Reduce the Risk of Arc Flash With a Reliable and Repeatable Repair and Preventative Maintenance Program

The importance of preventative maintenance programs can’t be understated. Especially when it comes to reducing the risk for arc flash. Accuracy and repeatability are critical to any machine operation, but that also applies to the preventative maintenance program itself. Facility and safety managers understand that repeatability makes work easier to implement.

Even the most conservative estimates say that there are up to five arc flash explosions occurring in electric equipment every day in the United States. Even more electrical incidents happen daily, but there are ways companies can significantly reduce the occurrence of these incidents to create a safer workplace.

Preventative maintenance can increase machine reliability, which decreases the need to access that equipment for repairs. This, in effect, increases overall plant safety when machines and equipment are operating as planned without the need for unscheduled maintenance. NFPA standard 70B outlines the best practices for setting up and maintaining an Electrical Preventive Maintenance (EPM) program. Additionally, the InterNational Electrical Testing Association (NETA) offers tremendous resources on preventative maintenance with their PowerTest Conference seminars.

An effective Electrical Preventive Maintenance (EPM) program helps avoid extra expenses, disruptions and potentially lost profits that may result from equipment breakdown or an arc flash. Typically, in setting up an EPM, it begins at the main service entrance and works its way through the electrical distribution system to automation and controls all the way to the machine level.

There are a variety of reasons why an arc flash may occur; it could be an accumulation of conductive dust inside an enclosure or purely equipment failure – likely the result of inadequate maintenance. In short, if electrical equipment is not maintained, then something is going to give.

An effective means of preventing electrical incidents and arc flashes is the anticipation and elimination of the conditions that may cause them. Spotting potential signs of an electrical failure include:

  • Identifying and repairing compromised insulation before it fails.
    Predictive maintenance systems can provide early warning of insulation degradation or failure. Visual inspections of the condition of insulation and electrical joints should be conducted whenever maintenance is performed.
  • Monitoring electrical equipment at critical joints including, lugs and compression fittings.
    Over time, heat cycles and vibration can loosen connections which can cause overheating and may lead to an arc flash. Thermal sensors can help monitor these critical joints.
  • Using infrared windows.
    Using infrared thermal scanning through IR windows enable technicians to perform scans without removing equipment covers or opening doors, lessening the likelihood of arc flash events caused by accidental contact and exposure.

It should go without saying, that before performing any electrical work in any form of maintenance, that it’s important to de-energize the equipment and verify that an electrically safe work condition has been established.

Verifying absence of voltage is important and the testing method to work on de-energized equipment must also be safe and effective. The electrical worker who conducts the testing needs to understand testing procedures and be repeatedly proficient with the testing devices.

Verifying the absence of voltage with the Panduit VeriSafe Absence of Voltage Tester before equipment is accessed makes it easy to verify that an electrically safe work condition has been established without exposure to hazards.

The results of having a reliable electrical safety and preventative maintenance program will reduce risk, minimize business interruptions and even extend the life of your plant’s electrical equipment.

Understanding Electrical Safety in Today’s Changing Landscape

Being able to identify electrical hazards and having tools, safety procedures and instructions available to mitigate risk is essential to ensuring safety.

 

It’s important to have a workforce that understands how keeping up with the times is paramount to staying safe in the workplace. Much can said about the importance of creating an electrically-safe workplace, but it is the responsibility of any employer to provide a safe environment, free of hazards to its employees.

In 2015, the National Fire Protection Association (NFPA) created an accreditation, the “Certified Electrical Safety Worker (CESW)” certification program, which was based on the most current edition of NFPA 70E, the Standard for Electrical Safety in the Workplace. The program ensures that electricians have the knowledge, training and experience to perform their jobs at the highest, safest level possible. Obviously, one key to safety during times of change is keeping aligned with consensus standards, which the NEC and NFPA updates every three years. Below are changes any plant might encounter and thus has a need to be prepared for.

