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ELECTRICAL SAFETY PROGRAM
1.0 INTRODUCTION
Nationwide more than 1,000 individuals are killed and another 30,000 injured each
year from electrical shock. University of South Carolina employees work with and
around electrical equipment every day. Therefore, University of South Carolina
has developed the following electrical safety program to comply with National Fire
Protection Association (NFPA 70E 2009 Edition and CFR 1910 Subpart SElectrical.
2.0 PURPOSE
The purpose of the Electrical Safety Program is to help employees have a better
understanding of how to safely work with and around electrical equipment.
3.0 LOCKOUT/TAGOUT/TRY PROGRAM
University of South Carolina requires that all equipment and systems be deenergized Lockout/Tagout/Tried prior to performing any type of work on the
equipment. The only two exceptions to this program are when continuity of service
is required such as when troubleshooting and diagnostic testing.
Important Note: When working on energized electrical conductors or circuit parts
that are not placed in an electrical safe condition “Lockout/Tagout/Tried” (i.e., for
the reasons of increased or additional hazards or infeasibility per NFPA 70-E
130.1), work to be performed shall be considered energized electrical work and
shall not be perform without a completed written permit. See Appendix A (USC
Energized Electrical Work Permit)
4.0 RESPONSIBILITIES
4.1 Managers and Supervisor
1. Verifies that all employees are trained to the requirements of the Electrical
Safety Program
2. Budgets sufficient funds to execute the Electrical Safety Program
3. Participates in the electrical safety training program.
4. Verifies that all contractors and subcontractors are following the program
requirements.
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4.2 Team leaders
1. Enforces the requirements of the Electrical Safety Program
2. Ensures that employees doing electrical work are properly trained.
3. Secures equipment/PPE necessary to perform electrical work safely.
4.3 Employees
1. Participate in training sessions.
2. Use proper equipment when doing electrical work.
3. Notify supervisor if any electrical equipment appears unsafe.
4. Review and adhere to all Electrical Work requirements set forth in this
program.
4.4 Contractors and Subcontractors
Adhere to the requirements of this program.
5.0 TERMS
5.1 Alternating current (AC) – a flow of electrons which regularly reverses its
direction of flow.
5.2 Ammeter – an instrument used for measuring current.
5.3 Ampacity – the current, in amperes, that a conductor can carry continuously
under the conditions of use without exceeding its temperature rating.
5.4 Ampere (A) – the basic unit of measurement for current.
5.5 Arc - is an electrical discharge generated when two energized conductors are
separated, causing a buildup of heat and gas to cross the gap.
5.6 Arc Flash Protection – the maximum incident energy resistance demonstrated
by a material (or a layered system of materials) prior to degradation or at the onset
of a second-degree skin burn. Arc rating is normally expressed in cal/cm2.
5.7 Battery – a DC electrical power source composed of two or more chemical
cells.
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5.8 Blast – pressure that is generated by an arc can result in an explosion or blast.
5.9 Burns – there are four types of burns:
a. First degree - this is a minor burn to the Epidermis layer of the skin and is
usually superficial. The appearance is red with no blisters. It usually takes
three to six days to heal.
b. Second degree - this is a burn that causes damage to the Epidermis layer
of the skin and the Dermis. All types of second degree burns are listed as
moderate burns.
c. Third degree - this is a critical burn that causes a destruction of all the
Epidermis and Dermis. It goes to the root of the hair follicle. A third degree
burn is called a Full Thickness Burn. It is usually dark
brown and has a leathery appearance. Skin grafting is recommended.
d. Fourth degree - the tissue beneath the skin is burned/destroyed. That
includes the muscles, tendons, ligaments and bones. Skin grafting is usually
needed to close up the areas.
5.10 Capacitor – an electric circuit element used to temporarily store an electric
charge, consisting of two conductors separated by an insulator or dielectric.
Designed to provide a specific amount of storage.
5.11 Circuit – an electrical path having a power source, load and conductors to
carry current.
5.12 Circuit breaker – a device designed to open and close a circuit by
nonautomatic means and to open the circuit automatically on a predetermined
overcurrent without damage to itself when properly applied within its rating.
5.13 Conductive – suitable for carrying electric current.
5.14 Conductor - is a material that allows free motion of a large number of
electrons. It has low resistance to current flow. Aluminum, steel, copper, water and
the human body are all good conductors.
5.15 Conductor, bare – a conductor having no covering or electrical insulation.
5.16 Conduit – specially built tubing to hold wire and protect it from damage.
5.17 Current – the flow of electrons through a conductor, measured in amperes.
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5.18 Dead front – without live parts exposed to a person on the operating side of
the equipment.
5.19 Deenergized – free from any electrical connection to a source of potential
difference and from electrical charge.
5.20 Direct current (DC) – a source of electrical energy where the polarity does not
change and current always flows in the same direction.
5.21 Disconnect – breaks the power to an electrical circuit.
5.22 Electrically safe work condition – a state in which the conductor or circuit
part to be worked on or near has been disconnected from energized parts,
locked/tagged in accordance with established standards, tested to ensure the
absence of voltage, and grounded if determined necessary.
5.23 Electricity – the existence of positive and negative charges and the potential
for a flow of electrons along a conductor.
5.24 Energized – electrically connected to or having a source of voltage.
5.25 Exposed – capable of being inadvertently touched or approached by a person.
It is applied to parts that are not suitably guarded, isolated or insulated.
5.26 Flame-resistant (FR) – the property of a material whereby combustion is
prevented, terminated, or inhibited following the application of a flaming or nonflaming source of ignition, with or without subsequent removal of the ignition
source.
5.27 Flash hazard – a dangerous condition associated with the release of energy
caused by an electric arc.
5.28 Flash Protection Boundary – an approach limit at a distance from exposed live
parts within which a person could receive a second degree burn if an electrical arc
flash were to occur.
5.29 Flash suit – a complete flame retardant clothing and equipment system that
covers the entire body, except for the hands and feet. This includes pants, jacket
and flash hood.
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5.30 Frequency – the number of times a waveform repeats its basic cycle each
second. The unit of measurement is the hertz (Hz).
5.31 Fuse – an electrical device put in a circuit to protect against overloading.
Current above the rating of the fuse will melt the fusible link and open the circuit.
5.32 Fused disconnect - a manual switching device, with fuses, used to disconnect
power from a circuit or load.
5.33 Ground – a conducting connection, whether intentional or accidental, between
an electrical circuit or equipment and the earth, or to some conducting body that
serves in place of the earth.
5.34 Ground fault – an unintentional, electrically conducting connection between
an ungrounded conductor of an electrical circuit and the normally non-currentcarrying conductors, metallic enclosures, metallic raceways, metallic equipment or
the earth.
5.35 Ground-Fault Circuit-Interrupter (GFCI) - a device intended for the protection
of personnel that functions to de-energize a circuit or portion thereof within an
established period of time when a current to ground exceeds the values established
for a Class A device. Class A ground-fault circuit-interrupters trip when the current
to ground is 6 mA or higher and do not trip when the current is less than 4 mA.
5.36 Impedance – measure of opposition to current flow that combines the
opposition from resistance and reactance. The unit of measurement is the OHM.
5.37 Incident energy – the amount of energy impressed on a surface, a certain
distance from the source, generated during an electrical arc event. One of the units
used to measure incident energy is calories per centimeter squared (cal/cm2).
5.38 Insulated – separated from other conducting surfaces by a dielectric
(including space), offering a high resistance to the passage of current.
5.39 Insulator - is a material that does not permit free motion of electrons. It has a
high resistance to current flow. Plastic, rubber, glass and ceramic are all good
insulators.
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5.40 Interrupting rating – the current rating a protective device (fuse or circuit
breaker) can safely interrupt. Interrupting rating is also referred to as ampere
interrupting capacity.
5.41 Limited Approach Boundary – an approach limit at a distance from an
exposed live part within which a shock hazard exists.
5.42 Line side - the wiring and connections on the power line (supply) side of any
electrical transfer device.
5.43 Live parts – energized conductive components.
5.44 Load – the device that is being driven by the source of power. It absorbs the
power from the supply voltage and converts it to heat, light, etc.
5.45 Load side - the wiring and connections on the power output (load) side of any
electrical transfer device.
5.46 Lug – terminal that is soldered or crimped on the end of a wire so that it can
be attached to some part of a circuit.
5.47 Motor control center (MCC) – an assembly of one or more enclosed sections
having a common bus, containing motor control units.
5.48 Motor starter - an automatic (or manual) power switching device, with motor
overload protection for electrical motors.
5.49 Multimeter – an instrument that can measure different values such as voltage,
current and resistance.
5.50 Ohm – the basic unit of measurement for resistance.
5.51 Ohm meter – an instrument that measures electrical resistance.
5.52 Overcurrent – any current in excess of the rated current of equipment or the
ampacity of a conductor. It may result from overload, short circuit or ground fault.
5.53 Overload – to apply excessive load to a device that results in a distorted
output and, in some cases, damages the equipment.
