PWS Attachment 4_TDA Arc Flash Program September 2023.pdf

i

The Dalles Lock & Dam

Arc Flash Hazard Program

Ron Twiner James B. Gale, PE Operations Project Manager Engineering Manager ii

Revision History

Rev. Date Description of Revisions

1.10 21 Sep 2023 Annual program review changes: Updated section 4.c

Supervisors responsibilities to include disciplinary action for violations of the program. Changed section 4.d heading “Affected Person” under responsibilities to reflect both Qualified and Non-qualified individuals. Reviewed for change to the NPFA 70E 2024.

1.9 03 Oct 2022 Annual program review changes: Updated arc flash clothing requirements per NFPA 70E 2021 requirements and added ASTM & ANSI references for PPE requirements. Updated training requirements to reflect mechanics and RMS being trained as qualified individuals.

1.8 30 Jun 2021 Updated to reflect neutral disconnect labeling, changes to OSHA 1910.269 App E table 7, updated available short circuit current from BPA model, removed reference to leased arc flash clothing, updated table of contents, updated list of tables and figures, and added an example of maintenance switch indication on labels

1.7 23 Jul 2019 Updated to reflect Safety Office guidance on calculations of incident energy on high voltage equipment in an outdoor environment. Update label format to address changes in labeling in NFPA 70E 2015. Updated Project policy on care of arc flash clothing.

1.6 02 Nov 2015 Annual Program Review changes, see review checklist

1.5 19 Aug 2014 Updated to reflect 2012 NFPA changes

1.4 26 Oct 2011 Implemented Program

1.3 13 Apr 2011 Signed Program

1.2.3 17 Aug 2010 Final Draft

1.2 31 Aug 2009 Pre-Final Draft

1.1 17 Jul 2009 Added template

Updated PPE policy

1.0 01 Jul 2009 Baseline document iii

Table of Contents

PAGE

Revision History ............................................................................................................................. ii

Table of Contents ........................................................................................................................... iii

List of Tables/Figures .................................................................................................................... iv

1. Introduction

2. Applicability

3. Background

4. Roles and Responsibilities

5. List of Locations with Electric Service

6. Arc Flash Hazard Analysis (AFH Analysis)

7. Hazard Control and Integration of Controls into Work Practices

8. Personal Protective Clothing and Equipment and Standard Work Clothing

9. Labeling and Boundary Markers.…………………………………………………………….17

10. Training.…………………………………………………………………………………….. 20

11. Inspections and Program Reviews

12. Incident and Accident Reporting

13. Documentation and Recordkeeping.…………………………………………………………23

14. References…………………….…………………………………………………………….. 24

15. Sub-program Appendix Links………………………………………………………………..25 iv

List of Tables PAGE

Table 1: Identification of Key Personnel 7

Table 2: Listing of Electrical Services for Facility 9

Table 3: IE from OSHA 1910.269 Appendix E table 7 10

Table 4: Arc Flash Training Levels 21

List of Figures PAGE

Fig. 1. Example Label, NFPA 70E 2012 style for Calculated IE and FPB 19

Fig. 2. Example Label, NFPA 70E 2015 and later style for Calculated IE and FPB 19

Fig. 3 Example Label, NFPA 70E 2015 and later style with maintenance switch IE and calculated IE and FPB 20

1. Introduction

a. An arc flash hazard (AFH) is defined as a dangerous condition associated with the possible release of energy caused by an electric arc. Employees working on energized electrical equipment have the potential for personal injury from arcing faults by conditions such as tools contacting electrical buses, insulation failures, loose connections, improper work procedures, impurities/dust buildup, corrosion, condensation, over-voltage conditions, or equipment malfunctions. Arcing faults produce hazards of extreme temperatures and arc blasts.

b. This document provides procedures used at The Dalles Lock & Dam and other facilities and equipment under its jurisdiction. The purpose is to establish and maintain an AFH Program. The requirements of this document are applicable to all activities involving energized circuits.

c. Elimination of AFHs is not possible in all cases. The most effective method to mitigate an AFH is to de-energize electrical equipment prior to maintenance activities. Only trained, qualified, and properly equipped personnel should be near energized equipment. The calculations and recommendations of applicable standards and this document are intended to identify and reduce arc flash (AF) incident energy (IE) levels. These procedures do not guarantee complete protection from AFHs; however compliance with these procedures will reduce the possibility of burns and other injuries. Personnel that work in our facilities must be adequately protected from the risk of exposure to electric energy.

