training • Automatic system that requires reader sign off and test. • Records updated automatically • Contractor training • Minimum requirement for contractors is the Electrical Safety Program. • Procedures identified on ISTC WEB page. • Training address qualified and unqualified workers

25. OSHA • At OSHA’s hearing in 12/05, Dr. Heinz Ahlers of NIOSH, spoke about the effect of training on accidents. “In a majority of those instances the fatality involved the worker who had been appropriately trained for the exposure that he subsequently came in contact with and just was not following the training and the company policy involved”.

26. AWARENESS DISCIPLINE

27. S-056 Electrical Safety Program Appendix A Limit of Approach Appendix B Energized Electrical Work and Switching Classification Appendix C Energized Electrical Work Permit Appendix D Job Briefing EWP-1 Electrical Safety Working Group EWP-2 Arc Flash Hazard EWP-3 Hazard Flash Analysis label EWP-4 Personal Protective Equipment for Electrical Shock Hazards EWP-5 Personal Protective Equipment for Electrical Arc/Flash Hazards EWP-6 Electrical Emergency Release Procedure EWP-7 Training and Qualification EWP-8 Testing and Inspection of Temporary Wiring, Portable Electrical Equipment, Extension Cords, and Portable GFCI’s. EWP-9 Electrical Documentation EWP-10 Contractor Electrical Safety EWP-11 Electrical W, X, Y Switching EWP-12 High-Direct-Voltage (DC Hi-pot) Test on Power Cables EWP-13 Demolition of Isolated Electrical Cables EWP-14 Temporary Personnel Protective Grounds EWP-15 Voltage-rated Test Equipment and Tools EWP-16 Electrolysis EWP-17 Basic Electrical Safety EWP-18 Energized Electrical Work EWP-19 Normal Electrical Switching S-56 Class Z EWP-20 Inspection and Troubleshooting Inside a 480-volt MCC Bucket EWP-21 Removing and Inserting a a 480-volt MCC Bucket EWP-22 Removing or Replacing a bolted Non Hinged Cover to expose an energized component 301 to 150,000 volts EWP-23 Testing for Absence of Voltage EWP-24 Qualification Requirements to Enter Electrical Rooms EWP-25 Repair Work 51-300 Volts EWP-27 Operation of Equipment Near Power Lines EWP-28 Ground Assurance Programs

28. Purpose: The Electrical Safety Program sets the minimum requirements to safeguard against electrical shock and electrical arc flash while installing, commissioning, maintaining and operating electrical equipment at the Bayer Baytown Industrial Park. Scope: The electrical safety program applies to all Bayer employees and contractors whose job requires them to install, commission, operate, service, inspect or maintain electrical equipment including electrical power distribution equipment.

29. Procedures for all electrical work, energized electrical work, emergency work and electrical switching shall comply with this program.This program does not cover: • Electrical work from 0-50 volts • Telephone company equipment owned and maintained by the telephone company • Utility electrical equipment owned and maintained by the utility company • Electrical equipment owned, maintained and operated by 3rd party operations

30. This procedure has four appendices: Appendix A Limits of Approach Appendix B Energized Electrical Work and Electrical Switching Classifications Appendix C Energized Electrical Work Permit Appendix D Energized Electrical Work Job Briefing

31. Appendix A Limits of Approach NOTE #1: The restricted approach distance is the working distance used to calculate the incident energy. If closer work distances are required on specific equipment, a deviation is required that is authorized by the Baytown PCT Head. The deviation shall include new incident energy calculations and a written procedure for the specific task to be completed.