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5.54 Panelboard – a single panel or group of panel units designed for assembly in
the form of a single panel, including buses and automatic overcurrent devices, and
equipment with or without switches for the control of light, heat or power circuits.
5.55 Qualified person – one who has skills and knowledge related to the
construction and operation of the electrical equipment and installations and has
received safety training to recognize and avoid the hazards involved.
5.56 Resistance – the quality of a material to oppose current flow.
5.57 Restricted Approach Boundary – an approach limit at a distance from an
exposed live part within which there is an increased risk of shock, due to electrical
arc over combined with inadvertent movement, for personnel working in close
proximity to the live part.
5.58 Shock hazard – a dangerous condition associated with the possible release of
energy caused by contact or approach to live parts.
5.59 Short circuit – a condition, usually undesirable, where conductors make
contact in such a way that current flows through a contact rather than through the
intended path.
5.60 Step-down transformers – a transformer used to reduce the voltage.
5.61 Switch – an electrical device that opens and closes circuits. The simplest
switches either turn a circuit on or off.
5.62 Switchboard – a large single panel, frame, or assembly of panels on which are
mounted on the face, back or both, switches, overcurrent and other protective
devices, buses and instruments.
5.63 Terminal – a point of electrical connection.
5.64 Transformer – a device that transforms voltage, current and impedance levels
through the interaction of magnetic fields between two coils of wires. Energy is
usually applied to the primary windings, and the transformed result is taken from
the secondary windings.
5.65 Unqualified Person – a person who is not a qualified person and is not
allowed to work on energized electrical equipment.
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Note: Unqualified Persons shall be trained in and familiar with any of the electrical
safety related practices necessary for their safety.
5.66 Volt – the basic unit of measurement for voltage.
5.67 Voltage – the electrical force that causes electrons to flow in a complete
circuit. Measure in volts (V).
5.68 Voltmeter – an instrument for measuring voltage.
6.0 ELECTRICAL SAFETY GENERAL RULES
Always de-energize equipment and systems before performing any type of work on
the equipment. Troubleshooting and performing diagnostic testing on equipment
are the only times employees can perform work on energized equipment.
Note: Job Briefing shall be required before starting each job, the employee in
charge shall conduct a job briefing with the employees involved. The briefing
shall cover such subjects as hazards associated with the job, work procedures
involved, special precautions, energy source controls, and personal protective
equipment requirements. See Appendix B (Job Briefing Checklist)
6.1 Always inspect the equipment before you start to perform the job task. Look
for any tears/cuts in the insulation, loose wires, etc. Always verify that the
equipment is in good working condition!
6.2 Only qualified persons are allowed to work on energized equipment.
Unqualified persons are forbidden to work on energized equipment.
6.3 When things do not look right, or you question the integrity of the electrical
system that you are working on, STOP and contact someone that will be able to
help you. NEVER continue to work if you are unsure of the equipment.
6.4 Expect the unexpected and be alert at all times. A wire pops out of the panel
when you open the door, someone before you left a tool in the panel, wires are old
and the insulation starts to crack and fall apart. NEVER be complacent when
working on electrical equipment.
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6.5 Always wear the required protective clothing and PPE when performing work
on live electrical equipment (>50 V) and position yourself within the Flash
Protection Boundary.
6.6 Never work on or near live electrical equipment when impaired due to illness,
fatigue or other reasons.
6.7 Be alert at all times when working near live parts greater than 50 V.
6.8 Never reach blindly into areas that might contain exposed live parts where an
electrical hazard may exist.
6.9 Do not enter spaces containing live parts unless illumination is provided that
enables you to perform work safely.
6.10 Never work on live electrical equipment where there is a lack of illumination
and/or obstructions preclude observation of the work to be performed.
6.11 All conductive tools and materials (tools, pipes, metal scaffold parts, etc.)
must never come within the Flash Protection Boundary.
6.12 Never enter a Flash Protection Boundary without the required training and
protective clothing and PPE.
6.13 Evaluate and control the work environment.
6.14 Plastic rimmed safety glasses with side shields and rubber soled work boots
are required when working on electrical equipment.
6.15 Wear rubber-insulated gloves with leather protectors when there is a
possibility that your hands may come in contact with an energized conductor.
16. Where possible, only place one hand in the panel at a time. Make sure that the
free hand is not touching a grounded surface, because any current path that
includes the heart (current running from hand to hand) is more likely to result in
heart fibrillation than one that doesn’t.
6.17 Never assume that a piece of equipment is de-energized. Always verify with a
voltmeter.
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6.18 Even after you verify that a piece of equipment is de-energized with a
voltmeter, never grab a deenergized part. Always touch the de-energized part with
the back of the hand first. This will eliminate your exposure to hold-on current.
6.19 Never wear jewelry of any kind while working on electrical equipment. This
includes large metal belt buckles and tool belts.
6.20 Use approved insulated tools when working on an energized conductor.
6.21 Inspect the probes and rubber/plastic stops for cracks and tears before using
them.
6.22 Verify that the meter and probes are rated for the voltage you are measuring.
6.23 Verify that the probes have good continuity before you take electrical
readings.
6.24 Test the voltmeter on a known source (wall outlet) before and after taking
electrical readings.
6.25 Wrap electrical tape around electrical switch contact screws before you place
them back into an electrical box. This will help prevent grounding the switch to the
metal box.
6.26 When turning off a disconnect, stand to the side, face away from the
disconnect, and pull the disconnect to the off position.
6.27 Never open a disconnect under load unless it is an emergency.
6.28 Use ground fault circuit interrupters (GFCI’s) when working with temporary
wiring and / or using electrical power tools and / or equipment.
6.29 When you are not working inside an electrical panel, always keep electrical
panel/cabinet doors closed.
6.30 Never store electrical tools, meters, parts, etc. inside an electrical panel.
6.31 When digging a trench or hole, you must always call the local Diggers
Hotline and identify the utilities before you start to excavate.
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6.32 Before drilling or cutting into a wall, identify where the electrical lines,
cables, phone lines, etc. are located.
6.33 Never stand in a puddle or on a wet surface while working on electrical
equipment.
7.0 BASIC CONCEPTS
7.1 There are three rules that electrical current will always follow.
7.1.1 Electricity always travels in a path of least resistance, and it will always
travel to ground.
7.2 To get an electrical shock, you must become part of the circuit.
7.3 Electricity needs a complete circuit in order to flow. A circuit is any path that
returns to the power source. A broken wire, loose connector, or a switch in the
"off" position will prevent flow. The electricity sits there and waits until the path is
closed, when it continues to flow.
7.4 Understanding the relationship between current, voltage, resistance and power.
7.4.1 Current is the flow of electrons in a circuit and is measured in ampere (A).
Current (Amperes) is a measurement of how many electrons flow through a device.
In a water tank analogy, current would be the flow rate of the water, such as
gallons per minute.
7.4.2 Voltage (V) is the force that moves electrons, forcing a current.
7.4.3 Resistance, measured in Ohms, slows down current flow. The higher the
resistance of a circuit, the lower the current will be. Resistance would be
equivalent to pipe size. If you have the water tank at a high level, but the exit pipe
is small in diameter, there is high resistance and not much water will flow. If you
use a bigger diameter pipe that offers lower resistance, the flow rate will be higher.
7.4.4 Electric power is measured in watt (W). Watts are used to measure the rate
at which electric power is being used in a given amount of time. This is a factor
that must be considered in determining the amount of energy used during a given
period. Usually this is done by multiplying watts by hours. When power is
measured in kilowatts and multiplied by hours, the result is kilowatt-hours.
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7.5 Ohm’s Law
Ohm’s law is the relationships between voltage, current and resistance.
8.0 ELECTRICAL HAZARDS
The three main electrical hazards are shock, arc, and blast.
8.1 Shock
Electricity travels in closed circuits, and its normal route is through a conductor.
Shock occurs when the body becomes a part of the circuit. The current enters the
body at one point and exits at another. Every year employees receive electrical
shocks that result in severe burns and scarring.
There are three primary reasons why these shocks occur:
- Employees perform work on energized electrical equipment, are careless
and become part of the circuit. Most commonly, an employee uses an uninsulated tool and grounds that tool to an energized part.
- Employee fails to de-energized and lockout the system before they perform
service on the equipment.
- Employees’ lockout and tagout the equipment but fail to verify that the
equipment is de-energized.
8.1.1 Factors determining severity of shock.
Shocks can be anything from mild to deadly. The severity of the shock depends on
many factors, including the amount, path and type of current, the exposure length,
the condition of the victim, contact pressure, and skin resistance.
a. Current path
Current may pass through the body from:
 Head to toe
 Arm to leg
 Arm to arm
Arm to arm is the most common flow. This is usually a result of placing
both hands inside a panel when taking electrical readings. To avoid this
situation, University of South Carolina requires employees to use an
alligator clip. The alligator clip is used to complete a contact to the ground.
