FACILITIES ELECTRIC SUBCONTRACTORS SAFETY MANUAL GENERAL DYNAMICS ELECTRIC BOAT CORPORATION June 28, 2011* *All changes as of this date are noted in red. 1 of 9
Table of Contents 1. Requirements 2. Tools 3. Test Equipment 4. Personal Protective Equipment 5. Electrical Transformer Substation Access 6. Equipment System Tagout 7. Safety Grounding Of Circuits 8. Working On Energized Systems 9. Barriers 10 Confined Spaces 11 Electrical Systems And Equipment 12 Electrical Work Procedures 13 Electrical Shock 14 Cardio Pulmonary Resuscitation (CPR) Attachments: Electric Boat Corporation Safety Manual # C14 Safety Manual C-14.pdf Electric Boat Corporation Safety Manual # F18 F-18.pdf Electric Boat Corporation Shipyard Standard Procedure 7.48 7.48.pdf Reference: Contractor Safety, Health and Regulations Manual 2 of 9
1. REQUIREMENTS 1.1. All contractor personnel expected to work on electrical equipment or systems must read this Safety Manual, including all referenced material and Electric Boat Corporation Safety Manual - Numbers C-14 and F-18 prior to working at Electric Boat Corporation (EBC), and annually thereafter. 1.2. Contractor shall submit to Facilities Engineering (D502) a statement signed by all personnel expected to work on electrical equipment or systems that they have read, understood, and will comply with this Safety Manual, including all referenced material and Electric Boat Corporation Safety Manual - Numbers C-14 and F-18. This statement must be submitted before persons are allowed to perform any work at EBC, and annually thereafter. 1.3. Contractor shall submit names of personnel qualified to work on low voltage (less than 600 volts) electric equipment or systems, and why they are qualified. Submittal shall be on company stationary and be signed by an authorized individual. Submittal must be received by Facilities Electrical Engineering prior to person working at EBC. 1.4. Contractor shall submit names of personnel qualified to work on high voltage (greater than 600 volts) electric equipment or systems, why they are qualified to work on high voltage, summary of past work experience on high voltage, qualifications to work on high voltage, and training qualifying them to work on high voltage. Submittal shall be on Contractor stationary and be signed by an authorized individual. Submittal must be received by Facilities Electrical Engineering prior to person working on high voltage at EBC. 1.5. All work must be performed per OSHA, The National Electric Code, Connecticut Building Code, Electric Boat Corporation Contractor Safety, Health and Regulations Manual, and this Safety Manual. If a conflict exists, use the more stringent requirements. 3 of 9
2. TOOLS 2.1. Use tools for only the job they are intended. 2.2. Maintain tools in good operating condition. Damaged tools shall be removed from the site and replaced. Foremen and/or EBC Representatives have authority to condemn tools. 2.3. All contractors must use GFCI protection for portable electrical tools or an assured equipment grounding program (29 C.F.R. 1926 404 b 1), at all exterior locations, industrial areas, or whenever extension cords are used. 3. TEST EQUIPMENT 3.1. Test equipment shall be used in accordance with the manufacturer's instructions. 3.2. Modification of test equipment is prohibited. 3.3. Never use equipment above the equipment's rating. 3.4. Carefully inspect all test leads for damage before use. If the leads are damaged remove them from job site immediately and replace. Never repair or modify test equipment leads. 3.5. Never assume test equipment is working, always check for proper operation. 4. PERSONAL PROTECTIVE EQUIPMENT(PPE) 4.1. Personal Protective Equipment (PPE) must meet the minimum performance standards established by OSHA, Safety or Industrial Hygiene, be readily available, be properly maintained and its use enforced. Personnel are to be properly trained in the use of personal protective equipment. PPE includes such items as safety glasses, hard hats, grinding shields, hearing protection, electrical gloves, flash suits, etc. 4.2. Contractor supervision is to ensure its employees are aware of and understand all limitations and precautions regarding safety equipment and protective clothing and is responsible for strictly enforcing the proper use of such equipment and clothing. 4.3. See the Contractor Safety, Health and Regulations Manual. 4 of 9
