PURDUE

UNIVERSITY
NORTH CENTRAL

The Center for OSH

ELECTRICAL SAFETY
PROGRAM

1. Purpose

Electricity is a serious hazard in workplaces, capable of causing injuries (electric shock,

electrocution, fire and explosions), serious property damage or death from electrocution.
Providing workplace electrical safety and training to maintenance personnel and other
affected employees is expected to reduce the risk of such incidents.

2. Scope

This program provides guidelines for training employees in basic recognition of electrical
hazards and safe practices in the workplace. Instruction alone does not qualify or
authorize anyone to perform electrical work.

All electrical wiring and equipment must comply with the National Electrical Code,
OSHA regulations, and other established safety and engineering standards.
This instruction should in no way be construed as a synopsis of all electrical requirements,
nor as a substitute for formal study, training, or experience in electrical design,
construction, or maintenance.

Occupations that have a higher than normal electrical risk:

Plant supervisors (1)

Electrical engineers and electronic engineers (1)
Electrical and electronic equipment assemblers (1)
Electrical and electronic technicians (1)
Electricians
Industrial machinery operators (1)
Material transfer equipment operators (1)
Mechanics and repairmen (1)
Painters (1)
Surveyors or Cablers and ordinary workers (1)
Plant engineers (1)
Welders

Note 1)

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Workers in these groups do not need to be trained if their job or the work they supervise
does not require others to be close enough to exposed parts of electrical circuits that
operate at 50 volts or more with ground ground.
[55 FR 32016, August. 6, 1990]

3. Responsibilities

Management is responsible for:

^ Identify qualified personnel to work in electrical system installations,

^ implement OSHA electrical safety updates and approved lockout/tagout standards,
^ provide qualified personnel and affected workers with safety training,
^ provide employees with the necessary Personal Protective Equipment (PPE),
^ ensure that all electrical safety inspections are carried out,
^ ensure that all electrical safety hazards are corrected,
1. and, ensure that all new electrical equipment and components comply with codes
and regulations (Appendix A).

Employees are responsible for:

^ immediately submit electrical safety risk reports,

^ do not work on electrical equipment without proper authorization and training,
^ e, inspect equipment before using it.

Risk management will be responsible for:

^ schedule on-site electrical training,

^ ensure that the safety of qualified and affected employees is carried out once a year;
for new employees once they join, and when necessary (such as the identification
of new hazards),
^ periodically evaluate electrical operations at the site to determine new electrical or
other emerging hazards (Appendix B),
^ use the training materials provided for staff training,
^ document training (Appendix C)
^ and, take exams about the electrical safety program.

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4. Definitions

Authorized/Qualified Person - A qualified person is an individual recognized by

management as having sufficient understanding of the equipment, device, system,
or having the facility to positively control any hazard that may arise. Qualification
or authorization to perform electrical or electronic work is based on a combination
of professional training and experience gained on the job site.
Circuit Breaker - (600 volts nominal or less). A design device to open and close a circuit
by manual means or to open the circuit automatically in the event of overload
without damage when operating within design conditions.
Conductor – Wire or portion of wire that can conduct current.

Formwork - The casing or envelope of an apparatus, or the fence or walls surrounding a

facility to prevent personnel from accidentally touching energized parts, or to
protect equipment from physical damage.
Electric current - The flow of electrons through a conductor.
Extension - Flexible cable that provides a convenient method of carrying current to a
device that is far from the power source and is always used as a temporary means
of conducting power.
Ground - Connection made, intentionally or accidentally, between an electrical circuit or
equipment and the ground or any body that serves as a ground.
Automatic Ground Fault Interrupter - Device designed to protect personnel by stopping
the flow of electricity when the current flowing to ground exceeds a
predetermined value.
Insulator - Matter that does not allow current to flow freely from one point to another.
Skilled Worker - An employee who is trained and authorized to perform work on
electrical equipment and components.
Resistance - Electrical resistance is the restriction to the flow of current through any
matter. (Resistance is measured in ohms). The skin has a resistance of
approximately 1000 ohms.
Unskilled Worker - An employee who has not been trained or authorized to perform
electrical work.