This allows the employee to work with only one hand inside the panel.
b. Individual heart reaction
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The heart is the most critical organ in the case of an electrical shock. How
the heart will react to an electrical shock depends on the condition of the
individual's heart. Everyone reacts differently to an electrical shock.
c. Skin attributes
The condition of the skin also plays an important role. With very dry skin, a
high voltage shock could produce a severe burn without necessarily
electrocuting the victim. Lower voltage applied to wet or sweaty skin could
cause death without any evidence of burning, particularly if the path of the
current is across the chest.
8.1.2 Range of current and the reaction.
Amount of Current
Less than 1 milliampere
1 – 5 milliampere
5 - 10 milliampere
10 - 20 milliampere
20 - 50 milliampere
50 - 200 milliampere
50 - 200 milliampere
Over 200 milliampere
Reaction
Nothing.
Slight but not painful shock. It is still
possible to let go of the circuit.
Painful shock, but muscles can still be
controlled.
Severe pain, loss of muscle control and
inability to let go of circuit.
Severe pain and labored breathing.
Severe pain, an agitated heart, erratic
heartbeat and possible loss of
consciousness
Severe pain, an agitated heart, erratic
heartbeat and possible loss of
consciousness
Severe pain, serious burns and possible
heart stoppage.
8.1.3 Secondary injuries resulting from an electrical shock. Anything that causes
you to react in an unplanned manner can cause an accident.
Injuries caused by the aftermath of an electrical event include:
 Shock
 Burn
 Hearing loss
 Eye damage
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 Cuts/bruises
 Broken bones
8.1.4 Electricity’s effect on the human body.
a. Electricity’s effect on the human heart.
8.1.4.1 Understanding the human heart and its capabilities.
The blood is the transport system by which oxygen and nutrients reach the body’s
cells and waste materials are carried away. The heart, a muscular organ positioned
behind the ribcage and between the lungs, is the pump that keeps this transport
system moving. Blood leaves the left side of the heart and travels through arteries,
which gradually divide into capillaries. In the capillaries, food and oxygen are
released to the body cells, and carbon dioxide and other waste products are
returned to the bloodstream. The blood then travels in veins back to the right side
of the heart, where it is pumped directly to the lungs. In the lungs, carbon dioxide
is exchanged for oxygen. This renewed blood flows back to the left side of the
heart, and the whole process begins again. It is important that fresh blood from the
aorta goes directly to the brain, because without constant oxygen the brain will be
irreversibly damaged.
8.1.4.2 Exposure to electric current can cause major heart disruptions.
a. Ventricular fibrillation is when the right and left side contractions will
cease to be coordinate. In this state, the little bundles of muscle surrounding
the heart cease to contract in unison and start to tremble or twitch so that no
effective pumping action is produced.
b. Cardiac arrest is when the heart stops completely.
b. Electricity's effect on human muscles.
The negative effect electric current has on muscles is that it causes them to
get shorter or contract.
8.1.5 PULMONARY PARALYSIS. Passage of continuous current through the
chest cavity can cause the chest muscles to contract - constantly - and restrict
breathing. This is called pulmonary paralysis.
8.1.6 HOLD-ON CURRENT.
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Muscles have pairs - flexors and extensors. The flexors are stronger than the
extensors. This means that gripping strength is stronger than releasing ability.
When person grabs an energized electric line, the current goes down their arm to
the muscles, and the current tells the muscles to contract. The hand closes. They
can't open their hand up because the electricity is causing the hand to close, not
their brain. This is called hold-on current. It can happen with even a small amount
of current - as little as 12 milliamperes.
 The danger with hold-on current is that unless you can manage to pull away
or unless somebody cuts the power to the circuit, you're stuck there.
Sometimes the only way to free yourself is to attempt to fall away, letting
your weight physically break you from the contact.
 Remember that if you see someone held-on; first try to de-energize the
equipment by shutting off the power. If necessary, push the individual away
with a nonconductive material (wooden board, etc.).
8.2 Arc
Electric arcs are extremely dangerous because they may produce a flash, cause an
explosion, and generate temperatures in excess of 35,000 degrees Fahrenheit.
There is no material on earth that can withstand this temperature. This heat is four
times greater than the surface temperature of the sun.
Burns are the most frequent injury associated with electric current. Heat is
developed from the combination of current and resistance. The severity of the burn
depends on the degree of thermal energy. This is called the incident energy and is
measured in cal/cm2. Second degree burns result when the skin is exposed to
approximately1.2 cal/cm2. The goal is to protect employees from experiencing
burns greater than second degree burns when they are exposed to an arc flash.
Electrical burns are often more severe than they appear to be from the outside.
Injury occurs not only at the contact site, but also along the path the electricity
takes, and at the exit point. Frequently, there is also extensive muscle damage that
will not be evident from a visual examination of the skin. Deep burns result in
unsightly scars that will often continue to enlarge for 12 – 18 months after the burn
occurs. These scars are not only a cosmetic problem, but may seriously interfere
with joint function. Burns that occur at 140-degrees Fahrenheit or less are
reversible. Burns hotter than that are not. The cells have changed such that the
damage is permanent.
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There are three kinds of burns associated with electrical shock. They are electrical
burns, arc burns, and thermal contact burns.
8.2.1 Arc burns are the result of high temperatures near the body. Arcs can cause
fatal burns within five feet of the arc, and disabling burns within ten feet.
8.2.2 Electrical burns are the result of the electric current flowing through the
tissue or bone. Experts have long believed that tissue damage in burn victims was
caused by heat generated by the passage of current. Recent medical research at the
University of Chicago found that electrical burns cause enlargement of pores in
cell membranes which allow ions to flow freely, leading to cell death. This causes
irreversible damage to the tissue.
8.2.3 Thermal contact burns are those normally experienced when the skin
comes in contact with hot surfaces of overheated electric conductors, conduits, or
other energized equipment. Additionally, clothing may be ignited in an electrical
accident, and a thermal burn will result. All three types of burns may be produced
simultaneously. The degree of burning will depend upon the energy at the point of
contact and its duration. Please be careful when dealing with a burn injury. What
may look like a superficial burn might be severe! The density will be greatest at the
point of contact, and the current may destroy tissue under what appears to be a
superficial skin burn. Medical attention is critical since the dead tissue may be
blocking the bloodstream, resulting in decaying and rotting of the tissue.
8.3 Blast
The blast comes from the pressure developed by the instantaneous heating of the
air surrounding the arc and from the expansion of the metal as it is vaporized.
There are three major hazards that are created by the arc’s blast.
8.3.1 Physical hazards. The electrical energy at the fault is changed into
other forms of energy like high thermal radiation; damaging noise levels;
explosive expansion of surrounding air due to high temperatures; and
vaporization or splattering of conductors and metal components.
8.3.2 The pressure wave is created by a high-energy arcing fault. The
individual that is exposed to the pressure wave will be propelled away,
decreasing their exposure and the burns associated with a fault. The hazard
comes from being propelled into other objects while being thrown. Hearing
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damage and possible concussion can occur. Pressure waves can be strong
enough to propel large objects, like panels, over a distance of many yards.
Pressures have been high enough to knock over a standard construction wall.
8.3.3 Projectiles. The arc will melt electrical components and the pressure
wave will blast the molten particles and other equipment.
9.0 BECOMING PART OF A CIRCUIT
9.1 Ten common electrical hazards in our industry:
 Conductive tools, ladders and equipment used near electrical conductors
 Damaged insulation on electrical cords and tools
 Insulated tool handles with damaged or missing insulation
 No Ground Fault Circuit Interrupter (GFCI) protection when using portable
cords and tools in wet conditions
 Detached conduits, missing covers, defective wiring and other wiring code
violations
 Misuse of electrical testing equipment
 Switches or resets located inside electrical panels
 Exposed wire ends or terminals in crawl spaces, attics and other seldom
visited places
 Broken/missing ground prongs on power cords
 Lack of lockout where circuits should be de-energized before working on
them
9.2 Four common situations that can lead to an electrical shock or arc
9.2.1 Touching an insulated conductor on which the insulation has deteriorated or
been damaged so that it is no longer protective This type of contact commonly
happens when employees are working on old equipment or working on the wiring
of an old building. The majority of contact comes from pulling or pushing on
wires, trying to either arrange them so a measurement can be taken or placing them
back into a box or panel. This pulling and pushing causes the insulation to crack or
break away, exposing the wire.
This is a common hazard when taking an electrical reading from a light switch.
In addition to stress, insulation can fail as a result of experiencing excessively high
voltage, temperature extremes, chemical reactions, or high moisture.
Use extra care with old wiring and insulation that's been exposed to chemicals.
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9.2.2 Another common way employees receive electrical shocks is when
equipment fails, resulting in an open or short circuit. A short circuit occurs when
the conductors bypass the load, since current follows the path of least resistance.
This may occur due to poor electrical contact, failed insulation, or a loose wire or
tool hitting a grounded source.
This is most common when working in a panel or disconnect, and the individual
grounds a screwdriver.
9.2.3 Faulty temporary wiring can also cause shocks. Temporary wiring goes
through wear and tear on a daily basis. This wear and tear can create problems with
the grounding continuity. Once the ground wire becomes damaged and continuity
is lost, the risk of electrical shock greatly increases. The best protection is the use
of a ground-fault circuit interrupter (GFCI).
