J.016 FAA Order JO 3900.64A - Air Traffic Organization Electrical SafetyProgram.pdf

ORDER

JO 3900.64A

Air Traffic Organization Policy Effective Date:

02/03/2021

SUBJ: Air Traffic Organization Electrical SafetyProgram

1. This order defines the Air Traffic Organization (ATO) Electrical Safety Program (ESP) and identifies program standards, establishes roles and responsibilities, and provides procedures and requirements for identifying and minimizing electrical hazard risks, providing electrical safety training and personal protective equipment, and implementing safe work procedures. This order seeks to protect ATO employees who work on or near electrical equipment or electrical related hazards.

2. This order requires the recognition and evaluation of electrical hazards, communication of identified hazards to affected personnel, and establishment of appropriate protective measures. This order identifies the minimum requirements for the ATO ESP; however, site-specific requirements may be more stringent based upon local risk assessments.

3. Compliance with this order fulfills the requirements of the Occupational Safety and Health Administration (OSHA) General Industry and Construction Standards and other applicable standards related to electrical safety and electrical workareas.

Teri L. Bristol Chief Operating Officer Air Traffic Organization

Distribution: Electronic Initiated By: AJW-23

RECORD OF CHANGES DIRECTIVE NO. JO 3900.64A

CHANGE

TO

BASIC

SUPPLEMENTS OPTIONAL

USE

CHANGE

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BASIC

SUPPLEMENTS OPTIONAL

USE MM DD YY MM DD YY

FAA Form 6000-25 (10/12)

Appendix B. Definitions............................................................................................................B-1

Appendix C. Drivers, Regulatory, and Consensus Requirements .............................................C-1

Appendix D. EEWP Instructions .............................................................................................. D-1

Appendix E. Energized Electrical Work Permit (Sample) ........................................................ E-1

Appendix F. Arc Flash Risk Assessment Flow Chart .............................................................. F-1

02/03/2021 JO 3900.64A

Table of Contents

Paragraph Page Chapter 1. General Requirements

1. Purpose of This Order ....................................................................................................... 1-1

2. Audience ............................................................................................................................ 1-1

3. Where Can I Find This Order ............................................................................................ 1-1

4. What This Order Cancels .................................................................................................. 1-1

5. Policy ................................................................................................................................. 1-1

6. Scope and Application ....................................................................................................... 1-1

Chapter 2. Roles and Responsibilities

1. ATO Executive-level Managers ........................................................................................ 2-1

2. ATO Managers .................................................................................................................. 2-1

3. ATO Environmental and Occupational Safety and Health (EOSH) Services Group ...... 2-1

4. Technical Operations Managers ........................................................................................ 2-2

5. ATO Safety and Health Specialists ................................................................................... 2-2

6. Frontline Managers and Supervisors ................................................................................ 2-3

7. ATO Project Managers/Project Implementers .................................................................. 2-4

8. Qualified Persons .............................................................................................................. 2-5

9. Unqualified Persons .......................................................................................................... 2-6

Chapter 3. Electrical Safety Program Requirements

1. Overview ........................................................................................................................... 3-1

2. Safe Work Practices .......................................................................................................... 3-1

3. Energized Electrical Work Permit ................................................................................... 3-12

4. Training Requirements .................................................................................................... 3-14

5. PPE .................................................................................................................................. 3-15

6. Insulated, Voltage Rated, and Contact Release Tools ..................................................... 3-20

7. Electrical Test Instruments and Equipment ..................................................................... 3-24

8. Design, Construction, and Acquisition Requirements .................................................... 3-25

Appendix A. Instructions to Access NFPA 70E Tables ........................................................... A-1 i

Appendix O. Example Job Briefing Checklist (Sample) .......................................................... O-1

Appendix P. Administrative Information ................................................................................. P-1

Table of Contents (Continued)

Paragraph Page

Appendix G. Example Labels ................................................................................................... G-1

Appendix H. Two-Person Rule Decision Tree ......................................................................... H-1

Appendix I. Personal Protective Equipment (PPE) .................................................................. I-1

Appendix J . Fault Current/Clearing Time Supporting Documentation .................................... J-1

Appendix K. Steps to Verify Equipment Labeled >40 cal/cm2 Is in an Electrically Safe Work

Condition............................................................................................................. K-1

Appendix L. Example Electrical Safety Audit Checklist Instructions ...................................... L-1

Appendix M. Example Electrical Safety Audit Checklist (Sample) ......................................... M-1

Appendix N. Example Job Briefing Checklist Instructions ..................................................... N-1

Appendix Q. Document Feedback Information ....................................................................... Q-1

List of Tables

Table Page

3-1. Electrical Safety Training Requirements. ...................................................................... 3-15 3-2. Glove Class Maximum Use Voltage.............................................................................. 3-17 I-1. PPE Categories.................................................................................................................. I-1 I-2. PPE Summary ................................................................................................................... I-3 ii

b. The ATO ESP establishes program-specific roles and responsibilities, defines the electrical safety requirements, and identifies program standards (including NFPA 70E, Standard for Electrical Safety in the Workplace).

