Excellence in Customer Satisfaction

Section: Rev:
Johnson Controls, Inc. 23 0
Effective Date # of pages:
ELECTRICAL WORK SAFETY 8/13/2008 21

23.0 PURPOSE
The National Safety Council estimates that there are at least 300 deaths annually from on­the­
job electrocutions in the United States.   Some form of  electrical power is used,   or  is 
present, at every JCI work area at the ORNLsite.   The commonplace use of electrical 
power requires that all affected employees receive, at a minimum, instruction from their 
supervisors regarding the potential hazards related to electrical power in their job.

The purpose of this program is to provide requirements and guidance for Johnson Controls, 
Inc. and their subcontractor employees for electrical safety practices in compliance with 
TOSHA   (29   CFR   1910,   Subpart   S),   regulations,   National   Fire   Protection   Association 
(NFPA)  70,  National Electrical Code  (2005),  and NFPA 70E,  Standard for Electrical  
Safety in the Workplace (2004), or to specify the governing code for work not covered by 
these standard.

The basic electrical safety requirements TOSHA 29 CFR 1910 shall be followed to protect 
JCI   employees   and   their   subcontractors   from   hazards   when   working   with   electrical 
equipment, tools, and appliances 

This standard addresses three groups of work:

• General electrical work  (including telecommunications)
• Certain electrical utility work
• Vehicles

This program is also designed to meet the requirements of the 10 CFR 851 Worker Safety and
Health Program standard. JCI employees and subcontractors shall coordinate their activities as
described in JHSPM Section 001 – Program Policy & Requirements and shall utilize the hazard
identification, risk analysis and control procedure detailed in Section 003 – Pre-Job Planningin
order to ensure that workers are made aware of the foreseeable hazards related to the activities
that they are performing and the protective measures needed to abate those hazards. This pre-job
planning process is primarily supported through the use of “standard” and “daily” activity hazard
analysis (AHA) documents which detail the anticipated activities, potential hazards, and
recommended actions to be taken to prevent worker injuries and illnesses.

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23.1 RESPONSIBILITIES

Position Responsibilities
Safety Supervisor • Ensure that the Electrical Work Safety Program is developed and followed by JCI and
subcontractor employees.
• Ensure all employees are trained to the requirements of the program.
• Ensure compliance with the provisions of this procedure.
• Ensures that electrical work equipment is properly inspected for safety hazards.
• Participates in Electrical work safety meetings.
• Ensures that employees and subcontractors are informed concerning the requirements of
Section 003 – Pre-Job Planning when conducting related activities.
Construction • Enforce requirements of the Electrical Work Safety program.
Supervisor • Ensures that employees doing electrical work are properly trained.
• Secures equipment necessary to perform electrical work safely.
• Ensures that employees and subcontractors adhere to the requirements of Section 003 –
Pre-Job Planning when conducting related activities.
Administrative • Maintains Electrical Safety training documentation.
Assistant
Employees • Participate in training sessions.
• Use proper equipment when doing electrical work.
• Notify supervisor if any electrical equipment appears unsafe.
• Review and adhere to all Electrical Work requirements set forth in this program.
• Adhere to the requirements of Section 003 – Pre-Job Planning when conducting these
activities.
Contractors • Adhere to the requirements of this program.
• Adhere to the requirements of Section 003 – Pre-Job Planning when conducting these
activities.

23.2 DEFINITIONS
The following definitions are presented to assist with understanding the terminology used in this
electrical safety program.

Arc Rating. The maximum incident energy resistance demonstrated by a flame resistant material
(or a layered system of materials) prior to the formation of one or more holes in the innermost
layer of the flame resistant materials that would allow flame to pass through the material. Arc
rating is normally expressed in cal/cm2.

Exposed Part. An energized electrical part capable of being inadvertently touched or of being
approached closer than a safe distance (see Appendix 23.5) by a person. This term is applied to
parts not suitably guarded, isolated or insulated.

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Flame-Resistant (FR). The property of a material whereby combustion is prevented, terminated,

or inhibited following the application of a flaming or non-flaming source of ignition, with or
without subsequent removal of the ignition source.

Flash Hazard. A dangerous condition associated with the release of energy caused by an electric
arc.

Flash Hazard Analysis. A study investigating a worker’s potential exposure to arc-flash energy,
conducted for the purpose of injury prevention and the determination of safe work practices and
the appropriate levels of PPE.