2. Applicability

a. This document is applicable for The Dalles Lock & Dam facilities that contain energized electrical equipment with voltages greater than 50 volts to ground. This includes, but is not limited to: warehouse, powerhouse, spillway, navigation lock, storage facilities, offices, recreation areas, mobile equipment, and other support areas.

b. This document does not address safety considerations other than AFHs and shall be used in conjunction with safety requirements for other hazards associated with operation, maintenance, and construction activities.

c. It is to be used in conjunction with Engineering Regulation (ER) 385-1-100, U.S.

Army Corps of Engineers, Arc Flash Hazard Program.

3. Background

a. Shock and electrocution have long been recognized as risks to those who work with electricity. In recent years, additional emphasis has been placed on the dangers associated with arc flash and arc blast energy. This risk arises, not from the passage of electric current through the body, but from the concentrated energy during an arcing fault. An electric arc can instantly vaporize material such as copper or steel. The arc, passing through the vaporized material, can create an extremely intense arc flash of very high and dangerous temperatures. The results may be severe burns to the hands, face, and body.

b. In 1979, the National Fire Protection Association (NFPA) introduced NFPA 70E, Standard for Electrical Safety in the Workplace. This standard covers methods of protecting workers from harm due to exposure to electrical systems and devices.

In 1995, NFPA 70E was revised to help protect individuals from arc flash dangers.

c. A 1999 study by the Electric Power Research Institute concluded that hundreds of employees have been injured or killed by arc flash energy and that the cost to the related industries was significant.

d. The USACE Safety and Health Requirements Manual, EM 385-1-1, dated Sep 2008, added requirements for an AFH Analysis to be conducted in accordance with NFPA.

e. Protection from AF energy is required by:

(1) OSHA [CFR 1910.269(l)(6)(iii) and 1910.335(a)(1)];

(2) NFPA 70E,

(3) EM 385-1-1

4. Roles and Responsibilities

Every employee has some roll and related responsibilities under this AFH Program.

Table 1 lists key personnel and contact information for The Dalles Lock & Dam AFH Program.

Table 1: Identification of Key Personnel

Role Phone

Operations Project Manager 541.506.8500

Hydropower Operations Manager 541.506.8200

Electrical Crew Supervisor 541.506.8340

Safety Specialist 541.506.8300

AFH Coordinator, Electrical Engr. 541.506.8315

a. District Commander shall ensure adequate resources are provided to comply with this regulation.

b. Operations Project Manager shall:

(1) Mandate the development, implementation, and enforcement of the AFH Program;

(2) Establish the necessary policies, practices, controls, and training to ensure the communication of the hazards and necessary precautions to affected personnel;

(3) Provide resources for the successful implementation of the AFH Program;

(4) Ensure the AFH Program is updated when a major modification or renovation takes place and that it is reviewed annually, as a minimum.

(5) Appoint an Arc Flash Hazard Coordinator (AFH Coordinator) to assist with implementation and management of the AFH Program;

(6) Ensure that Contractor employees are informed of known hazards that are covered by the AFH Program and that are related to the contract employer’s work and information about the facility that would require a contractor to make arc flash assessments.

c. Supervisors are responsible for the day to day oversight and implementation of the facility AFH Program and associated policies and shall:

(1) Ensure that personnel and visitors who will be in a flash protection boundary are trained in arc flash hazards; and only allow trained persons within the boundary area.

(2) Ensure safety precautions are in compliance with this regulation;

(3) Ensure that applicable Activity and Position Hazard Analyses address AFHs.

(4) Ensure violators of the policy shall be subject to appropriate administrative disciplinary action

d. Affected, Qualified and Non-Qualified, employees shall:

(1) Be knowledgeable of AF hazards;

(2) Be familiar and comply with, the facility’s AFH program;

(3) Report observed violations of the AFH Program to supervisors;

(4) Work in accordance with electrical safe work practices;

(5) Complete training as identified in the AFH Program;

(6) Participate in job briefings and Activity/Job Hazard Analyses. All job planning must be documented and documentation must be maintained and up to date;

(7) Use the appropriate personal protective equipment (PPE) as identified in section 8 for the activity they are performing;

(8) Erect barriers to clearly identify the Flash Protection Boundary (FPB);

(9) Report all arc flash related incidents and accidents to the supervisor.

e. . Relationships with Contractors. (Outside Service Personnel, etc.)