VeriSafe – Absence of Voltage Tester

Changes in Standards
As safety standards evolve, so too must the company and its workforce. The latest release of the NFPA 70E-2018, includes updates that are essential for the company and its employees to understand. When NFPA 70E released its 2018 update, a new exception was included that allows Absence of Voltage Testers (AVTs) listed to UL 1436 to be used to verify the absence of voltage instead of a handheld voltmeter. Changes to consensus standards can take safety at a facility from good to great.

Changes in the Plant
When business grows, the facility grows. New machines are added, the electrical capacity needs grow, and thus an increased need for overall, plant-wide electrical safety grows. Sometimes, there can be an overcrowding in electrical rooms and production areas with added equipment. Other times, challenges are created when multiple suppliers of equipment create anomalies. While codes and standards evolve, and as equipment is added, there can be these compatibility issues. Standardizing processes and procedures can help minimize or prevent human error. Panduit provides solutions for the electrical infrastructure that can help bridge multiple equipment manufacturers or areas of equipment as additions take place. The VeriSafe Absence of Voltage Tester is compatible across many equipment types and manufacturers, provided the specifications have been met.

Changes in Plant Operations and Performance 
The rise in automation in plants today is proof that the robots are here. The qualified electrical worker meets all of the training requirements set by NFPA 70E and OSHA, and as a general rule, each qualified electrical worker may need several days of training each year to maintain the level of skill. It may be a good idea to plan for that training over a three-year period – which helps to ensure that the qualification process continues to track changing requirements. It’s possible that effective training may be something that is repeated in different formats periodically in order to keep if fresh and top-of-mind. This may toggle between classroom instruction, hands-on skills demonstration and audits.

New equipment brings new types of hazards and risks. Being able to identify these hazards and having tools, safety procedures and instructions available to mitigate risk is essential to ensuring safety. Perhaps even more game-changing than automation is the availability of connectivity and networking on the plant floor. This allows safety procedures to become more connected and integrated into workflow with the ability to track and log tasks, as well as access to video for training and recording purposes.

Why Your Electrical Infrastructure is Too Important Not to Be a Maintenance Priority

The electrical infrastructure of a building, including distribution and controls, is the heart of any facility.

 

Too often, electrical systems aren’t always given the maintenance priority they might deserve. Today, we understand the importance of why the electrical infrastructure is critical to doing business and why plant safety can be enhanced with a little thought and planning.

For the majority of electrical work that happens in a facility, including scheduled maintenance, de-energizing the system is the fundamental requirement for safety. The electrical infrastructure of a building, including distribution and controls, is the heart of any facility. Without a reliable source of electricity, production would not be possible. So, what can be done to make electrical system maintenance a priority?

Schedule regularly, avoid spontaneity.
Even with the critical nature of electrical equipment, regularly scheduled maintenance needs to be a primary focus. Facility managers don’t often think about maintenance until a disruption, like an equipment failure, occurs within the system.

Neglecting regular maintenance of electrical equipment, especially over a long period of time, may lead to a disruption in facility operations and possibly a damaging system failure or an incident. Reliable equipment will increase safety and decrease property risks.

Don’t overlook the obvious.
Electrical equipment, especially what modern facilities are installing today, is well-designed, it’s safe to operate and it generally has a long service life. By nature, electrical systems are usually hidden from sight.

Thus, when it’s out of sight, it’s out of mind – awareness may not be raised as long as lights turn on and everything operates as it normally would. Even new equipment requires a proactive maintenance and service program and then it needs to be inspected to ensure it is properly installed, functioning and can be well maintained.

The Electrical System Can’t Always Speak for Itself.
Though sensors and condition-based monitoring are becoming more and more common, particularly thermal monitoring of critical electrical infrastructure, a fair amount of electrical equipment in use today still can’t warn us when a failure is imminent.

It could be less disruptive to operations if workers could identify equipment that is about to fail, before the failure occurs, so proper steps could be taken to prevent or minimize the downtime impact to people, processes, equipment and operations.

Regular maintenance is required to ensure that equipment can be operated as expected. For example, contacts that are not regularly exercised have a tendency to stick, or not open at all, leading to longer clearing times than expected.