Volt - unit of measurement of electrical potential.

5. Hazard Control

The following administrative, engineering and work practice control methods will be used
to prevent electrical-related incidents:
Engineering controls
^ All electrical power distribution panels, circuit breakers, disconnect mechanisms,
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 switches, outlet boxes, must be completely closed
^ Waterproof forms should be used if there is a possibility that any of the components
will be exposed to moisture.
^ Structural barriers should be used to prevent damage to electrical components
^ Conduits must be supported along their entire length, and accessories other than
electrical grounds are prohibited
^ Flexible cables must have strain reliefs.

Administrative Controls

^ Only qualified/authorized personnel may repair or provide electrical services

^ Contractors must have a license to carry out electrical work
^ Physical barriers should be used to prevent unauthorized persons from entering
areas where installations or repairs of electrical equipment or components are
being performed
^ Only authorized employees may enter electrical distribution rooms
^ All electrical control devices must be properly labeled
^ The general manager must authorize any work on the electrical energy circuits

Controls to execute the job

^ Employees covered under this electrical policy must wear personal protective
equipment appropriate for the hazard category including safety boots or shoes
^ Only use tools that have adequate insulation
^ Non-conductive gloves should be available for work on electrical equipment or
components
^ Fences appropriate to the risk category must be placed in front of all electrical
distribution panels
6. Electrical Equipment Inspections

It consists of the inspection and evaluation of the electrical motive and personal protective
equipment:

ß Electricity - Equipment, switches, automatic circuit breakers, fuses, switches

integrated with boxes, splices, special accessories, circuits, insulators, extensions,
tools, motors, grounding, national electrical code.

ß Personal Protective Equipment (PPE) - Type, size, maintenance, repair, age,

storage, assignment of responsibilities, purchasing methods, standards to follow,
training in care and use, rules to follow, method of assignment .

Electric equipment

Inspect all electrical equipment for hazards that could cause injury or death to employees.
Consider the following factors when determining equipment security:

^ Suitable for intended use

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 ^ Properly isolated
^ Effects under hot conditions
^ Effects of lightning
^ According to type, size, voltage, current capacity, for intended use

Personal Protective Equipment (PPE)

Employers must provide personal protective equipment (PPE) to be used by workers

exposed to electrical hazards. Employees must observe the following procedures for
the proper use of personal protective equipment (PPE) :

^ (PPE) is mandatory when contact with electricity may occur

^ Only wear PPE that has been designed for the job category
^ Inspect and test all PPE before use
^ Use protective overalls (leather, for example) if the work to be carried out could
damage the insulation of the (PPE)
^ Wear non-conductive head protection if there is a danger of electrical burns or
electric shock from contact with live parts.
^ Wear eye and face protection when there is danger of flying objects or lightning,
flashes, or electric arcs.

7. Staff Training

Qualified Personnel

Training for qualified personnel to perform electrical work consists of:

^ Team-specific procedures;
^ Training requirements set forth in OSHA standard 29 CFR 1910.331 to 1910.339.

Unqualified Personnel

Personnel not qualified or authorized to do work on electrical equipment or components

must be instructed in general electrical safety precautions to become aware of the dangers.

The following electrical safety rules also apply for unqualified personnel:
^ Do not do electrical repairs
^ Report all electrical hazards to your supervisor
^ Do not operate any equipment if you believe it is dangerous
^ Do not allow electrical equipment or components to come into contact with water
^ Remember that even low electrical voltages can be physically harmful.
^ Do not use extension cords or plugs that are not grounded.
^ Do not overload electrical receptacles

8. Steps to follow

^ All wiring and equipment must comply with the National Electrical Code, OSHA
regulations, and numerous state and local provisions in addition to engineering
standards.
^ Schedule local assessments to identify electrical hazards that may occur during normal
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 operation.
^ Use Appendix B and the list of electrical hazards during evaluations.
^ Repair all electrical hazards as soon as possible.
^ Determine which employees require electrical safety training.
^ Reference the lockout/tagout procedure when doing electrical safety training.
^ Use Appendix C and Appendix D to document the electrical safety training program.
^ Review the effectiveness of the program and make changes when necessary.