(1) USACE. Managers shall ensure that the Contracting Officer Representative (COR) informs the contract employers of:

• Known hazards that are covered by the AFH Program and that are related to the contract employer’s work

• Information about the employer’s installation that the contract employer needs to make required AFH analyses

• Facility personnel shall report observed contract employer-related violations of the AFH Program according to established procedures

(2) Contract Employer Responsibilities. Contractors are responsible for ensuring their employees, sub-contractors, and visitors who will be working in an AFH area are knowledgeable of the facility’s AFH Program. Contractors shall ensure their employees, sub-contractors, and visitors are trained in AFHs and the proper use of arc flash PPE. Contractors shall be responsible for providing appropriate PPE for their employees, sub-contractors, and visitors. The contractor will provide their AFH Program and procedures to the government designated authority (GDA) or the COR as a submittal, which must be accepted by the GDA prior to beginning work. The Contractor shall advise the government of the following and provide documentation of the communication:

• Any unique or unanticipated hazards presented by the contract employer’s work

• Hazards identified during the course of work by the contract employer that were not communicated by the Contracting Office or the Project.

• The measures the contractor took to correct any violations reported by the government to prevent such violations from recurring in the future

5. List of Locations with Electric Service. Table 2 summarizes the locations that have been identified at The Dalles Lock & Dam and evaluated by a qualified engineer.

Table 2. Listing of Electrical Services for Facility

Location Voltage Transformer Analysis Notes Powerhouse to 13.8 k 3ø Various Detailed Spillway to 4160 3 ø Various Detailed Navlock to 4160 3ø 1000 KVA Detailed Service Building to 4160 3ø Various Detailed Westrick to 480 3ø 50 KVA Detailed Intake Deck PH-roof to 230k 3ø Various Detailed Recreation sites to 480 3ø Various Detailed

6. Arc Flash Hazard Analysis (AFH Analysis).

A detailed Arc Flash Analysis (see Appendix D) was produced by the Hydroelectric Design center (HDC) for all equipment associated with The Dalles Lock and Dam.

An Arc Flash Analysis and associated labeling shall be completed prior to energizing new electrical equipment and for modifications to existing equipment.

The detailed Arc Flash Analysis shall include all systems greater than 50V to ground including high voltage systems (15kV) as well as DC systems. There are a few specific situations that require additional explanation for the IE analysis that is performed. These are outlined below:

1) For single phase AC systems the guidance of the EP 385-1-100 will be followed.

This document states that until further tools are available for work on 120VAC single phase systems the recommended arc flash level of protection should be based on an incident energy of less than 1.2 cal/cm2.

2) For high voltage systems greater than 15kV in an outdoor environment, the District Safety Office has instructed the Project to use the OSHA tables to determine the arc flash IE, see reference o. To use the OSHA 1910.269 Appendix E table 7 the short circuit available fault current and the maximum clearing time must be known. The short circuit current is provided by BPA from their Aspen system model. The maximum trip times are determined based on circuit breaker trip time, relay response time and communications channel response time. These times are as follows: 3 cycles, 3 cycles and 1 cycle respectively. The below chart summarizes the overall trip time and fault current and associated IE from OSHA

1910.269 Appendix E table 7.

Table 3. IE from OSHA 1910.269 Appendix E table 7

Position Available 3-Phase Short Circuit Current Isc, KA

Circuit Trip Time, cycles

OSHA 1910.269

App. E Table 7 IE, cal/cm2

Line 1 21 7 5

Line 2 20.8 7 5

Line 3 35.3 7 5

Line 4 34.8 7 5

Line 5 34.4 7 5

Line 6 34.8 7 5

*IE from OSHA 1910.269 Appendix E table 7 is based on a minimum working distance of 41.44” for 230 kV and 31.72” for 115kV.

3) For Generator neutral disconnect switches the Hydroelectric Design Center was consulted. Based on the discussion with HDC, it was determined that a label is required as there can be >50V to ground due to third harmonic voltages if the unit is running. It is our Project policy to operate the neutral disconnect de-energized, but all equipment is treated as energized until measured and proven de-energized by the acceptance of a clearance. The neutral disconnects are operated as part of establishing the clearance for the generating units. Since the clearance has not been accepted the disconnect is considered potentially energized. The neutral disconnects need to be labeled for the potential IE available which is determined based off the potential third harmonic single-phase voltage that could be present if the unit was running which is estimated to be 150-200V. Due to the low single phase voltage this position is treated the same as the guidance in the EP 385-1- 100 for single phase 120V AC systems. The neutral disconnects are labeled with the recommended arc flash level of protection based on an incident energy of less than 1.2 cal/cm2.

7. Hazard Mitigation and Integration of Controls into Work Practices.

a. Hazard mitigation will be accomplished through the following hierarchy of controls: elimination (design out), substitution (change protective relay settings), engineering controls (barriers, covers, insulated tools), administrative controls (hazard analysis, job briefings, labeling) and PPE (arc rate clothing & suits, gloves, face shields, ear plugs) .

b. Requirements of this AFH Program shall be integrated with other programs, practices and procedures to include: standard operating procedures, maintenance job tasks, safe clearance procedures and position hazard analysis.

c. An Activity Hazard Analysis (AHA) shall be developed when there is a potential for AFHs and shall detail each task, identified hazards and appropriate controls, to include any PPE that may be necessary to protect employees from the hazards.