Flash Protection Boundary. An approach limit at a distance from exposed live parts within
which a person could receive a second degree burn if an electrical arc flash were to occur.

Flash Suit. A complete FR clothing and equipment system that covers the entire body, except for
the hands and feet. This includes pants, jacket, and bee-keeper-type hood fitted with a face
shield.

Ground Fault. An unintentional, electrically conducting connection between an ungrounded

conductor of an electrical circuit and the normally non-current-carrying conductors, metallic
enclosures, metallic raceways, metallic equipment, or earth.

Ground-fault Circuit-interrupter(GFCI). This is a device intended for protecting personnel.

The GFCI is designed to de-energize the electric circuit, within an established period of time,
when a current to ground exceeds some predetermined value that is less than the current required
to operate the overcurrent protective device of the supply circuit.

Incident Energy. The amount of energy impressed on a surface, a certain distance from the
source, generated during an electrical arc event. One of the units used to measure incident energy
is calories per centimeter squared (cal/cm2).

Overcurrent. Any current in excess of the rated current of equipment or the ampacity of a
conductor. It may result from overload, short circuit, or ground fault.

Overload. Operation of equipment in excess of normal, full-load rating, or of a conductor of

rated ampacity that, when it persists for a sufficient length of time, would cause damage or
dangerous overheating. A fault, such as a short circuit or ground fault, is not an overload.

Working Near (live parts). Any activity inside a Limited Approach Boundary (see Appendix
23.5).

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Working On (live parts). Coming in contact with live parts with the hands, feet or other body
parts, with tools, probes, or with test equipment, regardless of the personal protective equipment a
person is wearing. Also includes anytime a person is working within the Prohibited Approach
Boundary (see Appendix 23.5) for the piece of electrical equipment – considered the same as
making contact.

23.3 GENERAL REQUIREMENTS

Pre-job planning documents (i.e. AHA) shall be developed in sufficient detail to ensure all
hazards are identified prior to performing work (see Section 003 – Pre-Job Planning).

Subcontractors performing electrical work on site are required to have a designated representative
on site during all periods of active electrical work activities who is knowledgeable of the project’s
hazards and have full authority to act on behalf of the electrical contractor. This person shall
make frequent and regular inspections of the construction worksite to identify and correct any
instances of noncompliance with project safety and health requirements. Any noncompliance
issues shall also be promptly reported to the JCI Safety Supervisor.

23.3.1 WORKING ON OR AROUND ENERGIZED PARTS

These requirements apply to workers who face a higher-than-normal risk of contact if they
are intentionally exposed to energized parts, whether or not they are classified as electrical
workers.

The following apply:

• Limited approach Boundary(near) (see Appendix 23.5)

This is the approach limit at a distance from an exposed live part within which a shock
hazard exists. This boundary establishes the distance around energized parts that only a
qualified person may enter. If an unqualified person must enter the limited approach
space to perform a minor task, (ex: inspection), then a qualified person must advise the
unqualified person of the possible hazards and ensure that the unqualified person is
safeguarded.

To enter limited spaces, the unqualified person must fulfill the following:

⇒ Determine whether personal protective equipment is required for the task to be

performed.
⇒ Have specific knowledge of the equipment.
⇒ Have a documented plan if the task may result in the accidental crossing of the
restricted boundary

• Restricted Approach Boundary (see Appendix 23.5)

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This is an approach limit at a distance from an exposed live part within which there is an
increased risk of shock, due to electrical arc over combined with inadvertent movement,
for personnel working in close proximity to the live part. This boundary establishes
thedistance around energized parts that only a qualified person may enter. To enter the
restricted approach boundary, the qualified person must take the following actions:

⇒ Use approved Energized Electrical Work Permit (EWP) (see Appendix 23.6).
⇒ Use control measures specified in the plan.
⇒ Minimize exposure to the prohibited space.

• Prohibited Approach Boundary (see Appendix 23.5)

This is an approach limit at a distance from an exposed live part within which work is
considered the same as making contact with the live part. Crossing a prohibited boundary
is considered working on exposed, energized conductors or circuit parts. This restriction
applies to crossing the boundary with hands, feet, other body parts, probes, tools, or test
equipment regardless of protective clothing.

To work within prohibited space, a qualified person must have an approved EWP (see
Appendix 23.6).

23.3.2 FLASH HAZARD RISK CATEGORIES AND PPE REQUIREMENTS

JCI has conducted an arc flash hazard analysis of all electrical equipment that JCI
employees and contractors could conceivably come into contact with during the
performance of their duties.