4.4. ELECTRICAL GLOVES 4.4.1. See Electric Boat Corporation Safety Manual - Number F18 4.4.2. Wear proper gloves for the work you are doing. Know and follow the regulations and instructions on the use of gloves. 4.4.3. Gloves must be rated for or above the class of voltage being worked on. 4.4.4. Avoid splinters, burrs and other sharp objects that might puncture gloves. Leather gloves will be worn over rubber gloves if a puncture exposure exists. 4.4.5. Never wear rings, watches, etc. when using electrical gloves. 4.4.6. Store gloves as recommended by the manufacturer and OSHA. 4.4.7. Gloves must be tested annually as a minimum. 4.4.8. Properly inspect gloves for damage and leaks before using. If the gloves are damaged or leak, do not use. Remove gloves from job site. 5. ELECTRICAL TRANSFORMER SUBSTATIONS ACCESS 5.1. Access is controlled; see Electric Boat Corporation Safety Manual - Number F-18, Procedures High Voltage Area With No Exposed High Voltage Bus Work or Connections and High Voltage Areas With Exposed Bus Work and Connection. 6. EQUIPMENT/SYSTEM TAGOUT 6.1. Never operate equipment with a "Danger-Do Not Operate" tag. See Electric Boat Corporation Safety Manual -Number C-14 and Number F-18. 6.2. Once a lockout/tagout procedure has begun for any specified circuit or system, the process must be followed through to completion without interruption. 7. SAFETY GROUNDS - PERSONNEL PROTECTION 7.1. All high voltage equipment, substation, switchgear, and distribution transformers must be safety grounded with equipment, rated for the available short circuit current, before starting work. All low voltage equipment should be grounded whenever possible, with equipment, rated for the available short circuit current, before starting work. This grounding is for safety of the personnel working on the equipment. 7.2. Grounds should be attached on both sides of where personnel will be working. 7.3. Equipment shall be discharged before securely attaching grounds. Discharging shall be accomplished with a hotstick and grounding assembly. A grounding assembly for the location shall be first clamped to a grounding electrode conductor, grounded steel or other ground. Then the grounding assembly shall be placed on all phases, closest phase first, with a hot stick. Proper electrical personal protective equipment (PPE) (i.e. electrical gloves, hard hat, safety glasses, face shield, etc.) must be worn. 7.4. The hot sticks must always be held away from the body. 5 of 9
7.5. Capacitors on a system require special attention. The load rated disconnects must be opened first, then allow ten minutes for the capacitors to discharge through their built in discharge resistors before grounding to the above procedures. 8. WORKING ON ENERGIZED SYSTEMS 8.1. See Electric Boat Corporation Safety Manual - Number F-18 Work on energized circuits including troubleshooting, will be performed to the following criteria. 8.2. Follow all OSHA and NFPA-70E requirements. 8.3. Where proper PPE when working, switching, troubleshooting, etc. 9. BARRIERS 9.1. Barriers (red tape) shall be used to enclose areas where work, such as the following is being performed: 9.1.1. Work on or near energized equipment 9.1.2. Testing with high voltage (all areas will be at high voltage potential). 9.1.3. Work being done in manholes. 9.2. Only personnel actually doing the work may enter an area where work is being done on energized circuits or high voltage testing is being performed. 9.3. Only qualified personnel may enter an area with barriers. 9.4. Barriers (red tape) shall also be used to isolate areas with energized circuits within a work station, when work is being performed only on de-energized circuits. This is used to remind personnel that all circuits in the area are not de-energized. 9.5. Work areas created by the use of barriers must be large enough to allow all necessary work to be done inside the area with proper equipment. Remember these barriers are to isolate you from external hazards and to keep unqualified/untrained personnel away from a hazard condition. 10. CONFINED SPACES 10.1. Never enter an uncertified/unposted tank or confined space ( Note: A manhole, vault, or underground tunnel is a confined space.). See Electric Boat Corporation Safety Manual - Number F-18 Entry Requirements to High Voltage Electrical Utility Manholes/Vaults. See Electric Boat Corporation Shipyard Standard Procedure #7.48. 11. ELECTRICAL SYSTEMS AND EQUIPMENT 6 of 9