32. S-056 “Electrical Safety Program”Appendix B: Energized Electrical Work and Electrical Switching Classifications

33. Appendix C Energized Electrical Work Permit {click on to view}

34. Appendix D ENERGIZED ELECTRICAL WORK JOBBRIEFING {click on to view}

35. 2.1 This Electrical Safety Working Group will manage and develop the electrical safety program for the Baytown site to meet the S‑056 “Electrical Safety Program”. Contractors and third party personnel working at the Baytown BMS site will comply with the requirements of the Baytown BMS Electrical Safety Program. 4.0 The “Electrical Safety Working Group” will use the following principles to implement the Electrical Safety Program. • Identify the hazard • Eliminate the hazard (whenever possible) • Control the hazard • Minimize the severity of potential injuries • Maximize the ability to recover from an injury

36. RESPONSIBILITIES The Electrical Safety Working group is responsible to develop and manage the following: The Baytown BMS S‑056 “Electrical Safety Program” Electrical Work Procedures (EWP) Electrical Safety Training Qualifications of personnel to perform electrical energized work and electrical switching Selection of live line tools and temporary safety grounds Selection of personnel protective equipment for energized electrical work and electrical switching Electrical Arc Flash Hazard analysis Label Electrical Equipment with an Arc Flash Hazard label

37. Electrical Shock • Over 30,000 non-fatal electrical shock accidents occur each year. • Over 350 people die from electrocution each year. • Electrocution remains the fourth (4th) highest cause of industrial fatalities. • Most injuries and deaths could be avoided

38. This procedure identifies the use, field care, testing and inspection of electrical PPE required when performing energized electrical work and electrical switching.

39. The Restricted Approach Boundary has two conditions, based on the voltage system as follows: Less than 750 volts The qualified person must keep face and body trunk, including legs, outside of the Restricted Approach Boundary. The Restricted Approach Boundary can be penetrated by qualified persons with the persons arm and hand if wearing PPE and rubber insulating gloves approved for the voltage class and identified by procedure. EXCEPTION: It is permissible to use the Class 00 or Class 0 rubber insulating gloves without the leather protectors, only if high finger dexterity is needed for the handling of small parts, and there is no potential for small parts to puncture, cut or tear the rubber glove; thereby permitting the energized part to contact the employee’s bare hand.

40. Greater than 750 volts The qualified person must keep all body parts outside the Restricted Approach Boundary. The Restricted Approach Boundary can only be penetrated by qualified persons with live line tools or test equipment approved to the voltage class of the system being work on and operated to the manufacturer’s instructions. The live line tools or test equipment must be operated by the qualified person wearing full PPE, including rubber insulating gloves approved for the voltage class with all body parts outside of the Restricted Approach Boundary.

41. Class 2 (17 kV) Insulating Rubber Gloves, with Leather Protectors

42. Arc-Flash • As much as 80% of all electrical injuries are burns resulting from an arc-flash and ignition of flammable clothing • Arc temperature can reach 35,000°F - this is four times hotter than the surface of the sun • Fatal burns can occur at distances over 10 ft. • Over 2000 people are admitted into burn centers each year with severe electrical burns • An Arc-flash also contains molten metal

43. The purpose of the procedure is to document the custody, care, and use of the Bayer Baytown Power Distribution System Model (“Model”). The Model is the electronic software representation of the entire Bayer Power Distribution System and is capable of providing short circuit calculations, arc flash boundaries, relay settings, circuit breaker settings, arc flash label information and other technical data.

44. The purpose of the label is to communicate in a consistent way, the electrical shock and arc flash hazards and limits of approach to energized components. This allows persons engaged in electrical work or switching to select the correct PPE. • Breaker panels, MCC and Switchgear above 300 volts will be marked with the Arc Flash Hazard Analysis label. • Electrical panels 50 volts to 300 volts will be marked with a label indicating the maximum voltage inside the panel. An Arc Flash Hazard Analysis label is not required on electrical panels 50 volts to 300 volts unless the circuit includes at least one 125KVA or larger transformer.

45. ARC FLASH HAZARD ANALYSIS LABEL

46. This procedure identifies the use, field care, testing and inspection of arc flash PPE that must be worn by BMS qualified personnel when they work inside the Arc Flash Protection Boundary. This procedure also applies to personnel who are not performing energized electrical work or switching, but are within the Arc Flash Protection Boundary. Personnel who perform electrical switching directly on non arc-resistant switchgear are considered to be in the arc-flash protection boundary and have to wear arc flash PPE.

49. Flash Suit Hood

50. ATPV in cal/cm2 – Level of Protection