The arc flash analysis has two primary purposes:

⇒ To determine the location of the arc flash boundary and associated flash hazard risk
category (based on a working distance of 18-inches) for each piece of electrical
distribution equipment being utilized by JCI employees when the electrical
component’s protective cover has been opened/removed.
Appendix 23.7 provides a table detailing the specific pieces of boiler annex
electrical equipment (main disconnects, 480 VAC panels, 15 KVA
transformers, and 208/120 VAC panels) and their determined hazard risk
categories.
Appendix 23.8 provides three tables detailing the hazard risk categories for
the Condensate Receiver/Pump Skids, Air Compressors, Generator Sets, and
Building 318 fans that JCI employees and/or contractors may be tasked to
work on.

⇒ To determine the rating of flame-retardant clothing that must be worn by employees

and/or contractors when performing work on and/or within 18-inches of the energized
electrical equipment when the electrical component’s protective cover has been
opened/removed. Appendix 23.9 provides a table which explains the relationship

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between the determined arc flash hazard risk category and the PPE (including flame-
resistant clothing) required to perform work under the noted conditions.

The arc flash hazard analysis performed determined hazard categories that ranged from 0
up to the maximum of 4. The vast majority of the electrical equipment in the Boiler
Annexes require Hazard Risk Category 0 (untreated cotton) to 1 (FR shirts and pants) PPE
clothing. Specific boiler annex Hazard Risk Categories other than 0 or 1 are as follows:

⇒ Boiler Annex 327 requires Hazard Risk Category 4 PPE (cotton underwear, FR shirt
and pants, and a multi layer flash suit) when work is performed on or near (within 18-
inches) the 480 VAC 3-phase main distribution panel.

⇒ Boiler Annexes 272W, 382, 234-5Z, and 200CC require Hazard Risk Category 3 PPE
(cotton underwear, FR shirt and pants, and a FR coverall) when work is performed on
or near their 480 VAC 3-phase main distribution panel.

JCI employees and contractors shall refer to and abide by the hazard risk categories and
required arc flash PPE requirements noted in Appendixes 23.7, 23.8 and 23.9 when
working near (within 18-inches) or on energized JCI-associated electrical equipment.

23.3.3 QUALIFIED PERSON (ELECTRICAL)

A Qualified Person under the TOSHA electrical safety standards is someone trained and
thoroughly familiar with the construction and operation of equipment and the hazards
involved. This person also must be familiar with the proper use of special precautionary
techniques for the task to be done, personal protective equipment (PPE), insulation and
shielding materials, and insulated tools and test equipment.
Training and experience determines whether an employee is considered a “qualified
person”. A person may be considered qualified with respect to work on or within the
limited approach boundary for certain equipment and unqualified with respect to other
equipment.
Trainees may be considered qualified persons for the performance of certain duties if they
meet all of the following:

⇒ Are undergoing on-the-job training.

⇒ Have demonstrated ability to perform their duties safely to their level of training.
⇒ Are under the direct supervision of a qualified person
⇒ Have been trained in accordance with section 23.3.4.

23.3.4 TRAINING REQUIREMENTS

The requirements and processes outlined below are mandatory. Guidance is included in
some sections to help Subcontractors understand and comply; such guidance is advisory
only. Electrical safety training documentation shall be accomplished using Appendix
23.10, or an equivalent form. The Administrative Assistantshall maintain JCI employee
training records.

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Employees who face a higher-than-normal risk of contact with electrically energized parts
50 V or more shall be trained to comply with TOSHA (29 CFR 1910) regulations, as well
as the NFPA 70E standard in regards to protecting workers from the hazards of electrical
arc flashes.
Johnson Controls, Inc. shall ensure that the person-in-charge shall have at least the same
level of TOSHA/NFPA-based training as the workers for whom they are responsible or for
whom they plan or supervise work.

NOTE: Employees who may be exposed to energized parts are considered to face higher-
than-normal risk of contact, whether or not they are electrical workers.

If the worker is unfamiliar with the construction or operation of the equipment or the
hazards associated with the task, additional training may be required. In these cases, the
Program Manager / Safety Supervisor shall document instructions the worker receives in
the use of safe work practices for the voltage levels to be encountered, and for the
selection, inspection, and use of PPE.