Plan for maintenance.
While de-energizing equipment is a fundamental requirement for electrical safety, de-energizing by its nature is disruptive to facility operations. Thus, it is best to anticipate and plan for maintenance.

A conscious plan for maintenance is far financially advantageous to the other option, when unplanned maintenance occurs when least expected. It also may be helpful knowing that a facility-wide shutdown is happening, so steps can be taken to ensure operational disruptions will be minimized.

Maintenance shutdowns have a cost and require planning, so it’s important to anticipate the need and even budget appropriately. If the facility does not have trained and qualified electrical workers to perform the system maintenance, then many qualified service companies exist and can offer these services.

Planned maintenance has the distinct advantage of making sure that experts can be present. Some equipment manufacturers can even be onsite to assist customers with large PM programs when maintenance is scheduled in advance and not unplanned.

From Problem to Solution: NFPA 70E and the VeriSafe Absence of Voltage Tester

The VeriSafe – Absence of Voltage Tester (AVT) from Panduit supports compliance in the lockout/tagout process described in NFPA 70E.

 

Electrical workers must comply with safety regulations that require a voltage verification test before servicing electrical equipment. NFPA 70E, the Standard for Electrical Safety in the Workplace, addresses best practices for protecting employees from electrical hazards through the use of safety programs, hazard and risk identification, training, and procedures.

One of the best ways to protect workers is to isolate the electrical supply, follow lockout and tagout procedures, and verify the equipment is de-energized before any electrical work is performed. Until now, this process has been complex and time-consuming, fraught with possibilities for human error and potential exposure to hazards.

The verification step often puts electrical workers at risk for exposure to electrical hazards while testing a handheld tester on a known voltage source, testing for absence of voltage phase-to-phase and phase-to-ground inside the equipment, and re-testing the tester to ensure it is still functioning properly.

Until these steps have been completed, it is best to assume the equipment may be energized and take all necessary precautions including use of adequate personal protective equipment.

In the 2018 edition of NFPA 70E, a new exception was included in Article 120.5(7) that offers an alternative to the traditional hand-held testers method used to verify the absence of voltage: the option to use a permanently mounted device.

The permanently mounted test device can be used to test the conductors and circuit parts at the point of work before the equipment is accessed preventing exposure to electrical hazards. These permanently mounted devices must be installed at the point of work in accordance with manufacturer’s instructions, listed and labeled for the purpose of verifying the absence of voltage, and satisfy additional requirements outlined in the standard.

The permanently mounted test device is different from the test portal interface that is sometimes used with a handheld voltage tester. Although the test portals reduce exposure when verifying the absence of voltage, this process– working with hand tools via a portal – does not meet the requirements of the new Exception 1 in 120.5(7) because:

  • It is not listed for the purpose of verifying the absence of voltage
  • There is no way to confirm that the probes of the tester are actually in direct contact with the electrical conductors inside the enclosure at the time of the test
  • They bring hazardous voltage to the door

An example of a permanently mounted device that does meet the requirements of NPFA 70E is the absence of voltage tester (AVT).

The VeriSafe Absence of Voltage Tester from Panduit is specifically designed to verify the absence of voltage and fully complies with the new NFPA 70E standard. This ultimately simplifies the testing process and reduces risk for the qualified worker performing electrical work.

Automating this process with the VeriSafe AVT:

  • Reduces testing procedure time and complexity
  • Reduces the risk of exposure to electrical hazards
  • Supports compliance in the lockout/tagout process described in NFPA 70E

A facility’s electrical infrastructure is a top priority. With more than 60 years of infrastructure expertise, Panduit is committed to developing innovative solutions to help companies achieve their operational goals, reduce risk, and increase electrical safety.

Learn more about the VeriSafe - Absence of Voltage Tester here: www.panduit.com/verisafe

How Electrical Safety Tools Evolved Using Prevention through Design Methods

VeriSafe™ Absence of Voltage Tester (AVT) from Panduit

The VeriSafe™ Absence of Voltage Tester (AVT) from Panduit simplifies the testing process by automating the voltage verification process.