8. Personal Protective Clothing and Equipment and Standard Work Clothing.

a. Personal protective clothing consists of Arc-Rated (AR) clothing. For the purposes of this document, the term PPE will encompass personal protective clothing and personal protective equipment. Protective equipment includes but is not limited to arc rated face shields, gloves, boots, and insulated tools.

b. The AFH analysis determines the arc flash protection boundaries and the estimated incident energy possible at a given working distance. The PPE used by the worker must be selected based on the incident energy of the hazard. PPE is intended to limit the thermal injury to a second-degree, i.e., curable, burn. PPE does not address protection against physical trauma injuries that could occur.

c. AR clothing and other PPE required for work on energized equipment has been provided by The Dalles Dam. Protective clothing includes, but is not limited too:

shirts, pants, coveralls, jackets, and parkas worn routinely by workers who, under normal working conditions, are exposed to momentary electric arc and related thermal hazards. AR rainwear worn in inclement weather is also included in this category.

d. Employees working within the FPB shall be provided with and shall use PPE that is designed and constructed for the specific part of the body to be protected and for the work to be performed. All parts of the body inside the FPB shall be protected. If only a part of the worker’s body is within the FPB and would be exposed to injury from the thermal hazard, the portion of the body exposed must be protected. If the entire body is within the FPB, all parts of the body – to include back of the head, torso and legs– must be protected from thermal injury.

PPE used for protection from thermal injury from an arcing fault must be arc-rated, AR equipment.

e. Arc Flash Clothing and PPE Requirements.

(1) PPE arc ratings are selected based on actual calculated incident energy for identified equipment (see section 8h).

(2) For IE’s above 40 there is no approved PPE. Local procedures shall be developed for situations requiring work within these flash protection boundaries. Administrative or Engineering controls shall be used to mitigate the hazard if de-energization is not possible.

(3) Flammable, synthetic materials are prohibited. These synthetic materials include acetate, acrylic, nylon, polyester, polyethylene, polypropylene and spandex, alone or in blends. These materials melt as a result of AF exposure conditions, form intimate contact with the skin, aggravate the burn injury, and shall NOT be worn by workers who have the potential for exposure to AFHs.

Other apparel – such as hard hat liners, hair nets, ear warmers, head covers, etc - made from materials that do not meet these requirements for melting, or made from materials that do not meet the flammability requirements shall not be permitted to be worn.

(4) Non-melting, flammable (Non-AR) materials are permitted. These materials include untreated cotton, silk, rayon, and wool fabrics (standard denim jeans, chinos, khaki slacks, etc.). Although permitted, these fabrics could ignite and continue to burn on the body, resulting in serious burn injuries.

f. Standard Work Clothing.

(1) All employees within the FPB, regardless of work being performed, shall wear non-melting untreated natural fiber standard work clothing, including undergarments as a base to the appropriate PPE, as identified in the AF Analysis and AHA, to protect the body from severe injury from an AF.

(2) Employees are responsible for providing standard work clothing while in the AFB. This clothing shall, as a minimum, be comprised of materials that are non-melting, flammable (non-AR) This type of clothing is permitted to be used as under layers to AR clothing. Tight-fitting clothing shall be avoided.

Loose-fitting clothing provides additional thermal insulation because of air spaces.

g. Personal Protective Clothing and Equipment (PPE). When AR clothing is worn, it shall cover and prevent all ignitable clothing (to include underclothing) from igniting and burning.

(1) Arc-rated AR protected equipment/clothing must contain a label or other mark that describes the maximum incident energy rating.

(2) The fit of AR clothing is important to the safety of the worker. When the surface of AR clothing is heated, heat is conducted through the material and any AR clothing touching the skin can result in a burn. To minimize this, AR clothing must fit loosely to provide additional thermal insulation, but must not fit so loose that it interferes with the worker’s movements. The ability of the worker to see in the necessary direction must also not be restricted.

Appropriately sized AR clothing has been supplied.

(3) All contents of pockets shall be removed so clothing fit is loose in the pocket areas.

(4) AF Suits. The suit design shall permit easy and rapid removal by the wearer (avoid zippers in the back of the suit).

(5) Head, Face, Neck and Chin (Head Area) Protection. Workers shall wear non-conductive head protection (ANSI Z89.1, Class E or G) and non-conductive PPE for the face, neck and chin (ANSI Z87.1) wherever there is a danger of injury from electric shock, burns, arcs or flashes or from flying objects resulting from electrical explosion. If employees use hair-nets and/or beard nets, these items must be non-melting and flame-resistant.