23.4 SAFE WORK PROCESS

All JCI employees and contractors shall follow the electric shock and arc flash hazard protection
requirements as detailed in sections 23.3.1 and 23.3.2 of this program when working on or around
energized parts.

23.4.1 DE-ENERGIZING LIVE, EXPOSED WIRE

NOTE: All subcontractor electrical work requiring EWP and/or Lockout/Tagout shall have
a technical review by a JCI designated person (LOTO Administrator/ Electrical Safety
Administrator).

23.4.1.1 Determine all possible sources of stored or potential energybefore

commencing work. Consult supplied equipment wiring diagrams, schematics
and as-built plans as necessary.

23.4.1.2 De-energize electrical parts operating at 50 V or more to ground with a current

capacity of 1 mA or more. Where possible, visually verify device is open.
Lock and tag the electrical parts to the maximum extent possible before they
are maintained or repaired, or parts are exposed within the limited approach
boundary. See section 24, lock/tag program. If de-energized but not locked
and tagged out, treat parts as live, except for equipment with a cord and plug.
Examples of when de-energized is not required:

• When it will cause increased or additional hazards including

interruptions of life support systems, shutdown of hazardous

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location ventilation equipment, removal of illumination for an area,

or deactivation of emergency alarms.
• When it is not feasible because of equipment design or operational
limitations that include the following:

⇒ Testing of electric circuits that can be performed only with the

circuit energized.
⇒ Work on circuits that form an integral part of a continuous
process that would otherwise need to be completely shut down,
creating a greater hazard, to permit work on one circuit or piece
of equipment.

• When energized parts operate at less than 50 V to ground or parts

have less than 1 mA of current potential, as long as there will be no
increased exposure to electrical burns or an increased chance of
explosion resulting from electric arcs.

23.4.1.3 If de-energizing parts will introduce additional risk, or is impractical as a

result of the design of the equipment or operational limitations, include an
EWP for working within the restricted boundary (see Appendix 23.5) of
electrically energized parts of 50 V or greater to ground with a current
capacity of 1 mA or greater.

23.4.1.4 Release stored electrical energy that might endanger personnel. Discharge
capacitors with an approved device, and short-circuit and ground high-
capacitance elements if the stored electric energy might endanger personnel.

23.4.1.5 Verify that the field conditions and documents match. Resolve any
differences before releasing work. If there are any unresolved differences that
could result in inadvertent re-energization from another source, the employee
may continue the work provided extra precautions are taken during the
potential exposure. Precautions include verifying that the circuit is de-
energized and conducting work in accordance with the safeguards required for
energized systems for the remainder of the work. An EWP is not required in
these cases if there is no expectation of re-energization.

23.4.1.6 It is acceptable to physically disconnect energy sources of systems,

equipment, or components to remove the hazards (ex: lifting cables from
circuit breakers in an energized panel). However, leave this physical
disconnect in a condition that prevents inadvertent reconnection (ex: cutting
back the cables in the energized panel), or physically identify the
disconnection (ex: tag the cables remaining coiled in the energized panel),
and communicate system status to affected workers and the controlling
organization.

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NOTE: If there are workers downstream that could be injured by re-

energization, identify in accordance with Section 24 – Lockout /
Tagout Program.

Prior to performing work, perform safe condition checks on any systems,

equipment or components disconnected from their energy source. Perform
voltage tests on each conductor to verify that it is de-energized.

23.4.2 WORK WITHIN THE LIMITED SPACE FOR EXPOSED, ENERGIZED

ELECTRICAL PARTS

• Inspect the work area for sufficient illumination, working space and safe
access.
• If a ladder is required for work near exposed energized parts, use portable
ladders with dry, non-conductive side rails.
• Use signs (designed in accordance with 29 CFR 1910.145), barricades or
attendants to isolate the work area and warn others of the exposed energized
electrical circuits. Electrical safety warning signs shall be worded as follows:

“DANGER – ELECTRICAL HAZARDS

AUTHORIZED PERSONNEL ONLY”

• If work area is accessible to authorized personnel only, no additional signs,

barricades, or attendants are required.
• Before work starts, the qualified supervisor or qualified person in charge shall
ensure that a briefing for all participants involved with the work has been
performed. Subsequent briefings shall be conducted for new participants.
• Any person receiving an electrical shock (other than static) shall stop work and
report to the supervisor.