9. Security practices. Procedures for De-energizing/Re-energizing

The following safety practices should be followed at a minimum when working with or
around electrical equipment:

A. Electrical equipment shall be de-energized, if possible, before and during work being
performed on the equipment. Follow all lock/tag out procedures. Only for equipment that
by design cannot be de-energized because it may create greater personal risk, will it be
allowed to work on live lines. Management approval is mandatory before live line work is
begun.

(The OSHA standard exempts circuits less than 50 volts from this requirement as long as
they do not increase the risk of exposure to electrical burns or arc flashes.)

B. A tag must also be affixed to the locking padlock announcing that the electrical
equipment cannot be energized and that the tag cannot be removed.

Tags are not necessary:

i. when only one circuit or piece of equipment is de-energized,

ii. when the blockage period does not extend beyond one work shift, and iii. when
workers exposed to re-energization hazards are familiar with this exception.

C. Electrical equipment that has been de-energized must be tested with appropriate
measuring devices to determine whether it was actually de-energized. This verification is
done using insulating gloves and any other personal protective equipment necessary
according to the electrical risk category.

D. Re-energizing electrical equipment can be carried out only:

i. when a qualified person performs tests and visual inspections, if necessary, to

verify that all tools, electrical junctions, short circuits, grounds, and other such devices
have been removed so that the equipment can be safely re-energize.

ii. when employees exposed to the potential hazards of re-energization have been
advised to stay away from circuits or equipment.

iii. when the lock/tag is removed by the same employee who placed it, with the
exception mentioned in the LOTTERY procedure.

E. If work is to be performed with live lines, appropriate personal protective equipment

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must be used, including gloves, boots, insulating clothing, insulating helmets, etc.

F. All capacitors on equipment under repair should be considered “energized” until

properly discharged.

G. No employee should connect or disconnect cables or extension cords with wet hands.

H. Handling electrical cables that have been submerged in water or any other conductive
liquid is not permitted without proper personal protection.

I. Electrical cables to be used in any area where conductive liquids are present must be
approved for such service.

J. If a cord or extension cord has been de-energized by the protective device, such as a
circuit breaker or ground-fault circuit breaker, the cause must be determined before re-
energizing it again. If the cause of the circuit interruption is evaluated as an overload, no
further analysis is needed.

K. Overcurrent protective equipment cannot be altered to serve beyond its capacity.

L. Circuits that repeatedly trip should be investigated to correct any problems.

M. Circuit breakers should not be used as switches of electrical equipment.

N. The use of electrical cords or extension cords near flammable liquids is not permitted
unless sufficient safety measures have been adopted and equipment appropriate for the
electrical hazard category is used. It is also necessary to have material storage containers
available if you are close to possible ignition sources.

O. Only non-conductive ladders may be used when working on or near any electrical
equipment.

P. Employees will not be permitted to enter spaces containing energized electrical

equipment unless proper lighting is ensured.

Q. Electrical measurement equipment will be inspected regularly and repaired when

necessary.

R. Where parts may present a hazard of electrical contact, employees may not carry out
cleaning tasks at undue distances since there is a possibility of contact, unless appropriate
safeguards (such as insulating barriers or equipment) are provided.

S. Servicing energized components in a conductive area (water, steel grating, etc.) can be
performed only after sufficiently insulated equipment has been placed in that location.

T. Electrically conductive cleaning materials may not be used while performing energy
repair services unless procedures are followed to avoid electrical shock.

U. Under no circumstances should an employee come into an area containing energy

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components "blindly."

V. In electrical panels, hinged doors, covers and other components must be fixed or
secured to avoid accidental closing that could reach the employee and cause injury due to
contact with energized parts.

W. Safety distances must be maintained when working on an electrical energy source.

The following table shows the safety distances that employees must observe:

VOLTAGE LIMITS / MINIMUM APPROACH DISTANCE

300 volts or less/avoid contact

Between 300 volts and 750 volts/1 foot
Between 750 volts and 2000 volts/1 foot 6 inches
Between 2000 volts and 15000 volts/2 feet

Note: Voltages greater than 15,000 volts require even greater distances. However, if such
voltages exist within the physical plant, they must be served by power company
personnel.

