Electrical Safety Procedure



Location Name: |Prepared By:

|Date Effective:

|Revision No.:

1 | |Operation Name: _________________________________________________

Area: ________________________________________________________

Approved By: ____________________________________________

Signature of Site/Department/Area Manager

Purpose and Scope

1 The purpose is to establish the (insert site or organization name) site’s procedure for the safe installation, use and maintenance of electrical equipment and systems and for the prevention of electrical and arc-flash related hazards and injuries including shock, burns, trauma and falls resulting from any work on or near exposed energized electrical equipment in excess of 50 volts to ground.

Electrical devices, equipment and systems are worked on in a de-energized state, unless de-energizing introduces an increased hazard or it is not feasible. Work on or near electrical equipment and systems are performed in conjunction with the requirements defined in the site's Hazardous Energy Control (LOTO) and Equipment and Machinery Safety procedures.

When work must be performed on exposed and energized equipment or systems it is conducted in accordance with the requirements in this procedure and the energized electrical work permit procedure.

3 The scope or coverage of the Electrical Safety Procedure includes: (enter a description of the site, plant, operational unit, research area, or building covered by this procedure).

Responsibilities and Accountability

1 The person accountable for the written Electrical Safety Procedure is: (insert name and/or job title and telephone extension).

2 All Personnel are responsible to:

Complete electrical safety training for assigned job responsibilities.

Understand the electrical risks and hazards associated with assigned job activities.

Perform only work activities for which they are trained or qualified.

Comply with all aspects of this procedure including not working on or near energized equipment for which they are not qualified.

Follow all safe work practices and utilize appropriate safety and personnel protective equipment when working on or near energized electrical parts.

1 Affected Persons are responsible to:

Not work within 10 feet/3 meters of exposed energized electrical parts.

Understand the risks associated with energized equipment.

Know the tasks that can be only be performed by Qualified Persons.

Know the importance of obeying electrical hazards, signs and tags.

1 Qualified Persons are responsible to:

• Distinguish exposed and energized parts from other parts of electrical equipment.

• Determine the nominal voltage of exposed and energized parts.

• Know the approach distances specified for various voltage levels.

• Be trained and authorized under the site's LOTO program.

• Evaluate electrical hazards and identify the necessary controls to perform electrical work safely.

2 Task-Qualified Persons are responsible to:

• Distinguish exposed parts from other parts of electrical equipment.

• Determine the voltage of exposed live parts through methods that do not involve direct voltage testing (e.g. reading signage, labels, and drawings).

• Know the approach distances specified for various voltages.

• Be trained and authorized under the site's LOTO program.

3 Line Management Personnel are responsible to:

• Complete required training and provide training for persons in their area of responsibility.

• Recognize and enforce safe electrical work practices and provide the safety equipment and administrative controls required to complete work in accordance with this procedure.

• Verify that personnel have the necessary qualifications, skills, knowledge and experience. Review and approve qualifications for Qualified and Task-Qualified Persons in consultation with site EHS.

4 Site/Area Management is responsible to:

Provide the resources necessary to implement and maintain an effective Electrical Safety Procedure

Verify that all electrical equipment are properly maintained

Monitor compliance and support program requirements during regular walk-through inspections and participation in periodic program reviews.

Introduce or participate in training sessions and demonstrate commitment and leadership.

1 Contractors and Third Party Service Providers are responsible to:

Provide qualified or licensed (where required) personnel.

Complete training meeting Merck requirements.

Submit safe electrical work practices to Merck for review and approval prior to work.

Resolve inconsistencies in procedures and ensure compatibility with Merck requirements.

Provide required safety and personal protective equipment (PPE).

1 Procurement Personnel and Engineering Services are responsible to:

Write project scopes and purchasing agreements to incorporate requirements of this procedure and findings from hazard identification and risk assessments.

Verify that electrical equipment complies with regulatory requirements and the requirements of this procedure.

1 Site EHS Personnel are responsible to:

Assist with program administration, implementation and verification of compliance with regulatory requirements and the requirements in this procedure.

Assess program status and verify that procedures comply with regulatory requirements, site needs and observations from annual program evaluations.

Assist line management, site engineering and procurement personnel in review of contractor and third party programs and qualifications.

Procedure

1 Personnel Qualifications

All electrical work is performed by personnel who are qualified, trained and approved by site management. Qualifications, work experience, training and task limitations for Qualified, Task Qualified, Affected and All Persons are defined in accordance with regulations and the requirements of this procedure.