Before performing electrical work, OSHA and the NFPA 70E Standard for Electrical Safety in the Workplace both direct workers to de-energize circuit parts to which an employee may be exposed.

After de-energizing, a qualified electrical worker is required perform a test to verify the absence of voltage. This is a complex testing process that includes a number of steps that can be cumbersome and time-consuming when using hand-held portable test instruments.

Tools that enable workers to safety monitor and test voltage have been evolving for decades. These range from non-contact proximity testers, solenoid testers, voltage detectors, digital multimeters, and an array of installed indicating devices. Each type of tool has advantages and disadvantages that may be specific to the application. Therefore, it is necessary for the electrical worker to understand any limitations of the tool he or she may be using. Selecting the proper tool is critical when verifying the absence of voltage.

Verifying the operation of the voltage test instrument itself is also a task that needs to be performed. Before beginning the absence of voltage test, it’s important to check the test instrument to ensure it is working properly – this is known as the “live-dead-live” test. The “live-dead-live” test is a best practice described in NFPA 70E. The “live” portion of the test involves using a known voltage source to verify that the test instrument is operating properly. After proving the tester is operational, you can then proceed to verify that the circuit parts are “dead” or de-energized by testing for voltage phase-to-phase and phase-to-ground. The final step is to verify that the test instrument is still operational by re-testing on a known “live” voltage source. Proving the test instrument is still operational on a known voltage source following the test ensures that there was no damage which would have caused an incorrect reading when performing the “dead” portion of the test. Similarly, OSHA has a requirement to verify the tester is functional after testing for voltage, but only above 600V.

The VeriSafe™ Absence of Voltage Tester (AVT) from Panduit simplifies the process to establish an electrically safe work condition by automating the absence of voltage verification process. The idea for the VeriSafe AVT is inspired by Prevention through Design. Prevention through Design is a methodology that focuses on preventing or reducing incidents caused by human error through design steps like eliminating the hazard, making substitutions that reduce the hazard, or introducing engineering controls.

The VeriSafe AVT is a permanently-mounted test device designed to verify that a circuit is de-energized prior to opening an electrical enclosure. With the VeriSafe AVT, the absence of voltage test is initiated with the push of a button; no additional tools are required.

More facilities are designing in advanced safety products that reduce the chances of human error and boost worker productivity. Just as the modern facility has advanced, so too has technology to verify the absence of voltage.

Learn more about Panduit absence of voltage testers here:
http://www.panduit.com/verisafe

Ten Top Electrical Hazards and Panduit Solutions

Panduit innovates the products that protect people, places and things

Here are 10 of the most common causes of electrical death and injury.

The world knows a lot about electricity. Humankind knows how it’s made, how to use it, and humans even have a rudimentary understanding of how to store it.

And while experts understand electricity, they also know to respect it.

Because even before Ben Franklin inexplicably survived his interaction with a key, a kite, and a bolt of lightning, humans have known electricity is dangerous.

What follows are ten of the most common causes of electrical death and injury. The reader should take heed; each of these represents a preventable mishap.

Much like poor or inadequate communication, or mislabeled wires, these hazards are rooted in human behavior. In fact, another type of article could simply list “human error” as a single major cause of electrical mishaps.

There can be accidents wherever there are humans and electricity; here are some of the most dangerous situations.

  1. Overhead power lines

In the United States, nearly 46 percent of fatal workplace electrical mishaps are caused by contact with overhead wires.

Conversely, overhead wires are involved with only two percent of non-fatal mishaps. Those statistics are a grim reminder of the danger posed by overhead power lines; they pose an exceptional danger to the life of anyone who comes in contact with one.

  1. Lockout/Tagout Failure

Lockout/Tagout literally means to lockout circuits during construction and other electrical work. And the process works well; OSHA estimates that nearly 50,000 injuries2 are prevented every year by using proper procedures.

Solutions such as Panduit’s full line of lockout/tagout equipment make it easier to comply with safety procedures. Check out the line here.