2. Audience. This order affects all Federal Aviation Administration (FAA) ATO personnel managing and/or working on or near electrical equipment.

3. Where Can I Find This Order? You can find an electronic copy of this order on the Directives Management System (DMS) website: https://employees.faa.gov/tools_resources/orders_notices/.

go to the MyFAA Employee website, select “Tools & Resources”, then select “Orders & Notices”.

4. What This Order Cancels. This order cancels FAA Order 3900.64, Air Traffic Organization Electrical Safety Program.

5. Policy. ATO policy requires employees to comply with the ATO ESP as part of an incident prevention program. This guidance represents the minimum requirements for the ESP. Site-specific requirements may be more stringent based upon local risk assessments. This ATO order fulfills the requirements of FAA Order 3900.19C, Federal Aviation Administration (FAA) Occupational Safety and Health Policy.

6. Scope and Application. The ATO ESP applies to ATO personnel and managers of those employees performing electrical work and where electrical related hazards may exist in ATO workspaces. This program presents the minimum requirements for the ESP. Additional site-specific requirements may be more stringent based upon local risk assessments.

Or

02/03/2021 JO 3900.64A

Chapter 1. General Information

1. Purpose of This Order. This order defines the ATO ESP, a comprehensive program designed to provide appropriate risk mitigation, controls and occupational protection to ATO employees from electrical hazards.

a. The ATO ESP defined by this order was developed to fulfill the requirements of OSHA, National Fire Protection Association (NFPA), National Electrical Code (NEC), and other applicable standards.

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Chapter 2. Roles and Responsibilities

1. ATO Executive-level Managers. ATO-Executive-level Managers ensure compliance with and incorporate the requirements of this order into programs and activities managed by their organizations, particularly those involving deployment of new systems and modernization projects that affect electrical safety or existing systems brought into compliance with current requirements.

2. ATO Managers. ATO Managers must:

a. Resolve or elevate all non-compliant electrical safety issues.

b. Ensure the reporting of any electrical incidents, accidents, or near-misses in accordance with accident report requirements in FAA Order 3900.19C and other applicable requirements.

c. Ensure the integration of electrical safety requirements in all planning, design, construction, installation, commissioning, modification, maintenance, and demolition activities for projects in which they are responsible.

d. Ensure qualified personnel conduct accident investigations in accordance with FAA Order 3900.19C, involving their employees, their facilities, or their projects.

3. ATO Environmental and Occupational Safety and Health (EOSH) Services Group. ATO EOSH Services Group must:

a. Serve as the Office of Primary Responsibility for the ATO ESP.

b. Provide technical requirements and resources to ensure the overall implementation of this order for the ATO.

c. Oversee the technical requirements of this order to ensure compliance with current FAA requirements, OSHA and applicable consensus standards.

d. Provide technical assistance to assist in the implementation of this order.

e. Ensure sufficient resources are available to support the effectiveness of this order.

f. Ensure the availability of training programs in accordance with this order.

g. Provide technical assistance to engineering and acquisition teams to ensure that new, current, and legacy FAA facilities, systems, and equipment incorporate electrical safety requirements in design, construction, renovation, and implementation projects.

h. Perform program audits for the national ESP. The frequency of the audit must not exceed three-years.

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i. Provide national program oversight for the ESP.

j. Ensure completion of Arc Flash Risk Assessment (AFRA) studies on all existing facilities/equipment that require an AFRA. Ensure warning labels are provided after those studies have been completed.

k. Ensure completion of a five-year review on all facilities/equipment requiring an AFRA in accordance with NFPA 70E.

l. Ensure that the respective Office of Primary Responsibility (OPR) integrates the most recent electrical safety requirements into ATO policy documents including maintenance procedures provided in maintenance handbooks and technical instruction books.

4. Technical Operations Managers. Technical Operations Managers must:

a. Resolve non-compliant electrical safety issues associated with their facilities.

b. Provide assistance as required during installation, construction, renovation, maintenance, or demolition activities at facilities to ensure compliance with the ESP.

c. Ensure that facility single line diagrams are updated during construction, installation, modification, and renovation projects at their facilities.

d. Ensure technical support staff review project design and/or renovation documents related to their facilities to ensure compliance with the ESP.

e. Complete the Joint Acceptance Inspection (JAI) and/or Contractor Acceptance Inspection (CAI) process to ensure compliance with the ESP as required for their facilities.

f. Ensure AFRAs are performed and updated every five years and that applicable warning labels are affixed as required by this order.

g. Ensure that generic labels are applied in accordance with this order Chapter 3, Section 2(h), Paragraph 5(e).

h. Ensure electrical equipment is maintained and documented in accordance with FAA policy (e.g. JO Order 6000.15H, General Maintenance Handbook for NAS Facilities, maintenance technical handbooks, and technical instruction books). In lieu of available FAA instruction, ensure electrical equipment is maintained in accordance with manufacturer specifications for their facilities.