11.1. All non-current carrying components (enclosures, raceways, frames, etc.) must be grounded. 11.2. Fuses rated for proper voltage, amperage, and classification must always be used. Never modify a fuse or fuse holder. 11.3. All equipment must be rated for the voltage and amperage it is being used for. Equipment must also have a short circuit withstand rating sufficient for the equipment's location in the system. 11.4. All equipment must be properly installed. Jury-rigging and/or improper installations are prohibited. 11.5. Green wire shall be used for equipment grounding, ground bonding conductors, or static grounding conductors. 11.6. All substations, panelboards, circuit breakers, disconnect switches, etc. must be properly labeled with voltage, equipment being supplied, and the electrical system designation. 12. ELECTRICAL WORK PROCEDURES 12.1. All circuits shall be assumed "LIVE" until tested. The proper procedure includes checking the tester on a known live circuit, checking the circuit to be worked on, and rechecking the tester on a known live circuit. The test shall be done at the work site, not at a remote site. 12.2. Before working on a circuit breaker with charging springs, make certain the springs are discharged. 12.3. Always use circuit breakers to interrupt/open or energize/close circuits under loads whenever possible. Switches rated for load switching may be used to interrupt/open or energize/close circuits under loads. 12.4. Never remove high voltage fuses when energized. 12.5. Always remove fuses with proper fuse pullers. 12.6. Always wear proper PPE when opening or closing high voltage switches. Stand to the side of the switch. 12.7. Always wear proper PPE and stand to the side when opening or closing low voltage switches and circuit breakers. 12.8. Use only insulated listed (UL or FM) ladders. 7 of 9
12.9. Never work on or near energized electrical circuits while standing in water. Manholes with water should be pumped and cleaned of all mud and water 12.10. High voltage cables shall not be cut unless it has been verified to be de-energized. The cable shall be visually traced from the source and checked with an approved cable tracer (known to be working) at the location to be cut. Tic tracers will not work on shielded cable. A cable insulation piecing tool, properly grounded and operated with a hot stick must be used to verify the cable is de-energized. 12.11. All equipment must be grounded. Equipment without proper grounding is a potential killer. Jury rigs and improper procedures are simply the practice of fools. If individuals from other trades disconnect leads or violate some other safety practice in ignorance of the effect, they are guilty at least of misconduct. If an electrician should do the same thing, he or she is potentially guilty of negligent homicide. There is no excuse for not knowing the proper practice, or the potential results of failing to follow proper practices. 12.12. Plugs and connectors shall not be disconnected while under load. Plugs and connectors 50 amperes and greater shall not be connected or disconnected while the line is energized. Open the disconnect means first. 12.13. Disconnect switches, panelboards, circuit breakers, etc. shall be accessible at all times. Do not block. A minimum of three feet clearance is required. 12.14. All wiring systems shall be permanent in accordance with applicable codes. Temporary wiring shall be used only for emergency use or during construction, remodeling or repairs and shall be a grounded system. 12.15. Breaker Rack-in shall be per OSHA requirements and shall be done only with breakers designed for this procedure and in accordance with the manufacturer's instructions. Prior to racking-in any circuit breaker, all barriers and doors shall be properly installed. This includes closing and securing the door in front of the breaker, if originally provided with the substation. Only the small access for the cranking wrench shall be open while racking-in the breaker. Circuit breaker enclosures in the vaults on Graving Docks #1 and 2 do not provide barriers between the circuit breaker and the buss, also the front door can not be closed while racking-in the breaker. Therefore as a minimum the following addition procedures must be followed. 1)Breakers shall be racked into only de energized busses, even if the entire substation must be secured. 2)Breakers in contact with energized buss shall not be operated with the front cover off, or only partially secured, while personnel are in the vault. 13. ELECTRICAL SHOCK 8 of 9
13.1. See Electric Boat Corporation Safety Manual - Number F-18 Treatment for Electrical Shock. 14. CARDIO PULMONARY RESUSCITATION (CPR) 14.1. Each contractor shall ensure that at least one person is trained and certified to administer CPR at each individual work site. The contractor shall also ensure that personnel designated as CPR qualified shall be recertified on an annual basis. 14.2. See Electric Boat Corporation Safety Manual - Number F-18. 9 of 9