The site implements appropriate safe electrical work practices, safety and personal protective equipment and other administrative controls as required. The site identifies by area or function the responsibilities for the installation, operation, servicing and maintenance requirements of electrical devices, equipment and systems. Site management approves and documents individual personnel qualifications for Qualified and Task-Qualified Persons.

Review of Qualifications

Site management assesses and approves personnel training and qualifications through a combination of field experience and supplemental electrical safety training. Qualifications for Qualified and Task-Qualified persons are documented using a standard form or the form presented in (site to specify-options include):

• Appendix 5.

The site reviews qualifications for Qualified or Task Qualified Persons initially and following any event or evidence indicating persons may no longer have the skills and knowledge to be considered a Qualified or Task-Qualified Person. This is accomplished by (site to specify review process).

Qualified Persons

Only Qualified Persons are permitted to work on or near energized electrical equipment. Qualified Persons understand requirements for the installation, operation and maintenance of a wide range of electrical equipment and systems, the related hazards and how to use safe work practices, safety and personal protective equipment and administrative controls in accordance with local regulations and this procedure.

Qualified Persons do not work alone, except for replacing fuses, operating switches, or other operations that do not require the person to contact energized high voltage conductors or energized parts of equipment, or emergencies involving hazard to life or property.

Qualified Persons are identified by name and job code/position description and department. This is accomplished by (site to specify-options include):

• List in procedure

• Attachment

Task-Qualified Persons

Task-Qualified Persons understand the requirements related to specific or assigned tasks for selected electrical equipment and systems, the related hazards and how to execute the required level of protective controls in accordance with local regulations.

Task-Qualified Persons are not permitted to perform any work on or near exposed energized electrical parts within the Prohibited Approach Boundary as defined in Appendix 3. The exception is while opening an electrical panel where by design the energized electrical equipment may be temporarily within the Prohibited Approach Boundary at the moment the cover is opened.

Task-Qualified persons are identified by name and job code/position description and department. This is accomplished by (site to specify-options include):

• List in procedure

• Attachment

Affected Persons

Affected Persons are not permitted to perform any work activities on or near exposed and energized electrical equipment. The only exception is disconnecting or one time resetting of a circuit breaker greater than 120V but not more than 480V with the protective panel on and no exposure to energized electrical parts. This task falls into Hazard Category 0 and the Affected Person must wear clothing and PPE consistent with Appendix 4. This is accomplished by (site to specify requirements).

2 Operational Procedures

Equipment Design, Procurement and Installation

The site designs, purchases and installs new and modified electrical devices, equipment and systems in accordance with all local applicable codes and standards, the Merck Engineering Design Standards and Guidelines and the requirements defined in this procedure. This is accomplished by (site to specify requirements).

Electrical Equipment Enclosures

The site installs all electrical equipment and enclosures in accordance with applicable codes and standards that include the following minimum requirements:

• All electrical installations are installed and maintained to protect personnel from electrical hazards under conditions of normal operation.

• All electrical installations are installed and maintained to prevent damage or physical contact to conductors.

• All indoor or outdoor electrical enclosures are suitable for the intended use, location and operating environmental conditions and are protected from physical damage.

• All covers, doors, gates or other closing devices are properly secured at all times unless the equipment is being serviced.

• Unused openings in junction and panel boxes, raceways, conduits, auxiliary gutters, cabinets, equipment cases or housings are covered or plugged with suitable devices providing protection substantially equivalent to the wall or case of the equipment.

Hazardous (Classified) Locations - Flammable/Combustible Atmospheres

When possible, repairs and maintenance are performed outside of the hazardous (classified) locations. Work in hazardous (classified) locations is conducted in accordance with the site Open Flame/Hot Work procedure and permit. Electrical equipment for hazardous locations is identified, installed and managed in accordance with regulatory requirements, including the following minimum requirements:

• Hazardous location areas or rooms are labeled at the points of entry.

• For all classified areas accurate electrical classification drawings and schemes are prepared.

• Enclosures in hazardous locations are securely closed unless equipment is being serviced.

• Enclosure covers are tightened and conduit seals are poured in accordance with regulations and manufacturer’s instructions.

• Equipment used in hazardous locations is approved and labeled for use in hazardous locations.

• Electrical equipment and installations in hazardous locations are installed and maintained in accordance with manufacturer’s instructions and local and company electrical codes and standards.

• All personnel performing electrical work in hazardous locations are trained in safe maintenance practices and the special considerations necessary to maintain electrical equipment integrity for use in hazardous locations.