5. ATO Safety and Health Specialists. ATO Safety and Health Specialists must:

a. Serve as the designated technical point of contact and provide assistance related to the ESP.

b. Maintain current knowledge on available electrical safety equipment to facilitate evaluations, recommendations, and the purchasing of appropriate equipment/personal protective equipment (PPE).

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c. Successfully complete and maintain currency in Electrical Safety Qualified Person (ESQP) training.

d. Assist respective training specialists in coordinating appropriate ESQP training.

e. Provide consultation for the completion and evaluation of the Energized Electrical Work Permit (EEWP).

f. Assist with the review of engineering package (e.g., specifications, scopes of work, transmittals, and drawings) for compliance with electrical safety requirements.

6. Frontline Managers and Supervisors. Frontline Managers and Supervisors must:

a. Ensure personnel managing and/or working on or near electrical equipment are current in ESQP training and that all training is documented in FAA Electronic Learning Management System.

b. Discuss safe working practices with employees prior to work, during mid-term and annual performance reviews, and throughout the duration of employment. Periodically observe employees in daily activities to ensure safe work practice and institute corrective measures when required, which could include retraining.

c. Manage the electrical PPE testing/exchange program for all equipment that requires periodic testing and/or calibration within required timelines for their employees.

d. Provide appropriate PPE, including insulating gloves and tools, arc–rated PPE, and other equipment to personnel working on or near electrical equipment.

e. Ensure that the EEWP (see Appendix E) is appropriately completed and implemented prior to commencement of energized electrical work by their employees. Ensure all contractors who will be working where an EEWP is applicable have an acceptable EEWP completed and signed by their respective management official (not the FAA).

f. Provide assistance as required during installation, construction, renovation, maintenance, or demolition activities at all facilities to ensure compliance with the ESP.

g. Observe employee performing routine fieldwork activities with a potential of exposure to electrical hazards at intervals not to exceed one-year (typically conducted once every performance cycle). Document this review and take corrective actions as needed. Reference form in Appendix L.

h. Plan and/or modify employees’ work schedules and tasks to minimize exposure to electrical hazards. Employees must not be permitted within the Limited Approach Boundary (LAB) while recognizably impaired due to illness, fatigue, or other reasons.

i. Successfully complete and maintain currency in ESQP training per Table 3-1 (managers of employees working on exposed energized conductors or circuit parts).

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j. Ensure warning labels are affixed for all AFRA, arc flash evaluations, and at the service entrance, where applicable.

k. Complete the JAI and/or CAI process to ensure compliance with the ESP program, as required.

l. Ensure the development and periodic inspection of, Lockout/Tagout (LOTO) procedures and hazard/risk evaluations associated with electrical equipment in accordance with ATO Order 3900.67, Air Traffic Organization Hazardous Energy Control (Lockout/Tagout) Program.

7. ATO Project Managers/Project Implementers. ATO Project Managers/Project Implementers must:

a. Ensure sufficient resources are requested to support the effectiveness of this order.

b. Ensure the integration of electrical safety requirements in all System Support Modifications within the System Support Directive.

c. Ensure that the most recent electrical safety requirements of this order are integrated into programs, policy, design of new equipment, and new installations.

d. Ensure project related non-compliant electrical safety issues are resolved prior to project closeout.

e. Ensure new installations and upgrades, etc., performed at all facilities are coordinated through the technical support staff, local facility management, and other appropriate site personnel.

f. Ensure submission of engineering packages as early as practicable for installations that will affect existing electrical systems to technical support staff, local facility management, Safety and Health Specialist, and other appropriate site personnel.

g. Ensure that all engineering packages meet or exceed the requirements contained in this order, and assist the Contracting Officer’s Representative with related contract requirements, as needed.

h. Coordinate review of project documentation with the safety and health specialist, technical support staff, and facility management (e.g., engineering package specifications, scopes of work, transmittals, and drawings) as needed, to facilitate compliance with the ESP.

i. Ensure that most recent electrical safety requirements of this order are integrated into technical documentation, such as specifications, technical instructions, and maintenance procedures.

j. Complete applicable EOSH Checklist/Integrated Risk Management Checklist and submit engineering package for installations that will affect electrical systems to the facility management, technical support staff and local safety and health specialist for review.

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k. Complete AFRA for modifications, renovations at operational facilities, or projects involving installation of new equipment in accordance with this order and the current version of FAA Order 6950.27A, Power System Analyses: Load Flow Calculations, Short Circuit Analysis, Protective Device Coordination Studies, and Arc Flash Hazard Analysis. Provide warning labels for completed AFRAs, and ensure the labels are installed/applied.

l. Ensure appropriate arc flash labels are installed/applied at the completion of equipment installation, modification, renovation, or replacement.

m. Ensure that the EEWP (see Appendix E) is completed and implemented prior to commencement of work, as appropriate.

n. Ensure that facility single line diagrams are updated during construction, installation, modification, renovation, and replacement projects.

o. Ensure installers are qualified persons (current in ESQP training and familiar with equipment).

p. Complete the JAI and/or CAI process to ensure compliance with the ESP, as required.

q. Ensure that manufacturer’s recommendations and maintenance requirements that result in the improved condition of maintenance are integrated in associated policy and instruction. Reference NFPA 70E General Maintenance Requirements.

r. Successfully complete and maintain currency in ESQP training per Table 3-1 (managers of employees working on exposed energized conductors or circuit parts).