10. Safe Use and Maintenance of Electrical Equipment

a. Plugs and cable connections

Equipment used with a cord and plug, including extension cords, should be handled with
care so as not to damage the insulation covering it. Likewise, when holding or hanging
them, damage to the insulation that covers them must be avoided. Power connections
must be placed in such a way that no danger is created for employees working in the area.
For example, an extension cord cannot be placed or hung in an area where material
handling equipment is used because a jerk may cause it to break, resulting in an electrical
shock.

Power cables within physical plants are acceptable only if daily inspections of all exposed
cables are performed. These visual inspections should be performed before starting work
shifts, looking for any defects, such as damaged insulation, defective terminals, loose or
deformed parts. If one of these power cables proves defective, repair or replacement must
be made before putting it into use.

b. Grounded electrical equipment and tools

Grounded power tools should use power cords and/or extension cords that have a
grounding conductor. Alterations of the ground connections are not permitted, for
example, an adapter without a ground to a cable that does have that ground.

Portable electrical equipment should not be manipulated to raise or lower it using its
electrical cords. This equipment should be visually inspected before each use and repaired
when necessary.

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11. Personal Protective Equipment (PPE) when working with electricity or near live
lines

Only qualified personnel are authorized to perform services on live lines or any other
equipment within the physical plant. Provision of services to energized equipment or
components is acceptable only when de-energization interferes with or prevents the repair
of the operations to be performed. Aside from these limited operations, the lock/tag
procedure must be applied.
Control procedures are necessary during operations such as changing motors, switches,
etc. (See company lock/tag procedure.)

When working with conductive materials near energized equipment components, extra
care must be taken to avoid contact between the worker and those components. This will
be done by isolating those materials or using additional personal protective equipment.
Live line operations in enclosed spaces, such as manholes or vaults, require additional
personal protective equipment and must be worn.

The employer must provide protective shields, barriers or insulating materials, which the
employee must use in the performance of all operations with live lines. Workers must
have personal protective equipment available at all times. This equipment must be in good
condition and replaced when necessary.

a. Specially insulated tools

Equipment protected from electrical shock (non-conductive) and personal protective

equipment must be used in order to provide services to energized components. For
example, if a fuse from a live fuse box is to be replaced, an extractor with adequate
insulating protection should be used.

Non-conductive tools should be used whenever possible when performing service on

energized equipment.

All cables and chains used near energized equipment must be of a non-conductive
material.

All stairs used within the physical plant near energized equipment must have non-
conductive sides.

b. Insulating Fabrics/Garment

Wear fire-resistant clothing. Synthetic materials or fabrics that can melt are prohibited.
The employee's clothing must be made of non-conductive material. So neither rings,
watches, nor necklaces are allowed during operations. However, these garments are
allowed to be worn if they are sufficiently covered by an insulating material.

c. Head Protection

Employees should wear ample head protection if near a live power line.

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d. Eye protection from lightning

During operations in which an electric arc may occur, sufficient protection for the eyes of
the employee performing them must be provided.

e. Safety curtains for welding areas

If welding activities are performed within the physical plant during production hours, and
other personnel may be affected by lightning, a safety curtain capable of protecting all
employees in the area must be used.

f. Warning Signs and Barriers

Signs should be placed in areas where repairs are being carried out with hot lines, to warn
other employees of the danger present. The barriers will be made of a non-conductive
material and should be placed around the work area where the energized equipment is as
other people could come into contact with the components. When signs and barricades do
not provide sufficient protection for others, then a guard will be posted to verbally warn
and protect passersby of the hazards present.