Maintenance of electrical installations equipment and systems located in classified areas follows the site Open Flame/Hot Work procedures and permit. Such areas must be ventilated and monitored as needed to eliminate or control any potential combustible atmospheres. This is accomplished by (site to specify).

Electrical System Documentation

Documentation for electrical distribution devices, equipment and systems is maintained. Documentation includes single-line diagrams and short circuit interruption study data if applicable. This is accomplished by (site to specify).

Access and Control

The site maintains clear and unobstructed access for electrical panels, control boards and controllers. Access is in accordance with local regulatory requirements and at a minimum is maintained for the full width of the equipment and for 1 meter (3.3 feet) outward.

Rooms or areas housing electrical distribution devices, equipment and systems are dedicated for such use and are kept free of combustible storage. This is accomplished/verified by (site to specify).

Rooms or areas with exposed and energized electrical equipment are physically secured, (e.g., locked) and access is restricted to Qualified Persons only. This is accomplished by (site to specify).

Labeling

Electrical enclosures, switches and control panels are labeled indicating:

Nominal voltage

• Upstream source or feed

• Downstream equipment supplied or served

• Incident energy and work distance

• Reference for personal protective equipment selection

The site applies appropriate hazard labeling to the exterior of the enclosures, switches and control panels. This is accomplished by (site to specify-options include):

• Appendix 6

3 Safe Electrical Work Practices

General Precautions for Electrical Safety

General precautions for electrical safety include requirements for the following:

Illumination, confined spaces, conductive materials, ladder types, housekeeping.

Working near overhead electrical lines.

Use of portable electrical tools.

Use of temporary wiring & extension cords.

Working near concealed electrical installations.

General precautions for electrical safety during electrical system installation, maintenance, repair or operation are defined in accordance with local regulations and the minimum requirements defined in this procedure. This is accomplished by: (site to specify – options include):

Appendix 2

Safe Electrical Work Practices - De-Energized Equipment

Equipment and systems are de-energized and secured to achieve a zero energy state prior to any physical access or contact where there may be exposure to energized electrical parts. This is the fail-safe method for avoiding contact with energized electrical parts. This is the required first priority and every attempt is made to de-energized electrical equipment and to achieve a zero energy state. This is accomplished by personnel who are authorized to apply and use LOTO devices in accordance with the site’s hazardous energy control LOTO program. This is accomplished by (site to specify practices).

De Energizing Equipment

Circuits and equipment are de- energized using the following basic sequence:

1. Identify all sources of energy to the equipment using drawings, diagrams, and identification tags and field verification.

2. Utilize an approved energy control procedure (ECP).

3. Remove the load current, and then open the disconnecting devices for each energy source.

4. Discharge all capacitors using approved methods; high-capacitance elements must be short-circuited and grounded before the associated equipment is touched or worked on.

5. Apply properly rated ground connecting devices where it is reasonably anticipated that conductors or circuits being serviced could contact exposed energized conductors or parts.

6. Where possible, visually verify that blades of disconnecting devices are fully open or that circuit breakers are fully withdrawn.

7. Apply lockout/tagout devices in accordance with the site LOTO procedure.

8. Test each phase conductor or circuit part with an adequately rated voltage detector to verify that the equipment is de-energized. Test each phase conductor or circuit part both phase-to-phase and phase-to-ground. Check the voltage detector before and after each test to be sure it is working.

9. Properly ground all possible sources of induced voltage and stored electric energy (such as, capacitors) before making contact. If conductors or circuit parts that are being de-energized could contact other exposed conductors or circuit parts, apply ground-connecting devices rated for the available fault current.

|Exposed electrical equipment must be considered energized until tested and verified to be de-energized by a Qualified |

|Person who is authorized to apply LOTO devices. |

Zero Electrical Energy State

Circuits in which the design creates a situation in which a zero energy state cannot be verified require the Qualified Person to isolate the system following the site’s LOTO procedure:

1. Apply LOTO devices to the known circuits.

2. Treat the circuit as energized and follow the procedures for documenting the justification, issuing an electrical work permit and determining electrical work controls (e.g. distances, PPE and tools).

3. Use electrical controls in place to test the known circuits feeding the equipment, as well as other circuits identified as sharing common neutrals. Utilize both clamp-on meter and voltage tester to determine if the neutral is energized or carrying current.

4. If voltage is detected, attempt to isolate and lockout/tag out the source before proceeding. If no voltage is detected it must be assumed that the current has the potential to energize the circuit.