9.2.4 Drilling and cutting into walls, floors and ceilings are common tasks for
University of South Carolina employees. The hazard lies in striking a hidden
electrical line, cable or other utility. Contact the customer to help you locate any
power lines that may be in your path.
Note: In some rare situations, employees may be required to dig a hole or trench.
Always call your local PUPS Hotline at least three days before doing any
excavation. If you run into a continuous piece of tape while excavating that means
that either an electric, gas, or fiber optic line is below the tape. Stop working
immediately and call your supervisor, customer contact, and your local Diggers
Hotline for help.
10.0 LIVE ELECTRICAL WORK
10.1 Conditions for live electrical work.
This University of South Carolina Program requires all equipment be de-energized
“Lockout/Tagout/Tried” if it is to be worked on. The only two exceptions to this
Program are: When continuity of service is required (troubleshooting and
performing diagnostic testing).
Important Note: When working on energized electrical conductors or circuit parts
that are not placed in an electrical safe condition “Lockout/Tagout/Tried” (i.e., for
the reasons of increased or additional hazards or infeasibility per NFPA 70-E
130.1), work to be performed shall be considered energized electrical work and
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
shall not be perform without a completed written permit. See NFPA 70-E 2009
Edition Annex J “Energized Electrical Work Permit”
10.2 Arc flash boundaries
There are four boundaries that need to be taken into consideration when
approaching exposed energized conductors. Employees that approach any of these
boundaries need to protect themselves from two primary hazards: Arcing, and
Shock. An arcing fault which can result from mechanical failure or human error is
created when current flows through the air between phase conductors, or phase
conductors and neutral or ground. Arcs can be produced by dropping tools,
accidental contact with energized components, or through the use of improper
work procedures. In addition to temperatures as high as 35,000°F, an arc can
generate a flash and blast that can create molten metal, pressure and sound waves,
shrapnel, and intense light. Shock can occur when a part of the body completes a
circuit between two conductors or a grounding source.
Only authorized employees are allowed to work within the following four
boundaries. Unauthorized workers are not allowed to work within any of the four
boundaries.
The four boundaries are:
a. Flash Protection Boundary – The distance from exposed live parts within
which a person could receive a second degree burn if an electrical arc flash
were to occur.
b. Limited Approach Boundary – The distance from an exposed live part
within which a shock hazard exists.
c. Restricted Approach Boundary – The distance from an exposed live part
within which there is an increased risk of shock due to an electrical arc,
combined with inadvertent movement, for individuals working in close
proximity to the live part.
d. Prohibited Approach Boundary – The distance from an exposed live part
within which work is considered the same as making contact with the live
part.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Nominal System
Voltage Range,
Phase to Phase
Less than 50
50 to 300
301 to 750
751 to 15 kV
15.1 kV to 36 kV
36.1 kV to 46 kV
46.1 kV to 72.5 kV
72.6 kV to 121 kV
138 kV to 145 kV
161 kV to 169 kV
230 kV to 242 kV
345 kV to 362 kV
500 kV to 550 kV
765 kV to 800 kV
Exposed Movable
Conductor
Exposed Fixed
Circuit Part
Not specified
3.05m (10 ft 0in)
3.05 m (10 ft 0 in.)
3.05 m (10 ft 0 in.)
3.05 m (10 ft 0 in.)
3.05 m (10 ft 0 in.)
3.05 m (10 ft 0 in.)
3.25 m (10 ft 8 in.)
3.36 m (11 ft 0 in.)
3.56 m (11 ft 8 in.)
3.97 m (13 ft 0 in.)
4.68 m (15 ft 4 in.)
5.8 m (19 ft 0 in.)
7.24 m (23 ft 9 in.)
Not specified
1.07 m (3 ft 3 in.)
1.07 m (3 ft 6 in)
1.53 m (5 ft 0 in.)
1.83 m (6 ft 0 in.)
2.44 m (8ft 0 in.)
2.44 m (8 ft 0 in.)
2.44 m (8 ft 0 in.)
3.05 m (10 ft 0 in.)
3.56 m (11 ft 8 in.)
3.97 m (13 ft 0 in.)
4.68 m (15 ft 4 in.)
5.8 m (19 ft 0 in.)
7.24 m (23 ft 9 in.)
Restricted
Approach
Boundary
Not specified
Avoid contact
304.8 mm (1 ft 0 in.)
660.4 mm (2 ft 2 in)
787.4 mm (2 ft 7 in.)
838.2 mm (2 ft 9 in.)
965.2 mm (3 ft 3 in.)
991 mm (3 ft 4 in.)
1.093 m (3 ft 10 in.)
1.22 m (4 ft 3 in.)
1.6 m (5 ft 8 in.)
2.59 m (9 ft 2 in.)
3.43 m (11 ft 10 in.)
4.55 m (15 ft 11 in.)
Prohibited
Approach
Boundary
Not specified
Avoid contact
25.4 mm (0ft 1 in.)
177.8 mm (0 ft 7 in.)
431.8 mm (1 ft 5 in.)
431.8 mm (1 ft 5 in.)
635 mm (2 ft 2 in.)
812.8 mm (2 ft 9 in.)
939.8 mm (3 ft 4 in.)
1.07 m (3 ft 9 in.)
1.45 m (5 ft 2 in.)
2.44 m (8 ft 8 in.)
3.28 m (11 ft 4 in.)
4.4 m (15 ft 5 in.)
10.3 Electrical exposure
Employees who are working on energized electrical equipment greater than 50 V
and are working within the Flash Protection Boundary are considered to be
EXPOSED and need to wear the appropriate clothing and personal protective
equipment.
 Factors influencing the need/type of personal protective equipment (PPE)
10.3.1 Evaluate the equipment that you are working on and the tasks that you need
to perform. Ask yourself these eight questions. To determine whether or not the
standard UNIVERSITY OF SOUTH CAROLINAPPE/uniform guidelines apply to
the work that you are performing. If the standard guidelines do not apply please
contact your supervisor.
a. Is the equipment in good condition or does something look unusual?
If the equipment looks dented, smashed, broken, etc. please stop work
immediately and contact your supervisor.
b. Will the circuit breaker protecting the equipment actually work?
For example, some breakers have never been exercised and may not work
when necessary. It is common practice to exercise breakers every two to
three years.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
If you believe the breaker will not work when it needs to because of its poor
or damaged condition, please stop work and contact your supervisor.
c. How close will you be to the exposed energized components?
Because the risk becomes greater the closer you are to the arc/flash, you may
need to wear additional/alternative PPE.
d. How much current is there? The greater the amount of amps available
means the greater energy potential.
e. How close are you to the power source?
Fault current decreases the farther you are from the “up stream” power
source. For example, the fault current would be much higher if you were
working on a 480 V chiller starter 30 feet from its power source than if you
were working on a roof top unit 500 feet away. The closer the power source
the greater the fault current.
f. Can you keep those around you at least six feet away from the exposed
live conductors? If this could be a problem use red “DO NOT ENTER” tape
to restrict access.
Do not carry on conversations with workers, contractors, subcontractors,
customers, etc. who are not wearing the required uniform or PPE within the
flash protection boundary.
g. Will you be working on the equipment at an elevated level such as a
ladder, platform or roof?
When working on energized equipment, make note of where you are
standing and how your body is positioned. If you were to become part of the
circuit, could you be freed without being exposed to a secondary hazard that
is also life threatening (ie. fall from a ladder, etc.) or limit your ability to be
freed because of limited access?
h. What are the consequences if something goes wrong?
Never make the assumption that an arc flash will not happen to you. Be
prepared and follow the required safe work practices when working on live
electrical equipment!
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
10.4 Incident Energy
Incident energy is the amount of energy created by an arc flash and is measured in
calories per square centimeter (cal/cm2). The following three factors contribute to
the amount of energy that is created by an arc flash.
a. Magnitude of the arc flash – the greater the amount of amps available
means the greater energy potential.
b. Length of the blast – the longer the blast continues the greater the energy
released.
c. Distance from the flash source - incident energy decreases as distance
from the flash source increases.
10.5 Protective devices
The amount of energy released during an arcing fault is based on two
characteristics of the protective device protecting the affected circuit. These two
characteristics are:
a. The time it takes the protective device to open.
b. The amount of fault current the protective device allows through.
For example: the faster the fault is cleared by the protective device, the
lower the amount of energy released. If the protective device can also limit
the current, reducing the actual fault current flowing through the arc, the
lower the energy released.
10.6 Interrupting rating
NOTE: Please use the following as a guideline only. Be careful when relying on
circuit breakers for protection, as they are just like other mechanical devices. If
they are not maintained properly, are located in a dirty environment, or are exposed
to airborne chemicals, they may not operate as you’d expect.
The current rating a protective device (fuse or circuit breaker), can safely interrupt.
Interrupting rating is also referred to as ampere interrupting capacity.