8. Qualified Persons. Qualified Persons must:

a. Successfully complete and maintain currency in ESQP training per Table 3-1 Electrical Safety Training Requirements. Immediate refresher training is required for employees who fail to demonstrate adequate skill, and knowledge.

b. Successfully complete associated technical training or on-the-job training (OJT) related to the construction and operation of the equipment and/or installations on which he/she will be working.

Immediate refresher training is required for employees who fail to demonstrate adequate skill, and knowledge.

c. Successfully complete training and maintain currency in first aid and other approved methods of resuscitation, including cardiopulmonary resuscitation (CPR) and automated external defibrillator (AED) use. Reference Table 3-1.

d. Conduct a shock risk assessment using NFPA 70E Table 130.4(D)(a) and 130.4(D)(b) to determine the Limited and Restricted approach boundaries on equipment not appropriately labeled prior to performing electrical work on exposed energized conductors or circuit parts.

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e. Put on the appropriate PPE based on the task and the maximum arc flash exposure hazard for the specific task. In absence of a label, use NFPA 70E Tables 130.5(C), 130.7(C)(15)(a) and 130.7(C)(15)(b) to determine the appropriate PPE and arc flash boundary. Instructions to access these NFPA 70E tables are located in Appendix A.

f. Develop, or assist in the development and periodic inspection of, LOTO procedures and hazard/risk evaluations associated with electrical equipment.

g. Assist in development of electrical safety and arc flash hazard surveys/evaluations (such as data collection).

h. Complete the EEWP in accordance with this order. (See Appendix D).

i. Conduct a Job Briefing, including the job safety plan and the information on the energized electrical work permit, if a permit is required, with personnel working on or near electrical equipment prior to performing any electrical work. (See Appendix O and NFPA 70E Risk Assessment Procedure).

j. Notify management whenever electrical safety equipment including PPE becomes defective and must be repaired or replaced.

k. Properly use, maintain and inspect assigned PPE in accordance with this ESP.

l. Communicate electrical safety concerns in their respective work area(s) to their manager.

m. Maintain electrical equipment in accordance with FAA policy and manufacturer specifications (e.g. JO Order 6000.15H, maintenance technical handbooks, and technical instruction books).

n. Follow all caution and safety signs and notifications in their respective work areas.

9. Unqualified Persons. Unqualified Persons must:

a. Not be within the LAB of exposed energized conductors or circuit parts unless advised of the possible hazards and continuously escorted by a Qualified Person.

b. Communicate electrical safety concerns in their respective work area(s) to their manager.

c. Follow all caution and safety signs and notifications in their respective work areas.

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Chapter 3. Electrical Safety Program Requirements

1. Overview. The most effective way to prevent an electrical injury is to establish an electrically safe work condition. This ESP addresses electrical safety requirements for FAA workplaces that are necessary for the practical safeguarding of employees during activities such as, but not limited to, the installation, removal, inspection, operation, maintenance, and demolition of electric conductors, electric equipment, signaling and communications conductors and equipment, and raceways. All contract personnel working in FAA work areas must comply with the applicable requirements of this order. This ESP addresses LOTO concerning establishing an electrically safe work condition.

Detailed LOTO requirements are located in JO Order 3900.67, related Notices, and the Hazardous Energy Control Program.

2. Safe Work Practices.

a. Equipment must be placed in an electrically safe work condition before performing work within the LAB except in the following situations:

(1) Where de-energizing equipment introduces additional hazards or increased risk.

(2) Where performing the work in a de-energized state is infeasible due to equipment design or operational limitations.

(3) Where energized conductors and circuit parts operate at less than 50 volts (V) and no hazard from arc or explosion exists.

(4) During testing and/or troubleshooting that requires the equipment to remain energized.

b. Consider all equipment energized until verified to be de-energized and placed in an electrically safe work condition.

c. The qualified person must perform a hazard identification and risk assessment before working on energized equipment. This includes the following:

(1) Determine if work will require contact with energized electrical conductors or circuit parts.

(2) Determine if an EEWP is required. Refer to Chapter 3, Paragraph 3.

(3) Determine if a second person is required. Refer to Appendix H for the Two-Person Rule Decision Tree.

(4) Determine what PPE, if any, is appropriate for the assigned task.

d. Two-Person Requirements (Refer to Appendix H for the Two-Person Rule Decision Tree).

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(1) Two persons are required in the following situations:

(a) All work requiring an EEWP, including, but not limited to, physical alteration or repair of energized conductors or circuit parts, making or tightening connections, and removing or replacing components.

(b) Testing, troubleshooting, verifying equipment is in an electrically safe work condition, and voltage measurements conducted on exposed energized conductors or circuit parts except when conducting infrared thermography/ultrasound/visual inspection outside of the Restricted Approach Boundary (RAB).