  1. Damaged tools and equipment

Damaged equipment and faulty tools cause 37 percent3 of non-fatal workplace electrical mishaps. Whether it’s an old electric hand tool, one that’s been dropped, by the time it starts smoking, it’s been dangerous for a long time. Regular checks, maintenance, and awareness are critical to keeping tools safe in the workplace.

  1. Overloaded circuits

The National Fire Protection Association (U.S.) estimates that more than $1.4 billion4 in property damage is caused by overloaded circuits in homes every year.

Commercial statistics are difficult to come by, but what’s certain is that overloaded circuits cause an enormous amount of damage to commercial and residential property all across the globe. It’s a problem that’s easily solved by accurate labeling.

Panduit labeling solutions make this safety step quick, easy, and a must-have for any commercial application.

  1. Damaged insulation

Mice chew on wires. So do squirrels. But even without a plastic-munching rodent problem, wires can be damaged when they rub on other surfaces.

Repeated wear on the wires can break the insulation, allowing electric current to escape. Much of this abrasion can be eliminated with a good pest control program and using abrasion protection products like these.

  1. Inadequate wiring and terminations

Non-home structure fires involving electrical failure or malfunction accounted for an estimated annual average of 12 civilian deaths5, 210 civilian injuries, and $614 million each year from 2010-2014. Some of that damage and loss of life can be prevented simply by terminating wires correctly. Learn how here.

  1. Exposed electrical parts

Inadequate labeling, poor equipment condition, and even user error can cause electrical parts to be exposed, posing a significant risk to safety.

Clear communication and labeling, along with using high-quality products at every turn is a critical step to reducing the thousands of injuries caused every year by exposed electrical parts.

  1. Improper grounding

Improper grounding is the #1 electrical violation according to OSHA. It’s often overlooked and poorly understood. The Panduit line of grounding solutions makes grounding a simpler task with a complete line of tools and products.

  1. Qualification of the “qualified” electrical worker

NFPA 70E and OSHA regulations instruct that electrical circuits or equipment with at last 50 volts of electricity must be covered, protected, or made inaccessible to everyone except “qualified electrical workers.”

That worker is considered “qualified” when they have attained the training and experience to be familiar with the construction and operation of the equipment, along with any hazards. But that vague definition allows for a huge range of experience. Only with an ongoing safety program can any organization determine its workers are “qualified.”

  1. Verification for Absence of Voltage

Test lights are decades old technology. But meeting the challenges of today’s regulations and expectations means using a tool that’s permanently installed, like Panduit’s VeriSafe.

VeriSafe minimizes risk by verifying the absence of voltage before equipment is accessed, making it easier for qualified electrical workers to identify an electrically safe environment in a fraction of the time of hand-held portable test instruments. Learn more about VeriSafe, and how you can meet the NFPA 70E requirements here.

 

1 (Source: Brenner B, Cawley JC (2009). Occupational Electrical Injury and Fatality Trends: 1992-2007. EHS Today. Available at: http://ehstoday.com/construction/news/occupational-electrical-injury-3991. Accessed 01/19/2018, via https://www.nfpa.org/News-and-Research/Fire-statistics-and-reports/Research-reports/Electrical-safety/Occupational-Injuries-from-Electrical-Shock-and-Arc-Flash-Events accessed 1/18/2018)
2 (Source: EFSI.org,  https://www.esfi.org/resource/lockout-tagout-your-life-depends-on-it-544 accessed 2/12/18)
3 (source: https://www.nfpa.org/News-and-Research/Fire-statistics-and-reports/Research-reports/Electrical-safety/Occupational-Injuries-from-Electrical-Shock-and-Arc-Flash-Events accessed 1/18/2018)
4,5 (source: NFPA fact sheet, accessed here: https://www.nfpa.org/News-and-Research/Fire-statistics-and-reports/Fire-statistics/Fire-causes/Electrical-and-consumer-electronics/Electrical accessed 1/25/18)
6 (source: Office of Compliance, Congressional Accountability, fact sheet. https://www.compliance.gov/sites/default/files/wp-content/uploads/2010/08/Exposed-Energized-Wiring-Fast-Fact-Feburary-2010.pdf accessed 1/25/18)