5. Complete the work with the electrical controls in place.

6. Report the design situation to supervision to initiate actions to correct the design or system instructions.

Safe Electrical Work Practices – Energized Equipment

If work must be performed on or near any exposed and energized electrical parts in excess of 50 volts to ground, justification must be obtained from management for energized electrical work. Such work is permitted only when it is allowed by local regulation and it can be demonstrated that de-energizing introduces additional or increased hazards or is not feasible due to equipment design or operational limitations.

All possible steps to de-energize must be considered, and line/area management must certify that the work on the energized system is required. Work on energized electrical is justified only if:

• Shut-down is not possible due to equipment design.

• Shut-down will result in the loss of a critical life safety or loss prevention system.

• Shut-down will result in the loss of process safety control resulting in operation outside of an established safe operating parameter or envelope.

• Shut down will disrupt a process resulting in loss of product sterility or containment.

• Shut down will cause loss of containment resulting in potential environmental impact.

• Disruption to a critical research effort resulting in loss of data or research materials.

• Disruption to a critical data system resulting in loss of data or system functionality.

• Disruption may result in additional safety or environmental hazard at time of system shutdown.

• A circuit is an integral part of a continuous process that would otherwise need to be shut down resulting in disruption to critical research, a validated process, product containment or sterility.

Justification is documented on an energized electrical work permit. If the work on or near energized electrical cannot be justified through one of the above criteria, the permit should not be issued. The work is then conducted after proper de-energization, verification of zero energy state, and application of LOTO devices.

Energized Electrical Work Permit

The site issues an energized electrical work permit when work on energized electrical equipment has been justified to document the justification and to ensure appropriate safe work practices and controls are established and approved prior to beginning work. The energized electrical work permit includes the following:

• A description of the circuit and equipment to be worked on and the location.

• Justification for why the work must be performed in an energized condition.

• A description of the safe work practices to be employed.

• An analysis of the shock and flash hazards.

• A determination of shock and flash protection boundaries - Limited, Restricted, Prohibited.

• Personal protective equipment to safely perform the assigned task.

• Access restriction of unqualified persons from the work area.

• Evidence of job completion, including a discussion of any job-specific hazards.

• Personnel rescue plans and emergency response.

• Approval signatures.

Safe electrical work practices and controls are identified on the energized electrical work permit and are observed and maintained for the duration of the energized work. This is accomplished by (site to specify). See Appendix #2 as a reference

Alerting techniques are used to warn personnel regarding hazards that may cause injury due to electric shock, burns or failure of parts. Alerting techniques are used when establishing restricted, limited and flash protection boundaries for energized electrical work. The site typically uses (site to specify – include all that apply):

• Safety signs and tags.

• Barricades and shields to prevent personnel entry into areas of exposed electrical hazards.

• Attendants are provided where signs and barricades do not provide sufficient protection.

• Additional redundant protection is provided when the work or the environment where the work is performed can damage the primary electrical insulation, PPE or other insulative barriers.

Exceptions for Completing an Energized Electrical Work Permit

Qualified Persons perform testing, troubleshooting, voltage measuring, and removal of panel covers to observe energized equipment on or near live parts without an energized electrical work permit provided they have the appropriate training, safe work practices and personal protective equipment. When a formal permit is not required, the expectation is that the Qualified Person will:

• Perform all tasks observing all of the safe work practices as detailed in this procedure.

• Enforce restricted work areas.

• Apply the open flame/hot work and hazardous energy control LOTO procedures and permits as required.

Re-energizing Equipment

To re-energize equipment, the Qualified Person follows the steps below in sequence:

1. Conduct tests and visual inspections as necessary to verify tools, electrical jumpers, shorts, grounds and other such devices have been removed.

2. Replace covers or shields are on exposed parts and/or establish proper boundaries to protect personnel upon re energization.

3. Remove hazardous energy control LOTO devices in accordance with the LOTO Procedure.

4. Apply any specific start-up or sequencing requirements.

5. Notifies others in area or affected of the intention to re-start or re-energize equipment.

Restore the system to the normal operating state following any specific and or normal start up procedures.

9 Safety and Personal Protective Equipment

Voltage Testing Equipment

Qualified Persons are authorized and trained to use voltage testing equipment. Voltage testing equipment is approved for intended use/range of use and inspected/tested on a periodic basis according to manufacturer's specifications.

Work Uniforms and Personal Protective Equipment

Qualified Persons with routine exposure to exposed and energized electrical equipment or who operate electrical devices, equipment and systems with potential for shock or arc flash hazards are identified and provided with arc/flame resistant uniforms and personal protective equipment (eye, face/head, hand, ear and foot protection) according to the hazard classification.