(c) Where deemed necessary by the Qualified Person and his or her manager, where additional hazards not covered within sections (a) or (b) are present, including but not limited to three phase power distribution equipment or when working space and clearances do not meet requirements referenced in Chapter 3, Paragraph 8 b. (2).

(2) The second person must have the following qualifications:

(a) Current in first aid, CPR, and AED use.

(b) Current in ESQP training or contractor equivalent.

(3) The second person is not required to have skills and knowledge on any specific equipment.

(4) The second person must remain attentive to the work being performed and is prohibited from work duties that would restrict his/her ability to sound an alarm and/or render aid.

(5) If the second person is within the LAB or arc flash boundary, the Qualified Person must inform the second person of the possible hazards specific to that equipment and continually escort. In this case, the second person is required to have completed ESQP training and must wear the appropriate protective clothing and other PPE.

e. Hierarchy of Risk Controls - The hierarchy of risk controls illustrates the priority for addressing electrical hazards. Reference NFPA 70E Annex F.

(1) Elimination - Accomplished by establishing an electrically safe work condition.

(2) Substitution - Accomplished by performing a risk assessment to determine the hazard, based on the task, and estimate exposure to determine the appropriate protective means needed to reduce the risk.

(3) Engineering Controls - Design considerations that help to reduce the magnitude of exposure, reduce likelihood of exposure, or enable achievement of an electrically safe work condition.

Design considerations include remote test points, bypass switches, zone-selective interlocking, energy reducing maintenance switching, current limiting devices, use of closed doors and hinged panels, etc.

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(4) Awareness - Identify the hazard by using warning signs and labels.

(5) Administrative Controls - Accomplished by employee training, arc flash risk assessments, using EEWP, following LOTO procedures, etc.

(6) Personal Protective Equipment - Accomplished by donning appropriate PPE. This is considered the last line of defense and is least effective.

(7) If the exposure to the hazard cannot be reduced through design or engineering controls, establish an electrically safe work condition prior to performing work activities.

f. Protective Measures for Existing Non-Compliant Clearance Issues. When there is insufficient work space around energized electrical equipment in accordance with OSHA 1910 Subpart S, and it is not feasible to place the equipment in an electrically safe work condition, the following protective measures must be implemented as applicable:

(1) Complete an EEWP.

(2) Place signs and barricades around the work area. Refer to Chapter 3, Paragraph 2.k. for additional information on signs and barricades.

(3) Restrict employee access to prevent interference with the worker.

(4) Place insulating blanket over the conductive parts of the obstruction (equipment rack, switchgear, etc.) where the worker may accidentally make contact.

(5) Ensure no conductive equipment is near the work area that may potentially contact the worker or the equipment.

g. Shock Hazard. A Shock Hazard is a source of possible injury or damage to health associated with current through the body, caused by contact or approach to energized electrical conductors or circuit parts.

(1) A shock risk assessment determines the hazardous voltage, boundary requirements, and PPE necessary to minimize the possibility of electric shock to personnel.

(2) The Limited and Restricted approach boundaries will be determined by a Qualified Person prior to starting work.

(3) Approach boundaries must be determined using the NFPA 70E Table 130.4(D)(a) and 130.4(D)(b) or from the calculated arc flash labeling.

(a) LAB

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(i) Only Qualified Persons may enter the LAB when electric conductors and equipment involved are not in an electrically safe work condition.

(ii) If an Unqualified Person(s) needs to cross the LAB for the purpose of OJT, a Qualified Person must advise him/her of the possible hazards and escort the Unqualified Person(s) while inside the LAB.

(b) RAB. Unqualified Persons are prohibited from crossing the RAB.

(c) Qualified Persons must not approach or take any conductive object closer to exposed energized electrical conductors or circuit parts operating at 50 V or more than the RAB unless the Qualified Person is isolated, insulated, or guarded from energized electrical conductors and no uninsulated part of the body crosses the RAB.

h. Arc Flash.

(1) Arc flash hazards relate to the thermal effects of electricity when the electrical current sustains a short circuit between the energized buses of electrical equipment or between an energized part and ground potential. The associated bright light, heating and decomposition of metals produce enough heat to cause serious burns to human skin. Arc-rated (AR) clothing is designed to provide a level of protection to protect the worker from the thermal energy hazards associated with the arc flash event.

(2) Arc blast hazards address the mechanical forces associated with an arcing fault. The explosive reaction near the arc can cause parts of the electrical equipment to move rapidly away from the arc in all directions. AR clothing may not protect the worker from the physical effects of the arc blast event.

(3) Arc Flash Exposure.

(a) An arc flash may be caused by, but not limited to:

(i) Human error/unsafe work practices.

(ii) Contact with energized parts.

(iii) Short circuit current capacity exceeding electrical equipment’s rating.

(iv) Dropped tools/hardware across energized parts.

(v) Incorrect wiring practices.

(vi) Contamination, such as dust on insulating surfaces.

(vii) Corrosion of equipment parts and contacts.

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(viii)Removal/Installation of equipment covers (i.e., dead front covers on panelboards).

(ix) Failure of internal or external mechanical parts and hardware, which can then contact energized components.

