NREL s Electrical Safety Culture Revitalization

Transcription

1 NREL s Electrical Safety Culture Revitalization Sal Sferrazza September 2014 NREL is a na*onal laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

2 NREL s Electrical Safety Culture Revitalization

3 NREL s Electrical Safety Culture Revitalization January 2013

4 Electrical safety is a challenge at NREL custom built equipment and systems (unlisted) Difficult to choose applicable design standards for R&D equipment changes in work, equipment, environment Many visitors users and students each year Subcontractors - Organizational Structure and Culture - Tendency for R&D community to rely on facilities and safety organizations for electrical safety expertise

5 NREL s Electrical Safety Organizational Changes NREL NEEDS MORE INVOLVEMENT IN ELECTRICAL SAFETY ACROSS THE ORGANIZATION Electrical Safety Panel Charter Modified DOE and Line Management is represented AHJ Authority clarified with DOE Created ESO and Advisors, selected by the AHJ/Charter Electrical Safety Officers (ESOs) and Advisors are key panel members and have been selected The ESO has a strong working background in the electrical field. (e.g. scien*st, EE, electrician, electronics technician, lineman)

6 NREL Electrical Safety Organiza*onal Structure Lab Director Senior Manager Champion AHJ Electrical Safety Panel Na*onal Center for Photovoltaics Transporta*on & Hydrogen Systems Chemical & Materials Sciences Buildings and Thermal Systems Biosciences Site Opera*ons Na*onal Wind Technology Center Environmental Health and Safety Power Systems Engineering Na*onal Bioenergy Center National Renewable Energy Laboratory Innovation for Our Energy Future

7 ESO Training train more, to fewer employees, and allow even fewer employees to do the work Extensive Training Program IniJated for ESOs and Advisors 5 Specialized Courses in the last 2 months of fiscal year 2013, 17 days of training at a cost of $100,000 Na*onal Electric Code for Lab Workers NFPA 70E Electrical Safety in the Workplace Specialized Officer training for Lab Workers Na*onal Electric Code Inspector Class (ICC Inspector Cer*fica*on prep class) Medium Voltage Power Systems 2014 Training: SEMI S22 Safety Guidelines for the Electrical Design of Semiconductor Manufacturing Equipment & EN Safety of Machinery Requirements for Semiconductor Fabrica*on Equipment NFPA 79 Electrical Standard for Industrial Equipment Addi*onal Medium Voltage Training for Electricians (cer*fica*on is goal)

8 NREL s Electrical Safety Engaging R&D Electrical InspecJon Process Improvements Working with Officers to id equipment for inspec*on Addi*ons to the Electrical Safety Lab Level Procedures Working on simple electrical tests to aid in approving equipment per NFPA 79, Chapter 18 Earthing Con*nuity Test,ground impedance tests, Dialec*c Tests, Residual voltage Encourage Research in Electrical Safety Encourage them to be the Expert Hazard iden*fica*on & control of lab electrical hazards (DC, RF, stored energy etc.) Third Party Cer*fica*ons 1/3 of ESOs are ICC cer*fied inspectors now QualificaJon Cards

9 NREL s Electrical Safety Culture Engaging R&D Engaged in Electrical InspecJon /Process Improvements Selected document control so[ware(filemaker Pro) : Document/Form Control LOTO Form Excava*on Permit Electrical Safe Work Permit INSPECTION FORM Arc Flash Reports PRO: FileMaker Pro is a record keeping database / compliance tool CON: More administra*ve overhead

10 PPE : Everyday wear NREL s Electrical Safety Culture Engaging Facilities We have recently adopted everyday wear for those engaged in daily electrical construction work. Mandated electricians to be third party certified to do construction inspections Facilities electricians are accepting and grateful for the opportunity All NREL electricians are licensed and ICC certified electrical inspectors Formal NFPA 70E training for mechanical technicians 10

11 Other Improvements Policy Updates Electrical Safety Policy Updates R&D hazards Shock boundary thresholds for special R& D hazards DOE Handbook Practical 11

12 Electrical Hazard Classification Adopted Classify according to waveform and source 60 Hz DC capacitors batteries RF 3 khz MHz subrf 1 Hz 3 khz inductors 1.x 2.x 3.x 4.x 5.x 6.x 7.x General Categories National Renewable Energy Laboratory Innovation for Our Energy Future

13 Other Significant Electrical Improvements PM Program for Electrical Equipment Year 1 of the PM program has started Budgeted $500,000 or $125,000 per year, 4 year cycle Priori*es Set #1 Equipment that poses the greatest arc flash hazard #2 Oldest equipment first Hiring a full *me employee to manage NREL s electrical preventa*ve maintenance program

14 Electrical Safety Challenges Administration for Electrical Safety Permit Library Equipment Labeling Inspection PPE Program Engineering Support Arc Flash Analysis Hazard Analysis Inspections Real Time Configuration Management / Equipment Alignment 14

15 How do we keep R&D engaged in Electrical Safety Program? Qualification and Training Recognition of Hazards Methods to Control Hazards Engineering Controls Equipment Approval Program Administrative Controls Work Control Two person rule Permits PPE Qualification and Training BUDGET PROVIDED TO ESOs

16 Recommended Additional Electrical Training UL 508 o Safety Standard for Industrial Control Equipment NFPA 790 & 791 o Standard for Competency of Third- Party Field Evalua*on Bodies o Recommended Prac*ce and Procedures for Unlabeled Equipment Evalua*on Third Party Medium Voltage Cer*fica*on Third Party Electrical Tes*ng Cer*fica*on National Renewable Energy Laboratory Innovation for Our Energy Future

17 NREL s Electrical Safety Culture Revitalization Observations There is a benefit of having the latest understanding of NFPA 70E and other codes and standards Sold the idea to management Managing the expectations Costs, but requires more discipline than cost Audits & inspections It is long term plan 17

18 Questions? 18