Insulated Tools, Gloves & Handling Equipment

Qualified Persons working near exposed electrical parts are authorized and trained to use insulated tools, gloves and handling equipment (e.g., hot sticks, blankets/mats and insulating protectors, grounding and rack-out devices). Insulated tools, gloves and handling equipment are:

• Protected from physical damage at all times.

• Selected based on the manufacturer’s protective rating and the potential voltage that may be encountered for assigned work.

• Inspected visually for damage and defects before each use and at intervals thereafter as service conditions and manufacturer require.

• Tested using both resistance testing and visual inspection for before initial use, and at intervals thereafter as service conditions, local regulations and manufacturer's specifications require.

Inspection/testing criteria are documented and tools insulated objects are marked/labeled with the certification date and next due date. This is accomplished by (site to specify process).

12 Rescue Plan and Emergency Response

The site includes instructions on methods to separate personnel who become physically attached to energized electrical parts using either energy isolation devices and/or of protective tools and devices. This is accomplished by (site to specify).

The site defines rescue plan actions that include training for Qualified Persons on the energized electrical work permit. This is accomplished by (site to specify).

The site provides for immediate life support capabilities including cardio pulmonary resuscitation and automatic defibrillation (CPR/AED) by qualified personnel within 4 minutes. This is accomplished by (site to specify).

Training

All personnel with exposure to electrical hazards are provided training commensurate with the hazards and risks present and in compliance with local, state and national regulations. Training is provided based on assigned duties, type and level of potential exposure to energized electrical devices, equipment and systems. Training is conducted if there is a change in electrical energy control design or work practices. Periodic training is provided on new or different electrical equipment based on complexity.

Training is conducted when observations, incidents, near-miss or periodic assessments reveal gaps or inadequacies in personnel understanding and/or application of safe electrical work practices.

Training requirements are defined by local regulations, job classifications and/or position descriptions and applicable departments using the site training matrix, plan or equivalent. The following additional training requirements apply:

• Affected Persons – Affected Persons complete training in general electrical safety-related work practices. Training is conducted (site to specify frequency) by (site to specify manner).

• Qualified Persons – Qualified Persons complete a competency-based training program in addition to meeting the site defined position qualifications. Training is conducted (site to specify frequency) by (site to specify manner).

• Task-Qualified Persons – Task qualified personnel complete competency-based training in addition to meeting the site defined position qualifications. Training is conducted (site to specify frequency) by (site to specify manner).

• Other Persons - Other Persons complete awareness-level electrical safety training. Training is conducted (site to specify frequency) by (site to specify manner).

Training is conducted at the following frequencies:

• Upon initial assignment

• Job change

• Equipment and machinery installation and modification as appropriate

• Following electrical safety-related incidents

• At least every (3) three years

Training is conducted (site to specify frequency) by (site to specify manner).

This is accomplished by: (site to specify and provide site specific guidance)- options are:

• Classroom Training

• On-Line Training

• Other ________________

Refresher training is conducted at time of equipment change, post-incident, or when deficiencies are noted from program assessments or at least every three (3) years.

(site to specify and provide site specific guidance) (site to specify frequency). Some options are:

• Classroom Training

• On-Line Training

• Other ________________

Training Records

The site maintains a record by job classifications or position descriptions and areas or departments where personnel are authorized to routinely perform work on or near exposed and energized electrical devices, equipment and systems.

Program Evaluation

Program information is evaluated and a trend analysis/data mining performed at least on an annual basis. (Site to specify the manner in which this requirement will be met).

The Electrical Safety Program is evaluated annually using High Risk Operations Appendix C: Program Evaluation Tool. The findings are documented and incorporated into program revisions.

The site’s Electrical Safety Program is revised as needed based upon the evaluation. The action plan for improving this program is the responsibility of (site to specify name or job title).

Recordkeeping

Electrical Safety Program records are maintained in accordance with local, state and/or national regulations and Merck policy. (Site to define responsible person or function and locations where required records are maintained).

These records include:

• Single line drawings for electric systems.

• Short circuit interruption study data.

• Description of flame resistance uniforms and approved types of PPE.

• Energized Electrical Work Permits for one month or until the self assessment is completed.

• Purchase specifications, inspection criteria and records for voltage rated tools, gloves and other protective devices.

• Applicable local or national regulations and standards

These records are documented in (site to specify) – options are:

•

• Other: ____________

Training documentation is maintained (site to specify the system, location and responsible area).

Regulatory Requirements

The site program maintains compliance with all applicable local, state and national regulatory requirements. These requirements include: (sites to specify any additional applicable regulatory requirements):

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