Circuit breakers can be rated in various increments between 5,000 A (the minimum
rating allowed) and 200,000 A. The interrupting rating is dependent upon voltage.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
The interrupting rating on a circuit breaker at 240 V may equal 18,000 A.
However, the same circuit breaker at 480 V has an interrupting rating of 14,000 A.
The following table identifies interrupting ratings for some common breakers and
fuses:
Circuit Breakers
15 A 120 V circuit breaker
20 A 240 V circuit breaker
30 A 120/240 V circuit breaker
20 A 240 V circuit breaker
20 A 277 V circuit breaker
100 A 600 V circuit breaker
Fuse
FRN 3.5 A 250 V fuse
FRS-R 30 A 600 V fuse
FRN-R 60 A 250 V fuse
FRN 200 A 250 V fuse
Rating
10,000 A
10,000 A
10,000 A
1 ph 10,000 A 3 ph 5,000 A
277 V ~14,000 A 125 DC 10,000 A
600 V 14,000 A 480 V 14,000 A 240 V 18,000 A
Rating
200,000 A
200,000 A
200,000 A
100.000 A
As shown above, circuit breakers have lower interrupting ratings than fuses.
Knowing how the equipment being worked on is protected—by either a circuit
breaker or fuse, will help establish the interrupting rating of that equipment and the
personal protective and safety equipment required when working on it. Equipment
protected by circuit breakers rated for interrupting ratings of 10,000 A and below
allow a decrease in the hazard class by one.
10.7 Using PPE
When working within the Flash Protection Boundary (exposure to incident energy
greater than 1.2 cal/cm2), employees are required to wear the required personal
protective and safety equipment. Employees not wearing the appropriate protective
clothing and equipment must stay outside of the Flash Protection Boundary at all
times.
a. All employees are required to wear safety glasses with side shields at all
times!
b. Meltable fibers like nylon, polyester and spandex cannot be worn as an
outer or under layer when working within a Flash Protection Boundary with
exposed live energized parts greater than 50 V.
c. All PPE must be inspected prior to use including FR uniforms and
coveralls. Defective equipment will be taken out of service immediately.
23
[SAMPLE USC SAFETY PROGRAM] August 26, 2010
d. FR clothing must cover all ignitable clothing.
e. FR clothing and PPE must allow the employee to move freely and allow
for good visibility.
f. Tight-fitting FR clothing must not be allowed due to the decrease in
protection. Loose fitting FR clothing provides air gaps that increase the level
of thermal protection.
g. FR clothing must fit properly so that it does not interfere with the work
task.
2. Washing/drying/repairing Indura cotton FR clothing
When washing, drying and repairing Indura cotton (FR clothing), the
following considerations apply:
a. Always pre-wash your FR clothing prior to wearing it for the first time.
This will remove any residual chemicals on the fabric from the
manufacturing process. The washing temperature should not exceed 160 F.
b. Do not wash your FR garments with any other garments. Fibers from the
non-FR clothing can accumulate on the FR garments and ignite during a
flash arc.
c. Do not bleach FR garments when washing. Bleaching will reduce the
flame resistant qualities.
d. Tumble dry your garments and remove them immediately from the dryer.
To help reduce shrinkage they should be left a little damp. Do not leave the
garments sitting in a hot dryer when the tumbler is not in motion. Do not use
drying temperatures above 160 F.
e. Repairs must be done using FR approved thread and patching material.
Note: The following is from the NFPA 70E 2009 Edition tables 130.7 (C) (9)
and 130.7 (C) (10).
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Table 130.7(C) (9) Hazard/Risk Category Classifications and Use of Rubber Insulating Gloves and Insulated
and Insulating Hand Tools
Task Performed
Equipment 240 V and
Below
Inspection outside the
restricted approach
boundary
Circuit breaker (CB) or
fused switch operation
with covers on
CB or fused operation
with covers off
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
0
N
N
0
N
N
0
N
N
1
Y
Y
1
Y
Y
Removal of bolted covers
1
N
N
Opening hinged covers
0
N
N
1
Y
Y
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
1
N
N
0
N
N
1
Y
N
2*
Y
Y
2*
Y
Y
Working on energized
parts, including voltage
testing
Remove/install CBs or
fused switches
Working on energized
electrical conductors and
circuit parts of utilization
equipment fed directly by
branch circuit of the
panelboard
Task Performed
Equipment >240 V and up
to 600 V
Inspection outside the
restricted approach
boundary
Circuit breaker (CB) or
fused switch operation
with covers on
CB or fused operation
with covers off
Working on energized
parts, including voltage
testing
Working on energized
electrical conductors and
circuit parts of utilization
equipment fed directly by
branch circuit of the
panelboard
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
600 V Class Motor Control
Centers (MCCs) - Note 2
(except as indicated)
1
N
N
CB or fused switch or starter
operation with enclosure doors
closed
0
N
N
Reading a panel meter while
operating a meter switch
0
N
N
CB or fused switch or starter
operation with enclosure doors
open
1
N
N
2*
Y
Y
0
Y
Y
2*
Y
Y
4
Y
Y
2*
Y
Y
Removal of bolted covers (to
expose bare, energized electrical
conductors and circuit parts) Note 3
4
N
N
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts) Note 3
1
N
N
Work on energized electrical
conductors and circuit parts of
utilization equipment fed directly
by a branch circuit of the
.motor control center
2*
Y
Y
Perform infrared thermography
and other non-contact inspections
outside the restricted approach
boundary
Work on energized electrical
conductors and circuit parts,
including voltage testing
Work on control circuits with
energized electrical conductors
and circuit parts 120 V or below,
exposed
Work on control circuits with
energized electrical conductors
and circuit parts > 120 V,
exposed
Insertion or removal of
individual starter "buckets" from
MCC - Note 3
Application of safety grounds,
after voltage test
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
Perform infrared thermography
and other non-contact inspections
outside the restricted approach
boundary
2
N
N
CB or fused switch operation
with enclosure doors closed
0
N
N
Reading a panel meter while
operating a meter switch
0
N
N
CB or fused switch operation
with enclosure doors open
1
N
N
Work on energized electrical
conductors and circuits parts,
including voltage testing
2*
Y
Y
0
Y
Y
2*
Y
Y
4
N
N
2*
Y
N
Removal of bolted covers (to
expose bare, energized electrical
conductors and circuit parts)
4
N
N
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts)
2
N
N
2*
N
N
1
N
N
600 V Class Switchgear (with
power circuit breakers or fused
switches) - Note 4
Work on control circuits with
energized .electrical conductors
and circuit parts 120 V or below,
exposed
Work on control circuits with
energized electrical conductors
and circuit parts >120 V,
exposed
Insertion or removal (racking) of
CBs from cubicles, doors open or
closed
Application of safety grounds,
after voltage test
Other 600 V Class (277 V
through 600 V, nominal)
Equipment - Note 2 (except as
indicated)
Lighting or small power
transformers (600 V, maximum)
Removal of bolted covers (to
expose bare, energized electrical
conductors and circuit parts)
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts)
27
[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
Work on energized electrical
conductors and circuit parts,
including voltage testing
2*
Y
Y
Application of safety grounds,
after voltage test
2*
Y
N
Revenue meters (kW-hour, at
primary voltage and current) Insection or removal
2*
Y
N
Cable trough or tray cover
removal or installation
1
N
N
Miscellaneous equipment cover
removal or installation
1
N
N
Work on energized electrical
conductors and circuit parts, including voltage testing
2*
Y
Y
Application of safety grounds,
after voltage test
2*
Y
N
Insertion or removal of plug-in
devices into or from busways
2*
Y
N
Perform infrared thermography
and other non-contact inspections outside the restricted
approach boundary
3
N
N
Contactor operation with
enclosure doors closed
0
N
N
Reading a panel meter while
operating a meter switch
0
N
N
2*
N
N
Work on energized electrical
conductors and circuit parts, including voltage testing
4
Y
Y
Work on control circuits with
energized electrical conductors
and circuit parts 120 V or below,
expos d
0
Y
Y
Work on control circuits with
energized electrical conductors
and circuit parts >120 V,
exposed
3
Y
Y
Insertion or removal (racking) of
starters from cubicles, doors
open or closed
4
N
N
NEMA E2 (fused contactor)
Motor Starters, 2.3 kV
Through 7.2 kV
Contactor operation with
enclosure doors open
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
Application of safety grounds,
after voltage test
3
Y
N
Removal of bolted covers (to
expose bare, energized electrical
conductors and circuit parts)
4
N
N
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts)
3
N
N
Insertion or removal (nicking) of
starters from cubicles of
arc-resistant construction, tested
in accordance with IEEE
C37.20.7, doors closed only
0
N
N
Perform infrared thermography
and other non-contact inspections
outside the restricted approach
boundary
3
N
N
CB operation with enclosure
doors closed
2
N
N
Reading a panel meter while
operating a meter switch
0
N
N
CB operation with enclosure
doors open
4
N
N
Work on energized electrical
conductors and circuit parts,
including voltage testing
4
Y
Y
Work on control circuits with
energized electrical conductors
and circuit parts 120 V or below,
exposed
2
Y
Y
Work on control circuits with
energized electrical conductors
and circuit parts >120 V,
exposed
4
Y
Y
Insertion or removal (racking) of
CBs from cubicles, doors
open or closed
4
N
N
Application of safety grounds,
after voltage test
4
Y
N
Removal of bolted covers (to
expose bare, energized
electrical conductors and circuit
parts)
4
N
N
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts)
3
N
N
Metal Clad Switchgear, 1kV
Through 38 kV
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
4
N
N
CB operation with enclosure
door closed
0
N
N
Insertion or removal (racking) of
CBs from cubicles, doors
closed
0
N
N
Insertion or removal of CBs from
cubicles with door open
4
N
N
Work on control circuits with
energized electrical conductors
and circuit parts 120 V or below,
exposed
2
Y
Y
Insertion or removal (racking) of
ground and test device with door
closed
0
N
N
Insertion or removal (racking) of
voltage transformers on or off the
bus door closed
0
N
N
Switch operation of arc-resistanttype construction, tested in
accordance with IEEE C37.20.7,
doors closed only
0
N
N
Switch operation, doors closed
2
N
N
Work on energized electrical
conductors and circuit parts,
including voltage testing
4
Y
Y
Removal of bolted covers (to
expose bare, energized electrical
conductors and circuit parts)
4
N
N
Opening hinged covers (to
expose bare, energized electrical
conductors and circuit parts)
3
N
N
Opening voltage transformer or
control power transformer
compartments
Arc-Resistant Switchgear Type
1or 2 (for clearing times
of <0.5 see with a perspective
fault current not to
exceed the arc resistant rating
of the equipment)
Other Equipment 1 kV
Through 38 kV
Metal-enclosed interrupter
switchgear, fused or unfused
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Task Performed
Hazard/Risk
Rubber Insulating Gloves
Insulated Hand Tools
Outdoor disconnect switch
operation (hooks tick operated)
3
Y
Y
Outdoor disconnect switch
operation (gang-operated, from
grade)
2
Y
N
Insulated cable examination, in
manhole or other confined space
4
Y
N
Insulated cable examination, in
open area
2
Y
N
General Notes (applicable to the entire table):
(a) Rubber insulating gloves are gloves rated for the maximum line-to-line voltage upon which
work will be done.