(6) Eye Protection. Workers shall wear protective eyewear whenever there is a danger of injury from electric arc, flashes or from flying objects resulting from electrical explosion. If the worker’s head is within the AF boundary, the worker’s eyes must be protected from the thermal hazard as well. Safety glasses meeting requirements of ANSI Z87.1 provide protection from impact and also filter damaging UV energy.

(7) Face Protection. If a face shield is worn, it must have an arc rating at least as great as the predicted incident energy. If a hood is worn for thermal protection, viewing window must protect the worker’s eyes from the thermal hazard. Protective eyewear in the form of safety glasses, must always be worn under the face shield or viewing window. Goggles shall not be worn with an ignitable or meltable component.

(8) Body Protection. Employees shall wear AR clothing when they are within the FPB and wherever there is possible exposure to an electric AF above the threshold incident energy level for a second-degree burn, 1.2 cal/cm2 (ASTM F1506).

(i) Clothing shall cover potentially exposed areas as completely as possible.

Shirt sleeves shall be fastened at the wrists, and top button of shirts and jackets must be fastened to minimize chance that heated air could reach below the AR clothing.

(ii) All flammable, non-melting clothing must be protected by at least one layer of clothing that has an established incident-energy rating. This clothing may be provided as an AF suit jacket and arc flash suit pants, shirts and pants or as coveralls or as a combination of jacket and pants, or, for increased protection, as coveralls with jacket and pants.

(iii) Various weight fabrics are available and shall be considered for comfort, heat stress, fit, ease of movement, etc. Generally, the higher degree of protection is provided by heavier weight fabrics.

(iv) The total system arc rating cannot be determined by adding the arc ratings of the individual layers. See NFPA 70E appendix M

(v) Outer Garments. Garments worn as outer layers over AR clothing (ie., jackets, rainwear) shall also be made from AR material. The arc-rating of outwear worn over arc-rated clothing as protection from the elements or for safety purposes, and that are not used as part of a layered system, is not required to have an arc-rating equal to or greater than the estimated incident energy exposure.

(vi) Underlayers. Significant injuries occur when fabrics melt onto a worker’s skin. Clothing made from materials that melt (i.e., acetate, nylon, polyester, polypropylene, spandex) are not permitted in fabric underlayers (underwear) next to the skin. An incidental amount of elastic used on non-melting fabric underwear or socks is permitted.

(9) Hand and Arm Protection shall be provided and worn when there is possible exposure to AF burn and shall be rated for the voltage for which the glove will be exposed (ASTM F496 & ASTM F696).

(i) The hands normally are the most exposed part of a worker’s body. The apparel described by NFPA 70E Table 130.5(G) shall be required for protection of hands from burns. Heavy duty leather gloves or arc flash rated gloves shall be worn when within the arc flash boundary and estimated incident energy exposure is equal to or greater than 1.2 cal/cm2.

When the worker’s hands are within the FPB, rubber insulating gloves shall not be worn without leather protectors. PPE that provides thermal protection offers no acceptable protection from shock or electrocution.

(ii) The same clothing worn for body protection must provide AF protection for the worker’s arms. Clothing selected and worn to protect the upper torso from thermal exposure must have long sleeves, fastened at the wrist.

The sleeves must not be shortened or rolled up. Apparel that provides thermal protection for the worker’s arms shall be an integral part of the apparel that protects the upper torso. Arm protection shall be accomplished by apparel described in NFPA 70E Table 130.5(G).

(10) Foot/Leg Protection. Heavy-duty leather and/or dielectric rated safety-toed shoes provide some AF protection to the feet and shall be used in all tasks within the arc flash boundary (ASTM F1117, ASTM 2412 & ASTM 2413).

Footwear other than heavy duty leather and/or dielectric maybe used provided it has been tested to demonstrate no ignition, melting or dripping at the estimated incident energy exposure. Shoes made from lightweight material shall not be selected. AR clothing worn to protect the lower torso must protect the worker’s legs from exposure.

(11) Conductive Articles Being Worn. Conductive articles of jewelry and clothing (i.e., large belt buckles, watchbands, bracelets, rings, key chains, necklaces, metalized aprons, cloth with conductive thread, metal headgear or metal frame glasses) shall not be worn while within a FPB or the restricted approach boundary per NFPA 70E 130.8.

h. PPE shall be maintained in a safe, reliable condition per the manufacturer’s recommendations. AR clothing will be laundered per the manufacturer’s instructions.