(b) A worker must wear AR PPE prior to crossing the arc flash boundary to perform a variety of tasks including but not limited to: verifying equipment is de-energized, measuring voltage, removing covers from a power distribution panel or performing energized work.

(4) AFRA Requirements

(a) The AFRA must determine the arc flash boundary and the incident energy at a specified working distance.

(b) The AFRA must be performed prior to installation of new facilities, or when a major modification occurs at existing facilities. A major modification includes but is not limited to the following:

(i) Addition of motor loads greater than or equal to 50 horsepower that are not controlled by a Variable Frequency Drive – AFRA required for the affected power system (typically, the entire facility).

(ii) Addition or replacement of power panels – AFRA required for modified/affected panels.

(iii) Engine Generator (EG) replacement – AFRA required for entire facility.

(iv) Replacement of service transformer or modification of service entrance conductors – AFRA required for the affected power system (typically, the entire facility).

(v) Uninterruptable Power Supply (UPS) replacement (excluding rack-mounted) – AFRA required for UPS and Maintenance Bypass Switch. Reference ‘vii’ for addition or replacement of feeder breakers.

(vi) Replacement of service entrance – AFRA required for the affected power system (typically, the entire facility).

(vii) Replacement of feeder circuit breakers greater than or equal to 150 A 3-Phase – AFRA required for downstream equipment to the next overcurrent protective device.

(viii)Addition or replacement of distribution transformer – AFRA required for downstream equipment except when replaced with a transformer of the same size, type, and impedance.

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(ix) Electrical Distribution System (Facility Type Code: ELD) power cable replacements – AFRA required for entire affected facility or facilities. Each AFRA must be reviewed periodically, at intervals not to exceed five-years, to account for changes in the electrical distribution system that could affect the results of the AFRA.

(x) The addition of a photovoltaic (PV) system on the load side of the utility transformer (typical FAA installation)

• If the PV system kilovolt amp (kVA) is less than or equal to 100% of the utility transformer, the impact is minimal. It would be prudent to complete an abbreviated study using the existing model, but the results will yield only minor changes in hazards outside of the PV system.

• If the PV system kVA is greater than 100% of the utility transformer, the impact cannot be assumed. The study will require an update to quantify the impact.

(c) Each AFRA must comply with this order and the current version of FAA Order 6950.27.

(d) The AFRA must take into consideration the design of the overcurrent device, its clearing time and the condition of maintenance.

(e) Complete the AFRA using applicable software. Due to NFPA requirements, usage of non SKM Systems Analysis, Inc. software must be approved by the Electrical Safety Program Manager on a case-by-case basis.

(f) All AFRAs regardless of project scope must be uploaded to the AFRA repository located at http://caeg.faa.gov/fpps as soon as possible after completion. The upload must include the report and all associate native files.

(g) The arc flash boundary and PPE requirements for equipment downstream of the service entrance may be determined using NFPA 70E Tables 130.5(C), 130.7(C)(15)(a), and 130.7(C)(15)(b) or the calculated/generic AFRA labels. Instructions to access these NFPA 70E tables are located in Appendix A.

(i) The maximum fault current and clearing time parameters in NFPA 70E Table 130.7(C)(15)(a) and 130.7(C)(15)(b) are assumed to be met for equipment downstream of the service entrance. This assumption is based on arc flash calculations performed on several types of FAA equipment and generic infinite bus calculations using voltage levels, transformer sizes, and protective device types common in the FAA. Supporting documentation is provided in Appendix J.

(ii) For any transformer size (kVA) larger than indicated in Appendix J at the respective voltage, contact a qualified engineer to perform an evaluation or AFRA. For example, a 225 kVA transformer at 208 V would require further evaluation by a qualified engineer.

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(iii) For any transformer with an impedance less than indicated in Appendix J for the associated kVA, contact a qualified engineer to perform an evaluation or AFRA.

(iv) For Alternating Current (AC) and Direct Current (DC) equipment labeled as dangerous or service entrance equipment that is not labeled, the following tasks can be completed with no arc flash PPE. All other tasks require establishing an electrically safe work condition (Reference Appendix L). Refer to Section 3 within the body of this order to determine EEWP requirements.

• Reading a panel meter

• Removal or installation of covers for wireways and junction boxes that do not expose bare energized electrical conductors or circuit parts

• Examination of insulated cables provided you are not manipulating them

• Work on control circuits with exposed energized conductors or circuit parts operating at 120 V or below without any other exposed energized equipment over 120 V including opening of hinged covers to gain access. This work must be limited to control voltage cubicles where the only exposed voltage is </= 120V and no other exposed voltages. This is not allowable within breaker cabinets, motor control centers (MCC), etc.

• Normal operation of a circuit breaker, switch, contactor, or starter if all of the following are true:

o The equipment is properly installed o The equipment is properly maintained o The equipment is used in accordance with instructions included in the listing and labeling and in accordance with manufacturer instructions o The equipment doors are closed and secured o All equipment covers are in place and secured o There is no evidence of impending failure

• Perform infrared thermography and other noncontact inspection outside of the restricted approach boundary with the doors closed, with covers in place, and secured.