(b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line
voltage upon which work will be done, and are manufactured and tested in accordance with
ASTM F 1505, Standard Specification for Insulated and Insulating Hand Tools.
(c) Y = yes (required), N = no (not required).
(d) For systems rated less than 1000 volts, the fault currents and upstream protective device
clearing times are based on an 18 in. working distance.
(e) For systems rated 1 kV and greater, the Hazard/Risk Categories are based on a 36 in. working
distance.
(f) For equipment protected by upstream current limiting fuses with arcing fault current in their
current limiting range (V2 cycle fault clearing time or less), the hazard/risk category required
may be reduced by one number.
Specific Notes (as referenced in the table):
1. Maximum of 25 kA short circuit current available; maximum of 0.03 see (2 cycle) fault
clearing time.
2. Maximum of 65 kA short circuit current available; maximum of 0.03 sec (2 cycle) fault
clearing time.
3. Maximum of 42 kA short circuit current available; maximum of 0.33sec (20 cycle) fault
clearing time.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
4~Maximum of 35 kA short circuit current available; maximum of up to 0.5 see (30 cycle) fault
clearing time.
Below are 4 examples of task performed with PPE and tool requirements:
 Tasks Preformed on Energized Equipment Panelboards or Other Equipment Rated
240 V and Below
Operation of circuit breaker with covers on
 Clothing - Nonmelting or Untreated Natural Fibers or FR Shirt (long sleeve), Pants
(long)
 Safety Glasses (nonconductive)
 Hearing Protection
 Leather Gloves (as needed)
 Tasks Preformed on Energized Equipment Panelboards or Other Equipment Rated
240 V and Below
Working on energized electrical conductors and circuit parts, including voltage
testing within 4 ft











FR clothing, minimum Arc Rating of 4
Shirt (long sleeve)
Pants (long) Or Coveralls
Arc-rated face or flash suit hood
Hard Hat (E-rated)
Safety Glasses (nonconductive)
Hearing Protection
Insulated Gloves
Leather Work Shoes (nonconductive)
Electrical Rated Tools
Barricade with safety signs
_____________________________________________________________________________________
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
 Tasks Preformed on Energized Equipment Panelboards or Switchboards Rated
>240 V up to 600 V (Fixed Circuit Part) within 4 ft
Circuit breaker switch operations with covers off











FR clothing, minimum Arc Rating of 4
Shirt (long sleeve)
Pants (long) Or Coveralls
Arc-rated face shield or flash suit hood
Hard Hat (E-rated)
Safety Glasses (nonconductive)
Hearing Protection
Insulated Gloves
Leather Work Shoes (nonconductive)
Electrical Rated Tools
Barricade with safety signs
 Tasks Preformed on Energized Equipment Panelboards or Switchboards Rated
>240 V up to 600 V (Fixed Circuit Part) within 4 ft
Working on energized electrical conductors and circuit parts, including voltage testing











FR clothing, minimum Arc Rating of 8
Shirt (long sleeve)
Pants (long) or Coveralls
Arc-rated face shield and sock hood or flash suit hood
Hard Hat (E-rated)
Safety Glasses (nonconductive)
Hearing Protection
Insulated Gloves
Leather Work Shoes (nonconductive)
Electrical Rated Tools
Barricade with safety signs
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Table 130.7(C) (10) Protective Clothing and Personal Protective Equipment (PPE)
Hazard/Risk Category
Hazard/Risk Category 0
Protective Clothing, Nonmelting (according to
ASTM F 1506-00) or Untreated Natural Fiber
FR Protective Equipment
Hazard/Risk Category 1
FR Clothing, Minimum Arc Rating of 4 (Note 1)
Hazard/Risk Category 2
FR Clothing, Minimum Arc Rating of 8 (Note 1)
Hazard/Risk Category 2*
FR Clothing, Minimum Arc Rating of 8 (Note 1)
Hazard/Risk Category 3
FR Clothing, Minimum Arc Rating of 25 (Note 1)
Protective Clothing and PPE
Shirt (long sleeve)
Pants (long)
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Leather gloves (AN) (Note 2)
Arc-rated long-sleeve shirt (Note 3)
Arc-rated pants (Note 3)
Arc-rated coverall (Note 4)
Arc-rated face shield or arc flash suit hood (Note 7)
Arc-rated jacket, parka, or rainwear (AN)
FR Protective Equipment Hard hat I
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Leather gloves (Note 2)
Leather work shoes (AN)
Arc-rated long -sleeve shirt (Note 5)
Arc-rated pants (Note 5)
Arc-rated coverall (Note 6)
Arc-rated face shield or arc flash suit hood (Note 7)
Arc rated jacket, parka, or rain wear (AN)
Hard hat
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Leather gloves (Note 2)
Leather work shoes
Arc-rated long-sleeve shirt (Note 5)
Arc-rated pants (Note 5)
Arc-rated coverall (Note 6)
Arc-rated arc flash suit hood (Note 10)
Arc-rated jacket, parka, or rainwear (AN)
Hard hat
Safety glasses or safety goggles (SR)
Hearing protection (ear 'canal inserts)
Leather gloves (Note
Arc-rated long-sleeve shirt (AR) (Note 8)
Arc-rated pants (AR) (Note 8)
Arc-rated coverall (AR) (Note 8)
Arc-rated arc flash suit jacket (AR) (Note 8)
Arc-rated arc flash suit pants (AR) (Note 8)
Arc-rated arc flash suit hood (Note 8)
Arc-rated jacket, parka, or rainwear (AN)
Hard hat
FR hard hat liner (AR)
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Arc-rated gloves (Note 2)
Leather work shoes
Hazard/Risk Category 4
FR Clothing, Minimum Arc Rating of 40 (Note 1)
Arc-rated long-sleeve shirt (AR) (Note 9)
Arc-rated pants (AR) (Note 9)
Arc-rated coverall (AR) (Note 9)
Arc-rated arc flash suit jacket (AR) (Note 9)
Arc-rated arc flash suit pants (AR) (Note 9)
Arc-rated arc flash suit hood (Note 9)
Arc-rated jacket, parka, or rain wear (AN)
Hard hat
FR hard hat liner (AR)
Safety glasses or safety goggles (SR)
Hearing protection (ear canal inserts)
Arc-rated gloves (Note
Leather work shoes
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
AN = As needed (optional)
AR = As required
SR = Selection required
Notes:
1. See Table 130.7(C) (1l). Arc rating for a garment or system of garments is expressed in cal/cm".
2. If rubber insulating gloves with leather protectors are required by Table 130.7(C) (9), additional leather
or arc-rated gloves are not required. The combination of rubber insulating gloves with leather protectors
satisfies the arc flash protection requirement.