23.4.3 WORK WITHIN THE RESTRICTED AND PROHIBITED SPACE FOR

ENERGIZED ELECTRICAL PARTS

• The PIC will determine the hazards, document the required PPE, and ensure
that workers exposed to energized parts follow the requirements.
• Because the electrical hazards may differ from job to job, PPE may also vary
according to the job. PPE may include voltage-rated rubber blankets, gloves,
pads, tools, or insulated protective barriers that provide protection at least
equivalent to that provided by ANSI-qualified materials.
• Workers shall not wear or carry in clothing pockets any conductive accessories
(ex: rings, watches, bracelets, metal-frame glasses, metal hats) that may make
contact with exposed, energized parts.

NOTE: Employees may wear rings under voltage-rated gloves

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• Employees shall wear natural fiber clothing whenever they may be exposed to
voltages greater than 150 V to ground. Welders’ coveralls are one example of
natural fiber clothing.
• A backup person is required for work on energized components. This person
observes the worker to ensure that clearances are maintained and performs
electrical emergency rescue if required. The backup person must be CPR
certified and trained in first aid.

EXCEPTIONS:
⇒ For voltages less than 150 V to ground / neutral, a backup person is not
required if the risk does not warrant it.
⇒ For testing and troubleshooting at any voltage, a backup person is not
required if the risk does not warrant it. Document the exception if
voltage is greater than 150 V to ground / neutral.

23.4.4 TESTING AND TROUBLESHOOTING ON LIVE, ENERGIZED PARTS

• Testing and troubleshooting on live energized parts requires an approved EWP.

• Verifying safe condition for an electrical L&T does not require an EWP.
• Remove fuses with fuse pullers or other approved means that provide
equivalent protection. When removing a fuse rated at 480 V or more, de-
energize fuse holders unless not feasible because of equipment design.

23.4.5 NON-CONDUCTIVE PROTECTIVE EQUIPMENT

• Store and use equipment according to manufacturers’ recommendations

• Inspect item(s) before use to verify that the item is in satisfactory condition and
has been tested in accordance with TOSHA(29 CFR 1910) regulations.
Inspect rubber gloves for holes, and air-test before using.

NOTE: Rubber protective equipment shall be inspected, sterilized, and

tested every 6 months minimum. Hot sticks shall be tested every 12
months and date stamped at that time.

• Inspect voltage-rated tools before each use for defects and surface
contamination (ex: moisture)
• Do not rely on insulated tools alone for complete protection.

23.4.6 ELECTRICAL TEST EQUIPMENT

Only qualified personnel who are trained on the operation and limitations of the
equipment shall use electrical test equipment.

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• Visually inspect electrical test equipment immediately before use and do not
use if defective. Identify defective test equipment by tagging it out of service,
and repair or dispose of properly.
• Use electrical test equipment only for intended applications. Make operating
instructions and limitations for the test equipment available to the electrical
worker.
• Check electrical test equipment for proper operation immediately before and
after use when verifying that circuits are de-energized. When performing zero
energy checks, ensure that stored electrical or mechanical energy cannot re-
energize the circuit.

23.4.7 REQUIREMENTS FOR GFCI PROTECTION OF PERSONNEL

• Use GFCI in 120 V circuits as specified below:

⇒ In damp or wet (standing water) work area

⇒ Outdoors
⇒ For AC receptacles that are not part of permanent structural wiring (ex:
extension cords)

NOTE: Portable or vehicle-mounted generators rated not more than

5 kW, with circuit conductors of the generator insulated
from the generator frame and all other ground surfaces, do
not require GFCI (2-wire, 120 V, single-phase ungrounded
“isolated” outpost).

• Test portable GFCI before each use. Test permanently installed GFCI’s at least
monthly. When monthly testing is not documented, test before each use. If
any damage that might expose employees to injury is evident, remove the item
from service.
• Use GFCI with portable electric hand tools in wet and damp locations, and
ensure that portable electric hand tools meet the requirements in Section 16 of
the JCI Safety Program.
• Use insulated tools and equipment when intruding into energized electrical
panels and elsewhere when appropriate.

23.4.8 FLEXIBLE CORDS AND CABLES

• Do not use extension cord sets to extend the permanent wiring of a building.
• Flexible cord sets used with grounding-type equipment must contain an
equipment-grounding conductor.
• Use flexible cords suitable for conditions and location of use.
• Protect flexible cords and cables from damage.

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NOTE: Protect cords and cables from damage by foot traffic, vehicles,
sharp edges, pinching, improper storage, etc.