(v) For non-labeled DC equipment, the following tasks can be completed with no arc flash PPE.

• Voltage testing on individual battery cells or individual multi-cell units if all of the following are true:

o The equipment is properly installed

3-7 o The equipment is properly maintained o The equipment is used in accordance with instructions included in the listing and labeling and in accordance with manufacturer instructions o The equipment doors are closed and secured o All equipment covers are in place and secured o There is no evidence of impending failure

• Removal of battery intercell connector covers if all of the following are true:

o The equipment is properly installed o The equipment is properly maintained o The equipment is used in accordance with instructions included in the listing and labeling and in accordance with manufacturer instructions o The equipment doors are closed and secured o All equipment covers are in place and secured o There is no evidence of impending failure

• Insertion or removal of individual cells or multi-cell units of a battery system in an open rack (open on two or more sides).

• Maintenance on a single cell of a battery system or multi-cell units in an open rack (open on two or more sides).

(vi) Tasks not listed in NFPA 70E Table 130.5(C) require an evaluation or AFRA as determined by a qualified engineer.

(vii) Clamp-on meters

• For AC equipment, o If cable manipulation is required or personnel are exposed to energized electrical equipment, arc flash PPE is required.

o If cable manipulation is not required and personnel are not exposed to energized electrical equipment, arc flash PPE is not required.

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• For DC equipment, o If cable manipulation is required or personnel are exposed to ≥24 volts direct current (VDC), arc flash PPE is required.

o If cable manipulation is not required and personnel are not exposed to ≥24 VDC, arc flash PPE is not required.

(viii)Battery Capacity Testing: PPE Category 0 (including face shield) is required while performing capacity testing. Reference Appendix I.

(h) Guidance on generic warning labels for selected systems is located in the AFRA Flowchart in Appendix F. Sample generic labels are located in Appendix G.

(i) Requirements for single-phase and three-phase systems may be determined using the AFRA Flowchart in Appendix F.

(j) Requirements for DC systems may be determined using the AFRA Flowchart in Appendix F.

(i) PPE for exposure to DC voltage < 24 V is not required.

(ii) PPE for exposure to DC voltage ≥ 24 V and < 100 V is defined as PPE Category

0. Reference Appendix I.

(iii) PPE for DC systems > 100 V; in the absence of specific maintenance technical handbook procedures or documented site-specific procedures PPE must be determined by a qualified engineer.

(5) AFRA Labeling Requirements

(a) As stated in the NEC and NFPA 70E, electrical equipment, such as switchboards, panelboards, industrial control panels, disconnect switches, and MCC that are in other than dwelling units and are likely to require examination, adjustment, servicing, or maintenance while energized must be field marked to warn qualified persons of potential electric arc flash hazards. The marking must be located to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment. Please note that transformers are not included in this list as energized work on transformers is not typically allowable per NFPA 70E and OSHA.

(b) Following the completion of the AFRA and shock risk assessment, label the electrical equipment as shown in Appendix G down to the last three-phase disconnect. Please note that AC single-phase equipment ≤ 2,400 V and DC ≥ 24 V and < 100 V will be labeled as part of the generic labeling effort. DC equipment ≥ 100 V will be included in the AFRA. Single-phase equipment > 2,400 V will be included in the AFRA and modeled as three-phase. Engineering judgment will be

3-9 used to determine if any other single-phase equipment represents a high risk and should be modeled as three-phase. The label must include the following information from the AFRA as a minimum:

(i) Arc Flash Boundary

(ii) For AC systems; the incident energy in calories per square centimeter (cal/cm2) at appropriate working distances.

(iii) For DC systems; the short-circuit current, working distance (18”), and PPE Category or incident energy in calories per square centimeter (cal/cm2).

(iv) Nominal System Voltage

(v) Class of Rubber Insulating Gloves

(vi) LAB in feet/inches

(vii) RAB in feet/inches

(viii)Equipment Name

(ix) Date of Survey

Note: Existing labels showing both PPE Category and calculated incident energy must be updated only where the review of the AFRA identifies a change that renders the label inaccurate.

(c) Arc Flash Evaluation Form

(i) The Arc Flash Evaluation Form uses Institute of Electrical and Electronics Engineers (IEEE) 1584 Guide for Performing Arc-Flash Hazard Calculations to provide labels for equipment for the following FAA equipment when considered separately from an AFRA study:

(ii) DC systems ≥ 100 V.

(iii) Three-phase systems operating at greater than 240 V and fed by a single Three- Phase Transformer (or bank of Single-Phase Transformers) rated less than 125 kVA in total and an Engine-Generator rated less than 100 Kilowatt (kW) (if installed).

(iv) Reference the Arc Flash Risk Assessment Flow Chart in Appendix F for additional guidance for determining whether the Arc Flash Evaluation Form applies.

(d) Generic Labels

(i) Generic labels were developed using conservative methods, specifically for FAA equipment, excluding service entrance equipment. (See Appendix G)

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(ii) Submit an Arc Flash Evaluation Form on https://arcflash.faa.gov to request generic labels.