3. The FR shirt and pants used for Hazard! Risk Category 1 shall have a minimum arc rating of 4.
4. Alternate is to use FR coveralls (minimum arc rating of 4) instead of FR shirt and FR pants.
5. FR shirt and FR pants used for Hazard! Risk Category 2 shall have a minimum arc rating of 8.
6. Alternate is to use FR coveralls (minimum arc rating of 8) instead of FR shirt and FR pants.
7. A face shield with a minimum arc rating of 4 for Hazard/Risk Category I or a minimum arc rating of 8
for Hazard/Risk Category 2, with wrap-around guarding to protect not only the face, but also the
forehead, ears, and neck (or, alternatively, an arc-rated arc flash suit hood), is required.
8. An alternate is to use a total FR clothing system and hood, which shall have a minimum arc rating of
25 for Hazard/Risk Category 3.
9. The total clothing system consisting of FR shirt and pants and/or FR coveralls and/or arc flash coat and
pants and hood shall have a minimum arc rating of 40 for Hazard/Risk Category 4.
10. Alternate is to use a face shield with a minimum arc rating of 8 and a balaclava (sock hood) with a
minimum arc rating of 8 and which covers the face, head and neck except for the eye and nose areas.
10.8 Labeling requirements
University of South Carolina is responsible for complying with NEC labeling
requirements. Complying with the labeling requirements is not the responsibility
of the equipment manufacturers or installers.
All switchboards, panel boards, industrial control panels and motor control centers
installed after 2002 needs to be labeled to warn against possible Arc Flash Hazard.
Equipment installed before 2002 must be labeled when modified or upgraded.
Note: All electrical panels and equipment must be kept clear and free from
obstacles at all times.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
There are several types of labels ranging from basic to labels that have the specific
hazard analysis information including the Flash Protection Boundary, Flash Hazard
Category, Arc Rating (cal/cm2) and PPE requirements.
Example Label:
10.9 Insulated tools
UNIVERSITY OF SOUTH CAROLINA employees should never be working on
or near energized parts with any type of hand tools. However, there may be some
special circumstances that will require the use of insulated tools.
Insulated tools will be used whenever tools might make accident contact with
energized parts. Insulated tools will be:
10.9.1 Rated for the voltage that is present.
10.9.2 Inspected prior to use.
10.9.3 Constructed with two color layer insulation so that a visual inspection
can detect insulation damage.
10.9.4 Properly stored and maintained.
11.0 EQUIPMENT
11.1 Common electrical equipment in the HVAC field.
Please keep in mind that when working with panels and disconnects, there can be
two or more sources of power. Usually the second source is the control voltage.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
The only way that you can determine how many power sources are in a panel is by
examining the panel and using your voltmeter to verify that either the equipment is
energized or de-energized.
11.2 Starter panel.
STARTER PANELS can be considered as just big on-off switches. The job of the
starter panel is to provide power to run the load when needed, and to shut off the
power to the load off when it is not needed. The power enters the panel and travels
to the panels on/off master disconnect switch fuses, and down and out to the line
side of the contactors. If the contactors’ coils are not energized, the line power is
interrupted. When the contactor coils are energized, contact is made and power
flows out of the panel to the load.
11.3 Hand-off-auto switch.
Please note that when working on equipment that has a hand-off-auto or on-offauto switch, the switch may not be wired to perform the functions that are labeled
on the switch. There is equipment that can be damaged if left on for a period of
time.
For example: A compressor may have an on-off-auto switch but the on side of the
switch is not wired. This is done so that the compressor is not accidentally left in
the on mode. If left on, the compressor would run until it burned out.
11.4 Control panel.
The CONTROL PANEL gives the starter panel the information it needs to activate
the starters and motors. The control panel may have many sources of power but in
most cases the power to energize the starter contacts comes from a control
transformer in the starter panel. The step down transformer may provide a fused
120-volt power supply.
11.5 Motor control center.
The MOTOR CONTROL CENTER provides power to the system loads. These
loads may include the motors, circulation pumps, and dehumidification. Signals are
sent from the various control panels to the motor control center to activate or deactivate the loads. This center may have a series of operations going on
simultaneously and may be the “trigger” for other systems.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
For example, before a chiller can start up, the circulation pumps need to be
operating. A signal confirming operation is sent from the motor control center to
the starter panel, permitting start up of the chiller.
The MCC is like a large breaker with a bus-like-grid that feeds the power to the
individual disconnects or “cans”. The line side of the disconnect will stay hot
unless you either de-energize the entire MCC, or pull the entire disconnect from
the bus. Since the MCC is controlling a number of different pieces of equipment,
de-energizing the MCC is normally never done. Pulling the disconnect represents a
number of different hazards since you are pulling it from a live bus. If you do not
have a clean pull (removing) or a clean push (installing) you could create an arc. If
the equipment is faulty or old, you may snap off the blade that makes contact with
the bus, causing an arc. Remember that you want to avoid any practices that could
create an arc. When you de-energize the disconnect you should test all “LOAD
SIDE” equipment (fuses, transformers, starters, etc.) and verify they are deenergized prior to working on the piece of equipment.
Since the MCC is an intertwining of loads, there are multiple relays and power
sources. Just because you have locked out one power source does not mean that a
second power source is not present. Failure to take this into consideration may
cause an electrical shock or arc.
11.6 Disconnect.
DISCONNECTS are devices that manually remove power from a starter or MCC.
It may be a circuit breaker, knife switch or some other positive action switch.
Disconnects can be designed to remove power from a single component or an
entire system. In no case, unless for an emergency, should a disconnect be used as
a START/STOP switch. Never shut off a disconnect under load!
11.7 Capacitor.
Locking out a capacitor does not mean that it has been de-energized!
If the capacitor is large enough to have its own disconnect, when you disconnect
the capacitor no energy will be allowed to run through the contacts. HOWEVER, if
you have to work on the capacitor, it may still be charged!
You can de-energize a capacitor by using your voltmeter. Take your alligator clip
to ground and take your probe to hot. Please make sure you discharge both sides!
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
NEVER use a screwdriver to discharge a capacitor.
NEVER assume that the capacitor is discharged unless you test it with your meter.
11.8 How to safely shut a disconnect off.
You must always, without exception, shut all disconnects off by standing to the
side facing away and, with one swift motion, shut the disconnect to the off
position. This way, if something malfunctions you will not be in the way of any
flash, blast, and projectiles that will be created by the arc.
When turning a disconnect on or off, always remember to use a swift motion,
because if there is a hesitation, the knives or blades may not fully engage or
disengage causing an arc. Most disconnects have a spring action device that slams
the knives or blades in or out of position.
11.9 Line side and load side.
The area where outside power comes into the panel and connects to the first
contact is called the LINE SIDE. The line side will always stay energized unless
you go to an outside disconnect and shut it off. When working inside the panel you
must always keep this in mind. If you bump the contacts with a screwdriver or
metal tool, you may cause an arc!
The voltage coming off the contact is called the LOAD SIDE.
11.10 Single-phase and three-phase.
The difference between single and three-phase is that, for single-phase, only one
voltage wave and one current wave exists, which means the AC voltage wave is
exactly the same throughout the system. The three-phase system uses three lines
called either phase legs or lines. Unlike single-phase systems, the time relationship
of the voltage wave in each line differs. The most widely used polyphase system in
the United States is the three-phase system.
12.0 MULTIMETER
The following steps should be followed to verify that your multimeter is properly
functioning. We are using the Fluke 87 multimeter for this example; the steps will
be the same regardless of the brand of multimeter you use.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
12.1 These steps should be done prior to using the meter:
 Inspect test leads and rubber stops for cracks and tears in the
insulation. Only test leads with rubber stops are allowed to be used.
The rubber stops help protect your fingers from coming in contact
with the circuit.
 Plug the black test lead into the common jack
 Plug the red test lead into the voltage jack
 Set the function switch to resistance
 Push the Peak Min/Max button
 Verify that the test leads have good continuity by touching the tips
together. You should hear a steady beep.
 Set the function switch to Volts AC
Note: Remember that you must wear safety glasses with side shields and rubber
soled work boots when performing work on electrical equipment. Also, never wear
jewelry of any kind while working on electrical equipment. This includes large
metal belt buckles and tool belts.
 Test the meter on a known source.
 The meter is now ready to be used.
12.2 The following steps should be followed when verifying that an electrical
energy source has been deenergized:
We will use a basic three-phase 480 V disconnect as an example.
These steps should be done prior to using the meter:
 Inspect test leads and rubber stops for cracks and tears in the
insulation. Only test leads with rubber stops are allowed to be used.
The rubber stops help protect your fingers from coming in contact
with the circuit.
 Plug the black test lead into the common jack
 Plug the red test lead into the voltage jack
 Set the function switch to resistance
 Push the Peak Min/Max button
 Verify that the test leads have good continuity by touching the tips
together. You should hear a steady beep.
 Set the function switch to Volts AC
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Note: Remember that you must wear safety glasses with side shields and
rubber soled work boots when performing work on electrical equipment.
Also, never wear jewelry of any kind while working on electrical equipment.
This includes large metal belt buckles and tool belts.