(1) Inspection. Workers shall inspect their arc-rated AR clothing, per the manufacturer’s instructions, visually before each use to ensure that the clothing is not soiled or contaminated with grease, oil, flammable liquid, or combustible materials. The clothing must be free from tears, cuts or rips.

Workers shall be trained to understand how to inspect AR clothing and how to determine when the rating of the AR clothing is voided (presence of materials discussed above). PPE or AF suits that are contaminated or damaged to the extent their protective qualities are impaired, shall not be used.

(2) Storage. PPE shall be stored in a manner to prevent physical damage and damage from moisture, dust or other deteriorating agents or contamination from flammable or combustible materials. Contamination reduces the thermal protection provided by the clothing. There are multiple locations for arc flash PPE storage. The locations are near employee offices and changing areas. It is available for use anytime by qualified employees.

(3) Cleaning, Repairing and Affixing Items. Arc-rated AR clothing and other arc-rated PPE and must be maintained in a clean and sanitary condition and must be cleaned and maintained as defined by the clothing manufacturer. The manufacturer’s instructions for cleaning and care of their products will be very specific, since certain cleansers and chemicals will affect the AR characteristics.

i. The Dalles Lock & Dam –Require PPE based on incident energy hazard analysis. Use incident energy from arc flash label to identify which PPE is required. The list below is taken directly from NFPA 70E table 130.5(G).

Incident Energy of 1.2 – 12.0 cal/cm2

Arc-rated clothing with an arc rating equal to or greater than the estimated incident energy

Arc-rated long-sleeve shirt and pants or arc-rated coverall or arc flash suit (SR) Arc-rated face shield and a rc - ra t ed bal ac l ava or arc flash suit hood (SR)

Face shields are to have wrap-around guarding to protect not only the face but also the forehead, ears, and neck. If the back of the head is within the arc flash boundary then a balaclava or arc-rated flash suit hood is required to be worn to protect the back of the head and neck.

Arc-rated outerwear (jacket, parka, rainwear, or hard hat liner) (AN) Heavy duty leather gloves, arc rated gloves, or rubber insulating gloves with leather protectors (SR) Hard hat Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather footwear

Incident Energy of greater than 12.0 cal/cm2

Arc-rated clothing with an arc rating equal to or greater than the estimated incident energy

Arc-rated long-sleeve shirt and pants or arc-rated coverall or arc flash suit (SR) Arc-rated flash suit hood Arc-rated outerwear (jacket, parka, rainwear, or hard hat liner) (AN) Arc rated gloves or rubber insulating gloves with leather protectors (SR) Hard hat Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather footwear

*AN: as needed (optional), SR: selection of one required.

9. Labeling and Boundary Markers

a) Equipment warning labels serve as a reminder to employees that the equipment they may be working on present serious hazards and their work procedures need to take these hazards into account.

b) Arc Flash Labels. The arc flash label layout used by The Dalles Project is provided by HDC. HDC has recently changed their label to account for the changes made in the NFPA 70E 2015. Both IE and hazard category are no longer allowed to be on the label together. The Dalles Project has chosen to include the arc flash IE. All new labels applied will have the same format as before without the hazard category number on the label. When the next Power Systems Analysis (PSA) is done at The Dalles Dam, all labels will be replaced with the newer label style. The prohibited approach boundary for shock hazard is also no longer on the arc flash label.

c) Multiple Labels. Some equipment enclosures have multiple potential IE exposures due to multiple voltages and protective device locations. Therefore some equipment will be labeled for BUS SIDE FAULTS and for LINE SIDE FAULTS, see EP 385-1-100 for further discussion on this subject. The qualified worker shall choose PPE based on the IE posted for the work being performed.

d) Placement on Equipment. The labeling shall be located so as to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment. Even if equipment is in close physical proximity, its electrical characteristics can vary greatly. So, equipment with different available incident energy and flash protection boundary may require individual labels, regardless of nearness.

e) Maintenance Switches. In the lower section of the label it will indicate if there is a maintenance switch (ARMS or ERMS) that can be used to lower the IE. The IE will be listed for when the maintenance switch is placed in maintenance mode. Once the maintenance switch is placed in maintenance mode an associated light will illuminate indicating that the upstream protective relay is in maintenance mode. Only when the maintenance mode light is illuminated can the reduced IE be used to determine the necessary PPE required.

For equipment with IE and FPB calculations, labels such as shown in Figure 1, 2 and 3 shall be used.