(e) Generic Label Application - Generic labels may be used on any of the following equipment:

(i) DC systems < 100 V

(ii) Single-phase systems ≤ 2,400 V

(iii) Three-phase systems operating at less than 240 V and fed by a single Three- Phase Transformer (or bank of Single-Phase Transformers) rated less than 125 kVA in total and an Engine-Generator rated less than 100 kW (if installed).

(iv) Reference the Arc Flash Risk Assessment Flow Chart in Appendix F for additional guidance for determining whether generic labels apply

(f) Label Specifications

(i) Labels must be made of a durable coated laminate material that can withstand environmental conditions.

(ii) The label must be of the appropriate size for the equipment while remaining legible.

(iii) Warning label header must be orange with black lettering.

(iv) Danger label headers must be red with white lettering to conform to OSHA recommendations.

(v) Arc flash warning labels placed on equipment cabinets, other than switchgear, power panels or MCC, are applicable to the operation and/or maintenance of the power source disconnects (e.g. rack/cabinet circuit breakers) ONLY. They are not applicable to the maintenance of the electronic equipment/system, unless a Qualified Person determines there is increased exposure to electrical burns or to explosion due to electric arcs.

(g) Label Placement

(i) Affix calculated and generic labels to electrical equipment downstream of the service entrance section’s main disconnecting means.

(ii) Affix generic service entrance equipment label to the incoming side of the service entrance equipment’s main disconnecting means. This label is only applicable when either an AFRA or an arc flash site evaluation has not been performed.

3-11 https://arcflash.faa.gov/

(iii) Affix DC labels to closed battery racks, battery disconnects, DC switchboards and other DC supply sources or at any location where personnel are capable of coming in contact with the full string voltage.

(iv) Do not affix labels to Transformers

i. Infrared Inspection

(1) PPE is not required to perform infrared thermography outside the restricted approach boundary. PPE is required when opening doors or covers.

(2) When performing infrared thermography inside the restricted approach boundary with the doors open and covers removed wear the proper PPE in accordance with NFPA 70E Tables 130.5(C), 130.7(C)(15)(a), and 130.7(C)(15)(b) or the warning label. Instructions to access these NFPA 70E tables are located in Appendix A.

j. Illumination - Adequate illumination and an unobstructed view of the work to be performed, as determined by the Qualified Person, are required prior to employees entering a work area containing energized electrical conductors or circuit parts.

k. Signs and Barricades

(1) Use safety signs, safety symbols, etc., where necessary to warn employees of potential electrical hazards. (See NFPA 70E Alerting Techniques and American National Standards Institute National Electrical Manufacturers Association (ANSI/NEMA) Z535.2 Environmental and Facility Safety Signs)

(2) Use barricades in conjunction with safety signs where it is necessary to prevent or limit employee access to work areas. Do not use conductive barricades where it might cause an electrical hazard.

(a) The barricades must be located no closer than the arc flash boundary if this boundary exceeds the LAB to the energized conductor(s) or circuit part(s).

(b) If a Qualified Person determines that signs or barricades do not provide sufficient warning and protection from electrical hazards, an attendant must be stationed for the sole purpose to warn and protect employees.

3. Energized Electrical Work Permit (See Appendices D and E)

a. Energized work is permitted:

(1) Where de-energizing introduces additional hazards or increased risk.

(2) Where the task to be performed is infeasible in a de-energized state due to equipment design or operational limitations.

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(3) Where energized electrical conductors are operating at less than 50 volts and a qualified person has determined that there will be no increased exposure to electrical burns or to explosion due to electric arcs.

Note: Operation of equipment under normal conditions is permitted.

b. An EEWP is required:

(1) When performing work within the RAB of energized electrical conductors or circuit parts (Refer to definition of “Working on” in Appendix B.

(2) When the employee interacts with the equipment where conductors or circuit parts are not exposed but an increased likelihood of injury from an exposure to an arc flash hazard exists including racking equipment in or out.

(3) When the work task requires a worker to make any physical change to equipment such as making or tightening connections, removing or replacing components, or adding components.

c. Use Qualified Personnel and Obtain Management Approval – A Qualified Person must make the decision to work energized on a case-by-case basis with management approval. By signing the permit approving energized work by the Qualified Person, the manager acknowledges the associated risks of the energized work. Energized electrical work may only proceed after approval of the FAA EEWP. When the work involves contract personnel, the contractor must complete an EEWP for their company, signed by a management official in that organization (not the FAA manager).

d. The manager cannot approve the EEWP if the Qualified Person determines that he/she cannot perform the energized work safely.

e. An EEWP is not required in the following situations (please note that the Qualified Person must still determine that the work can be done safely while energized):

(1) Performing Lockout/Tagout and verifying the system is de-energized.

(2) For work on energized conductors operating at less than 50 volts, unless a Qualified Person determines there is increased exposure to electrical burns or to explosion due to electric arcs.

(3) Testing, Troubleshooting, Voltage Measurement - A Qualified Person may perform diagnostics on energized electrical conductors or circuit parts related to testing,…