 Test the meter on a known source.
 The meter is now ready to be used.
 Evaluate the work area and equipment that you are going to be
working on. Make sure that there is no water on the floor, equipment
is in good condition (no dents, loose controls, etc.) and nothing is on
top of the disconnect that could fall and create an arc.
 Stand to the side, face away from the disconnect, and with one swift
motion snap the disconnect to the off position. Standing to the side
carefully open the disconnect and expect the unexpected – wire pops
out of the panel when you open the door, someone before you left a
tool in the panel, wires are old and the insulation starts to crack and
falls apart. NEVER feel complacent when working on electrical
equipment.
 Evaluate the inside of the cabinet. Verify that everything inside the
cabinet is in good working condition. When things do not look right,
or you question the integrity of the electrical system that you are
working on, STOP and contact someone who will be able to help you.
NEVER continue to work on if you are unsure of the equipment.
 During the evaluation you also want to examine the disconnect for all
incoming power sources. Every disconnect and electrical panel is
different and some of them have multiple energy sources! For this
example, we examine the disconnect and determine that there is only
one power source coming into the cabinet and to the contacts.
Remember by turning the disconnect off you only de-energized the
load side. This means that the line side will always be energized
unless you de-energize the electrical panel that is supplying power to
this disconnect.
 Change your common probe to an alligator clamp. Using the alligator
clamp allows you to place only one hand inside the cabinet.
Remember, you never want to have both hands inside the cabinet at
the same time. Always make sure that your free hand is not touching a
grounded surface.
 Set the function switch to resistance.
 Push the Peak Min/Max button
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
 Verify that the alligator clamp and probe have good continuity by
touching the probe tip to the alligator clamp. You should here a steady
beep.
 Clip the alligator clamp to the cabinet. You may have to twist the
clamp so that it breaks the painted surface and makes contact with the
metal.
 Verify that the alligator clamp and probe have good continuity by
touching the probe to the cabinet. Remember, you may have to push
down on the probe to break the painted surface. You should here a
steady beep. If you do not hear a steady beep, you will have to adjust
the alligator clamp until you do.
 Set the function switch to Volts AC, stand to the side of the cabinet
and test the load side of the contacts. Test all three phases. The load
side is de-energized when you do not get any voltage readings.
 Carefully close disconnect and place your lock, hasp and
identification tag on the disconnect.
13.0 DETERMINING VOLTAGE
13.1 Power generation.
In fossil-fueled plants, burning coal, oil or natural gas in a boiler produces heat. At
nuclear plants, the heat is produced by fission, splitting atoms in nuclear fuel. The
nuclear reaction heats water under pressure to prevent it from boiling, much like a
pressure cooker. That water is then used to heat another water system that is not
under pressure, which boils and produces steam. The steam spins a turbine; the
turbine spins a generator filled with magnets and coils of wire, and electricity is
produced.
The generator produces the electricity, typically at about 20,000 volts AC. This
electrical power is then distributed to a generator transformer, which steps up the
voltage to either 230,000 or 345,000 volts. The power is distributed to a switchyard
or substation where the power is then sent offsite. Remember that voltage is
pressure, so the utility needs to step up the voltage so that it can travel long
distances at higher pressure.
Most utility companies will distribute power to buildings in the range of 13,200 V
to 26,400 V. It is then up to the building owner to “transform” this power into
usable voltage. This is done by transformers.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Voltage is regulated by how the transformer wires are wound. The winding that
receives current from the line side is called the primary winding. The winding that
delivers current to the load side is called the secondary winding.
The relationship of the primary voltage to the secondary voltage is called the
voltage ratio. If one winding has twice as many turns of wire as the other, it will
have twice the voltage. When the ratio is given as 10:1, it means that the highvoltage winding contains 10 times as many turns as the low-voltage winding. The
higher value in the ratio pertains to the high-voltage winding, and the lower value
(often 1) to the low-voltage winding. The ratio of the number of turns of wire in
the primary to the number of turns of wire in the secondary is known as the turns
ratio.
14.0 Training Requirements
14.1 Safety Training. Employees shall be trained in safety-related work practices
and procedural requirements as necessary to provide protection from the electrical
hazards associated with their respective job or task assignments. Employees shall
be trained to identify and understand the relationship between electrical hazards
and possible injury. This training shall be classroom or on-the-job type, or
combination of the two. The training shall be documented to reflect date,
instructor, and verification of competency. This training shall be conducted before
possible exposure to electrical hazards, annually, and additional training when
required by the supervisor.
14.2 Emergency Procedure. Employees exposed to shock hazards shall be trained
in methods of release of victims from contact with exposed energized electrical
conductors or circuit parts. Employees shall be trained in CPR/AED/FA annually.
15.0 Auditing
15.1 Auditing of this program will be conducted annually for verification of
compliance and effectiveness.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Appendix A
University of South Carolina
ENERGIZED ELECTRICAL WORK PERMIT
PART I: TO BE COMPLETED BY THE REQUESTER:
Job/Work Order Number ___
(1) Description of circuit/equipment/job location: _____________________________________
_____________________________________________________________________________
(2) Description of work to be done: ________________________________________________
_____________________________________________________________________________
(3) Justification of why the circuit/equipment cannot be de-energized or the work deferred until
the next scheduled outage: ________________________________________________________
______________________________________________________________________________
Requester/Sign: ___________________________________________
Date: _____________
PART II: TO BE COMPLETED BY THE ELECTRICALLY QUALIFIED PERSONS
DOING THE WORK:
(1) Detailed job description procedure to be used in performing the above detailed work:
______________________________________________________________________________
(2) Description of the Safe Work Practices to be employed:
______________________________________________________________________________
(3) Results of the Shock Hazard Analysis:
______________________________________________________________________________
(4) Determination of Shock Protection Boundaries:
______________________________________________________________________________
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
(5) Results of the Arc Flash Hazard Analysis:
______________________________________________________________________________
(6) Determination of the Arc Flash Protection Boundary:
______________________________________________________________________________
(7) Necessary personal protective equipment to safely perform the assigned task:
______________________________________________________________________________
(8) Means employed to restrict the access of unqualified persons from the work area:
______________________________________________________________________________
(9) Evidence of completion of a Job Briefing including discussion of any job-related hazards:
______________________________________________________________________________
(10) Do you agree the above described work can be done safely? Yes No (If no, return to
requester)
Electrically Qualified Person(s) _________________________________ Date: _____________
PART III: APPROVAL(S) TO PERFORM THE WORK WHILE ELECTRICALLY
ENERGIZED:
_______________________________
Department Manager
Date: __________________________
____________________________________
Maintenance/Engineering Manager
Date: _______________________________
_______________________________
Department Safety Manager
Date: ___________________________
____________________________________
Electrically Knowledgeable Person
Date: _______________________________
_______________________________
Assistant Department Director
Date: _________________________
____________________________________
Department Director
Date: _______________________________
Note: Once the work is complete, forward this form to the Department Safety for review
and retention.
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[SAMPLE USC SAFETY PROGRAM] August 26, 2010
Appendix B
Job Briefing and Planning Checklist
Identify:
The hazards: ___________________________________________________________________
The voltage levels involved: ______________________________________________________
Skills required: _________________________________________________________________
Any “foreign” (secondary source) voltage source: _____________________________________
Any unusual work conditions: _____________________________________________________
Number of people needed to do the job: _____________________________________________
The shock protection boundaries: __________________________________________________
The available incident energy: _____________________________________________________
Potential for arc flash (conduct an arc flash-hazard analysis): ____________________________
Ask:
Can the equipment be de-energized? ________________________________________________
Are backfeeds of the circuits to be worked on possible? _________________________________
Is a “standby person” required? ____________________________________________________
Check:
Job plans: _____________________________________________________________________
Single-line diagrams and vendor prints: _____________________________________________
Status board: ___________________________________________________________________
Information on plant and vendor resources is up to date: ________________________________
Safety procedures: ______________________________________________________________
Vendor information: _____________________________________________________________
Individuals are familiar with the facility: _____________________________________________
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Know:
What the job is: ________________________________________________________________
Who else needs to know-communicate: _____________________________________________
Who is in charge: _______________________________________________________________
Think:
About the unexpected event…What if? ______________________________________________
Lock-Tag-Try: _________________________________________________________________
Test for voltage-first: ____________________________________________________________
Use the right tools and equipment, including PPE: _____________________________________
Install and remove grounds: _______________________________________________________
Install barriers and barricades: _____________________________________________________
What else? ____________________________________________________________________
Prepare for an Emergency:
Is the standby person CPR trained? _________________________________________________
Is the required emergency equipment available? _______________________________________
Where is it? ___________________________________________________________________
Where is the nearest phone? ______________________________________________________
Where is the fire alarm? __________________________________________________________
Is confined space rescue available? _________________________________________________
What is the exact work location? ___________________________________________________
How is the equipment shut off in an emergency? ______________________________________
What is the emergency phone number? ______________________________________________
Where is the nearest fire extinguisher? ______________________________________________
Are radio communications available? _______________________________________________
47