12. New team

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All new equipment must be approved by a laboratory certified to meet OSHA regulations
and other National Electrical Code standards. Equipment designed at the customer's
request must be inspected by a qualified person and certified that applicable electrical
standards were applied.
13. References

Ohio Bureau of Worker's Compensation, Sample Written Program – Electrical Safety,

Retrieved March 21, 2008 from
[Link]
[Link]

Small Business Handbook, OSHA Small Business Safety and Health Management Series,
OSHA 2209-02R 2005

This training program has been developed by “Purdue University North

Central”, by “Construction Advancement Foundation”, by “City of Michigan City
Planning and Inspection Department” and by “Lewellyn Technology” with the
sponsorship of
“Susan Harwood Training Grant Program” SH-16612-07-60-F-18

PURDUE
UNIVERSITY
NORTH CENTRAL

CONSTRUCTION
ADVANCEMENT
FOUNDATION

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 Appendix
A
Electrical safety
inspection list

□ Are compliance with all OSHA standards required for contracting electrical work?

Are all employees required to report as soon as possible any obvious danger to life or property related to electrical
□
equipment or power lines?
Are employees instructed to make preliminary inspections and/or tests to determine conditions before beginning work on
□
electrical equipment or lines?

When equipment or power lines are undergoing repair, maintenance or adjustment, has the lockout/tagout procedure been
□
applied to the extent possible?

□ Are portable power tools and equipment grounded or of the double-insulated type?

□ Appliances such as vacuum cleaners, polishers, vacuum cleaners, etc., do they have grounding?

□ Do extension cords have a grounding conductor?

□ Are adapters with multiple plugs prohibited?

□
Are there ground fault circuit breakers on each temporary 15 or 20 amp or 120 volt alternating current (AC) circuit in
locations where construction, demolition, modifications, alterations, or excavations are being performed?

□ Are all temporary circuits protected by proper plug-and-disconnect switches and outlets, or is there permanent wiring?

Do you have dangerous electrical installations in dust or vapor areas? If so, do these installations comply with the National
□
Electricity Code (CNE) for hazardous areas?

□ Are damaged cables or wiring that is frayed or have defective insulation repaired or replaced quickly?

□ Are flexible extensions free of splices or branches?

Are clamps or other means provided for securing flexible extensions or for securing them to plugs or receptacles or tools,
□
equipment, etc., kept in place?

□ Are the cables and conduit channels intact and secure?

In damp or wet locations, are the appropriate power tools and equipment available for use, or in other words, are they
□
protected?

Is it clearly determined where power lines are located (overhead, underground, under the floor, other side of walls, etc.)
□
before digging, drilling, or similar actions?

Are metal measuring tapes, strings, or similar handheld devices with metallic thread weaves prohibited because they may
□
come into contact with energized parts of equipment or circuit conductors?
Are metal ladders prohibited when the person or the ladder itself may come into contact with energized parts of the
□
equipment, facility, or circuit conductors?

□ Are all switches and circuit breakers marked indicating which equipment or area is served?

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□ Are there ways to disconnect before changing fuses?

□ Does all interior wiring include ground for electrical conduits, equipment and fixtures?

□ Are all electrical channels, fixtures and receptacles properly secured to remain in place?

Are all energized parts of electrical circuits or equipment guarded against accidental contact and are such cabinets or
□
panels approved?

□ Is there sufficient access and work space around electrical equipment to allow for safe conditions and maintenance?

□ Are all unused openings (including duct openings) with covers or outlets in place?

□ Are all electrical fixtures such as switches, receptacles, junction boxes, etc. securely fastened with covers or plates?

□
Are electrical switches for motors over two horsepower capable of opening the circuit when the motor stalls without
causing it to burn out? (Power switches must be equal to or greater than the rated power of the motor.)

Is low voltage protection provided for motors of machines or equipment that could cause injuries due to inadvertent
□
starting?

□ Are the switches or circuit breakers for each motor located within view of the control device for those motors?

□ Is each motor within sight of its controller or means of disconnecting that controller? Are the means of disconnecting that
controller within sight of the engine?

□ Is the controller for each motor over two horsepower equal to or greater than the motor's rated horsepower?

Are employees who regularly work with or around energized electrical equipment trained in cardiopulmonary resuscitation
□
(CPR)?

□ Are employees prohibited from working alone on power lines or equipment over 600 volts?