Fig. 1. Example Label, NFPA 70E 2012 style for Calculated IE and FPB

Fig. 2. Example Label, NFPA 70E 2015 and later style for calculated IE and FPB

! WARNING

96 inches Flash Hazard Boundary

36 inch Working Distance

2.8 cal/cm^2 Flash Hazard at 36 inches

PPE Level FR Shirt & Pants

4160 VAC Shock Hazard when cover is removed 1 Glove Class 60 inches Limited Approach 26 inches Restricted Approach 7 inches Prohibited Approach

Arc Flash & Shock Hazard - PPE Required

Bus: SP Bus #2A Prot: Differential

****BUS SIDE FAULT****

Warning: Changes in equipment settings or system config. may invalidate results. (Existing Case, Date:Jul 2014 No: XP1/2-003)

Fig. 3 Example Label, NFPA 70E 2015 and later style with maintenance switch IE and calculated IE and FPB

f) Boundary Markers. Boundary markers shall be of the retractable belt barrier type. Boundary markers shall be placed prior to working on energized equipment and shall be placed no closer than the FPB. Boundary markers are stored east of the control room on the 157.7’ level.

10. Training.

a. Much of the material for arc flash may be new to employees. Electrical safety training that incorporates use of new and existing PPE shall be given to all employees who could be exposed to electrical equipment. This assists them in understanding the scope of what is involved in the dangers of an AF and helps them identify possible electrical hazards in the field.

Table 4. Arc Flash Training Levels

Title Q/U1 Training Administrative U Awareness

Contractor U Awareness Electrician Q Detailed

Engineering U Awareness AFH Coordinator Q Detailed

Labor U Awareness Mechanic Q Detailed Operator Q Detailed

RMS Q Detailed Others U Awareness

1 U = Unqualified, Q = Qualified.

b. AFH training for affected personnel must concentrate on how to recognize and avoid electrical AFHs. AFH training shall be required upon employment and additional training shall be required:

(1) If a supervisor or annual inspections indicate that the employee is not complying with the safety-related work practices;

(2) Upon new technology, new types of equipment, or changes in procedures which have been implemented at the facility;

(3) If new safety-related work practices are required or the Arc Flash Program is updated;

(4) At least annually for qualified employees and every 3 years for unqualified employees (may be performed in conjunction with other safety training, i.e., electrical safety training, control of hazardous energy training, etc.);

(5) For Qualified personnel, if work tasks are performed less often than once per year retraining prior to performing the work shall be required.

c. Employees in the Mechanic, Electrician, Operator and RMS trades are expected to receive training to achieve a “Qualified” status. An employee can be considered qualified with respect to specific equipment and tasks and be unqualified for others. AFH training for qualified personnel must address, as a minimum, the following:

(1) Skills and techniques necessary to distinguish exposed energized electrical conductors and circuit parts from other parts of electrical equipment;

(2) Skills and techniques necessary to determine the nominal voltage of exposed energized electrical conductors and circuit parts;

(3) Approach distances specified in NFPA 70E Table 130.4(E)(a) and 130.4(E)(b) and the corresponding voltages to which the qualified person will be exposed;

(4) Decision making process necessary to determine the degree and extent of the hazard and the PPE and the job planning necessary to perform the task safely;

(5) Review of the local AFH Program;

(6) How to avoid exposure to arc flash hazards;

(7) How to determine the degree of each hazard: labels, work permits, one-line diagrams;

(8) How to minimize risk by body position;

(9) How flash protection boundaries are implemented and enforced;

(10) Required level, proper use, fit, and location of PPE and AR clothing for each hazard/risk category;

(11) Required maintenance and inspection procedures of PPE;

(12) Required maintenance practices and tools to mitigate energy levels;

(13) Emergency Procedures;

(14) Incident/Accident Reporting;

(15) Proper identification and use of test equipment.

d. AFH training for unqualified personnel must address the following:

(1) Review of local AFH Program;

(2) AFH awareness – definition and recognition;

(3) How AFHs affects the body;

(4) How to recognize an AF label and flash protection boundary;

(5) Emergency Procedures;

(6) Accident/Incident Reporting.

(7) The prohibition of crossing the arc flash boundary or limited approach boundary.

e. AFH training may be performed by classroom training, on the job training but most effective training will be comprised of both types. Any training given, whether classroom or on the job, must be documented with instructor, content, and date the training was received.

f. Instructors, whether government or contractor, shall have an appropriate level of technical knowledge, skills, or abilities in the subject of arc flash hazards.

Instructors shall be competent in delivery techniques and methods appropriate to adult learning.