• Inspect extension cords and tool cords before use, except those that are for
extended service and are not exposed to damage.
• Discard damaged cord sets or have any break in the insulation repaired by a
qualified electrician so that it is equal; to or better than the original. Do not
repair cords smaller than number 12.

23.4.9 DRILLING INTO WALLS

Because of unusual conditions at the ORNL Site, it is not always easy to identify
energized lines. Treat walls as if they contain energized lines and take the
following precautions.

• Review drawings before starting job. Before starting the job, visit the jobsite
to determine whether there are obstructions in the driller’s path.
• Wear appropriate PPE for working on energized components and use double-
insulated tools.
• Review Section 20 of the JCI Safety Program – Excavation, Trenching and
Shoring.

23.4.10 WORK AFFECTING ELECTRICAL UTILITIES OPERATION (EUO)

• Notify EUO at least 48 hours before planned operations and activities near
overhead (more than 600 V) electrical utility lines or equipment; also notify
EUO when the work is complete.
• In addition to the general notifications above, notify EUO if you intend to do
any of the following:

⇒ Move any equipment taller than 14 ft under overhead power lines.

⇒ Operate equipment within 20 ft horizontal from overhead high-voltage
(more than 600 V) power lines.
⇒ Perform any operations near power lines during bad weather or hazardous
conditions (ex: rain, range fires, dust, wind storms)

NOTE:
See the ORNL Hoisting and Rigging Manual, 14.4.7 –
Operating Cranes Near Energized Transmitters or Electrical
Power Lines.
23.4.11 ACTIVITIES GOVERNED BY NATIONAL ELECTICAL CODE (NEC)

Install new electrical installations and modification in accordance with NEC

requirements and have them inspected by a qualified electrical inspector.

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Appendix 23.5

APPROACH DISTANCE TO EXPOSED ENERGIZED ELECTRICAL CONDUCTORS

AND CIRCUIT PARTS (FOR SHOCK PROTECTION)
Note: For SI units (1 in = 25.4 mm) and (1 ft = .305 m)
Nominal system Voltage Limited Approach Restricted Prohibited Approach
Range Boundary Approach Boundary
Boundary

Exposed Exposed Includes Standard Includes Reduced

Phase to Phase Movable Fixed Inadvertent Inadvertent Movement
Conductor Circuit Part Movement Adder Adder

NOTE: All dimensions are distance from live part to employee

300 V and less 10’, 0” 3’, 6” Avoid Contact Avoid Contact

301 V to 750 V 10’, 0” 3’, 6” 1’, 0” 1”

751 V to 15 kV 10’, 0” 5’, 0” 2’, 2” 7”

15.1 kV to 36 kV 10’, 0” 6’, 0” 2’, 7” 10”

36.1 kV to 46 kV 10’,0” 8’,0” 2’, 9” 1’, 5”

Source: NFPA 70E Standard for Electrical Safety in the Workplace, Table 130.2(C)

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Appendix 23.6

ENERGIZED ELECTRICAL WORK PERMIT

Area: Location:

JOB DESCRIPTION – (include activities to be performed, components involved, voltages, etc.)

Restricted space work Prohibited space work

SAFE WORK REQUIREMENTS

Introduces additional hazards Infeasible due to equipment design
Introduces increased hazards Infeasible due to operational limitations

Justification Explanation:

SAFE WORK REQUIREMENTS

Qualified personnel assigned to perform work
Person trained in CPR and First Aid
Stand-by person equipped with insulating equipment needed for emergency response
Adequate working clearance and egress routes available
Communications available and in operating condition
Work area has adequate lighting
Work area control measures:
Barriers and signs; Attendant
Conductive items removed (metal rings, watches, jewelry, buckles, badge holders, etc)
De-energize and isolate equipment to the extent feasible
Flash Hazard Risk Category determined for the equipment to be worked on or near. NOTE: Category 0: Untreated Cotton;
Category 1: FR Shirt & Pants; Category 2: Cotton Underwear, FR shirt & Pants; Category 3: Cotton Underwear, FR Shirt &
Pants, and FR Coverall; Category 4: Cotton Underwear, FR Shirt & Pants, and a Multi Layer Flash Suit
 Insulating protective equipment to be used:
Line hoses and covers; Rubber insulating matting; Rubber blankets
Voltage rated insulated tools
Portable ladders with dry, non-conductive aide rails
Testing equipment at work site is compatible with voltage present
Other:

PERSONAL PROTECTIVE EQUIPMENT

Nonconductive Head Protection Rubber Gloves / Protectors
Safety Glasses Rubber Sleeves
Faceshield Nonconductive Clothing
Flash Hazard PPE Requirements (circle correct Category): 0, 1, 2, 3, or 4) Other:
Other:

__________________ ________ ___________________ _________

JCI Supervisor Date Subcontractor Date
Standardized yesno

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Appendix 23.7
Summary of Hazard Risk Category for Boiler Annex Equipment
Boiler Building Main Disconnect 480 VAC Panel 15 KVA Transformer 208/120 VAC Panel Comments
Annex Equip. ID# Hazard Risk Equip. ID# Hazard Risk Equip. ID# Hazard Risk Equip. ID# Hazard Risk
Category Category Category Category
1 See note 2
1 See note 2
1 See note 2
1 See notes 2 and 3
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
1 See note 2
Note 4 Note 4
1 See note 2
1 See note 2
1 See note 2

Appendix 23.7 (Continued)

Note 1: Fed by Facility Electrical Distribution System.

Note 2: All equipment downstream of the branch circuit breakers on the 480 VAC distribution panels and the 208/120 VAC lighting panels in each Boiler

Section 23 JHS Program Manual page 15 of 19

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 Excellence in Customer Satisfaction

Annex are Hazard Risk Category 0.

Note 3: Panel DP-234-5Z is a Hazard Risk Category 1 when supplied by the utility transformers and a Hazard Risk Category 3 when supplied by the diesel
generator.
Note 4: Building 329 boiler units are powered by 120 VAC circuits. The hot water circulation pumps are powered by 3-phase 208 VAC circuits from Panel
P-2. Panel P-2 and the electrical equipment downstream between P-2 and the circulation pumps are Hazard Risk Category 0.

Section 23 JHS Program Manual page 16 of 19

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 Excellence in Customer Satisfaction
Appendix 23.8
Summary of Hazard Risk Category for AHU #xxxx
Building AHU Location Power Source Hazard Risk Category(1)

Note 1: Hazard Risk Category applies to all electrical equipment downstream of the power source.

Summary of Hazard Risk Category for Air Compressors

Building Air Compressor ID Power Source Hazard Risk Category(1)

Note 1: Hazard Risk Category applies to all electrical equipment downstream of the power source.

Summary of Hazard Risk Category for Generator Sets

Building Hazard Risk Category Comments
Generator Downstream of Generator
Output Breaker

Summary of Hazard Risk Category for Building

Building Fan ID Power Source Hazard Risk Category(1)
0
0
Note 1: Hazard Risk Category applies to all electrical equipment downstream of the power source.

Section 23 JHS Program Manual page 17 of 19

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 Excellence in Customer Satisfaction
Appendix 23.9

Hazard Risk Categories and PPE Clothing Requirements

Incident Incident Hazard Clothing Description Clothing Required
Energy Energy Risk Layers Minimum Arc
From To Category Rating of PPE
(cal/cm2) (cal/cm2) (cal/cm2)
0.0 1.2 0 Untreated Cotton 1 N/A
1.2 4.0 1 Flame Resistant Shirt & Pants 1 4
4.0 6.0 2 Cotton Underwear + FR Shirt & 1 or 2 8
Pants
6.0 25.0 3 Cotton Underwear + FR Shirt & 2 or 3 25
Pants + FR Coverall
25.0 40.0 4 Cotton Underwear + FR Shirt & 3 or more 40
Pants + Multi Layer Flash Suit

NOTE: If a flash hazard analysis suggests that the intensity of the arc flash could expose a worker to 40
cal/cm2or greater, the work must not be performed unless an electrical safe work condition has been
established. If the intensity is greater than 40 cal/cm2, no protective equipment exists that can adequately
protect the worker from the intense pressure (arc blast) that also will be produced by the arcing fault.

Section 23 JHS Program Manual page 18 of 19

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 Excellence in Customer Satisfaction
Appendix 23.10

ELECTRICAL WORK SAFETY TRAINING LOG

Topic _____________________________________
Instructor:
I have trained the employees listed below on the requirements of Johnson Controls, Inc. Electrical
Work Safety Program. This training included use of the following materials:

Instructor Signature:
Employee Name (Print) Employee Signature Organization Date

Section 23 JHS Program Manual page 19 of 19

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