Executed by ______________________________________________________________

Signature_________________________________ Date_________________________

Measures to follow ________________________________________________________

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 Appendix
B
Periodic inspection for electrical hazards

Place ____________________ Date _________________/_____/_____

Area/Building/Identification Danger detail

Executed by ____________________________________________________

Measures to follow ______________________________________________

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 Appendix
C
Training record

Training description:

Date: ________/______/______ Was Quiz used? _____Yeah _____ No

Instructor:______________________ Instructor Signature:________________

Material Used: ________________________________________________________

Write your name Space for your signature

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 Appendix
D
Electrical Safety Quiz

SELECT THE BEST ANSWER.

1. Which place is most dangerous to use electrical equipment?

A. interiors.
B. exteriors.
C. close to the water.
D. near other electrical equipment.

2. You discover that an electrical cord on a drill is defective and does not have
sufficient insulating protection. What would you do?

A. Use tape around the fault to prevent electrical shock.

B. See if the job is still working.
C. put an out of service tag and notify maintenance personnel
D. Be sure that the electrical cord does not touch the floor.

3. What is the safest ladder for electrical work?

A. wood.
B. fiberglass.
C. aluminum.
D. a seat.

4. Earth, water, concrete and the human body are conductors of electricity.

A. TRUE
B. Fake

5. The effects of electric shock on the body depend on the following factors EXCEPT:

A. the current.
B. the route.
C. the duration.
D. body weight.

A. electrical shock that could result in electrocution

B. falls.

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 C. Burns.
d. all of the above.

7. Out of Service Outlet Boxes:

A. They should be reported and repaired as soon as possible.

B. are permitted by OSHA.
C. They are common because replacing them is expensive.
D. They pose no danger as long as the wiring has been re-routed.

8. From the following list, what is acceptable to OSHA standards?

A. an unqualified person energizing a tripped circuit breaker.

B. connect one extension to a second extension.
C. remove the ground terminal to allow connection to two-prong outlets.
D. a qualified person repairs an extension cord.

9. Flexible extensions can be used in workplaces:

A. as a substitute for permanent wiring.

B. if they go behind the walls to reduce damage and abrasion.
C. If larger gauge cables are needed for temporary use.
D. if obvious connections are repaired with electrical tape.

10. It is the responsibility of all employees to understand and use electrical safety
procedures every day.

TO. TRUE

b. Fake

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6. Which of the followingElectrical Safety
injuries can Quizby(Answers)
be caused electricity?
SELECT THE BEST ANSWER.

1. Which place is most dangerous to use electrical equipment?

TO. interiors.
b. exteriors.
C. close to the water.
D. near other electrical equipment.

2. You discover that an electrical cord on a drill is defective and does not have
sufficient insulating protection. What would you do?

A. Use tape around the fault to prevent electrical shock.

B. See if the job is still working.
C. tag out of service and notify maintenance personnel
D. Be sure that the electrical cord does not touch the floor.

3. What is the safest ladder for electrical work?

TO. wood.
b. fiberglass.
c. aluminum.
d. a seat.

4. Earth, water, concrete and the human body are conductors of electricity.

TO. TRUE
b. Fake

5. The effects of electric shock on the body depend on the following factors EXCEPT:

TO. the current.

b. the route.
c. the duration.
d. body weight.

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 A. electric shock that could result in electrocution B. falls.
c. Burns.
d. all of the above.

7. Out of Service Outlet Boxes:

A. They should be reported and repaired as soon as possible.

B. are permitted by OSHA.
C. They are common because replacing them is expensive.
D. They pose no danger as long as the wiring has been re-routed.

8. From the following list, what is acceptable to OSHA standards?

A. an unqualified person energizing a tripped circuit breaker.

B. connect one extension to a second extension.
C. remove the ground terminal to allow connection to two-prong outlets.
D. a qualified person repairs an extension cord.

9. Flexible extensions can be used in workplaces:

A. as a substitute for permanent wiring.

B. if they go behind the walls to reduce damage and abrasion.
C. If larger gauge cables are needed for temporary use.
D. if obvious connections are repaired with electrical tape.

10. It is the responsibility of all employees to understand and use electrical safety
procedures every day.

TO. TRUE

B. Fake

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