11. Inspections and Program Reviews. Periodic inspections and program reviews shall be designed and conducted to identify and correct any weaknesses or deficiencies in the program or procedures, employee training, or enforcement of the requirements.

a. Management shall ensure that periodic inspections and program reviews are performed. This will be accomplished by using the computerized maintenance management system to automatically generate a work order to perform the necessary reviews.

b. Periodic inspections and program review shall be performed at least annually by teams knowledgeable in the Arc Flash Hazard Program, to include a Qualified Person. Personnel internal to the facility shall conduct the inspection one year and personnel external to the facility shall conduct the inspection the following year.

c. Periodic inspections and program reviews shall cover all elements of the AFH Program, assess implementation of this program in the facility and employee understanding and compliance.

d. Periodic inspections and program reviews shall be documented (date, persons involved, results) and identified deficiencies noted. Corrective actions taken to improve the program or employee knowledge of the program must include how any revision of specific procedures or a general change is communicated to the workers. Documentation shall be retained for at least two years

e. Arc Flash Hazard Analysis Review. The arc flash hazard analysis shall be updated when a major modification or renovation takes place and shall be reviewed periodically, not to exceed five years, by a qualified engineer. The review is to account for changes (fault current or protective device clearing times) in the electrical distribution system that could affect the results of the arc flash hazard analysis. This generally includes installation of new equipment or changes to the protection devices/settings. Also, any changes (utility contribution) exterior to the facility may affect accuracy and should prompt reevaluation of the entire facility model. These updates may result in raised or lowered energy levels, thus changing labeling, PPE and procedures. The review shall be documented and stored in The Dalles Dam ProjectWise Database.

12. Incident and Accident Reporting.

a. All mishaps involving arc flash (near misses, incidents or accidents) shall be immediately reported to the employees’ supervisor. Supervisors will report to Operations Project Managers who will assign Project Safety Officer (PSO) and an Arc Flash Team. The PSO will report the arc flash mishap to the district safety office within 24 hours. The PSO and the Arc Flash Team will perform the following:

(1) A technical investigation shall be conducted and lessons learned shall be developed. For near misses and incidents results will be reported in ENGLINK. For accidents reporting will be in accordance with ER 385-1-99.

(2) A Board of Investigation shall be conducted for all mishaps resulting in a fatality, permanent disability, or property damage of $200,000 or more.

b. A record of all arc flash hazard incidents shall be maintained. These records will be used to create lessons learned and identify any trends that may need to be addressed in the AFH Program.

c. If reporting criteria is met for the incident an ENG-3394 will be developed by PSO and submitted through upper management to District Safety Office within 10 calendar days.

d. Employees are encouraged to report and seek medical attention for any electrical injury.

13. Documentation & Recordkeeping

Documentation of program reviews will be notated within the revision history table located on page ii. Inspection documentation will be kept on file on an annual basis and any findings will be addressed and incorporated within the revision history table located on page ii. Training documentation will be kept in the employees’ official training file for the duration of employment. The training documentation will contain the course outline, syllabus or training objectives as well as the dates of attendance.

14. References

Industry Standards

a. 29 Code of Federal Regulation (CFR) 1910.147, The Control of Hazardous Energy Sources (Lockout/Tagout)

b. 29 Code of Federal Regulation (CFR) 1910.269 (l) (6), Electric Power Generation, Transmission, and Distribution

c. ANSI Z10, American National Standard for Occupational Health and Safety Management Systems

d. ANSI Z87.1, Occupational and Educational Personal Eye and Face Protection Devices

e. ANSI Z535.1, Safety Color

f. ASTM International (ASTM) F1506-08, Standard Performance Specification for Flame Resistant Textile Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards

g. IEEE Std. 1584A, Guide for Performing Arc Flash Calculations

h. NFPA 70, National Electric Code (NEC), National Fire Protection Association

i. NFPA 70B, Recommended Practice for Electrical Equipment Maintenance

j. NFPA 70E, Standard for Electrical Safety in the Workplace

k. OSHA Standards 29-CFR, Part 1910.333

US Army Corps of Engineers Standards

l. Engineering Manual (EM) 385-1-1, U.S. Army Corps of Engineers, Safety and Health Requirements Manual

m. Engineering Regulation (ER) 385-1-100, U.S. Army Corps of Engineers, Arc Flash Hazard Program

n. Engineering Pamphlet (EP) 385-1-100; U.S. Army Corps of Engineers, Implementation of Arc flash Hazard Program

o. Email dated 6/18/19 from John Cannon, Chief Safety and Occupational Health

p. OSHA 1910.269 Appendix E table 7

15. Sub-program Appendix Links:

Appendix A – Electrical Work Permit

Appendix B – Electric Shock Policy

Appendix C – Incident Energy Chart

Appendix D – Arc Flash Analysis, HDR March 2015

Appendix E – EP 385-1-100

Appendix F – NFPA 70E