Implementation of Electrical Safety
Procedures & Techniques forAccelerator Operations

Presented by Martin Murphy (Fermilab) at the
7th Workshop on Accelerator Operations
Daejeon, Korea 15 April 2010

Fermilab Operations Department
Overview• Five crews of four or five operators• Five Crew Chiefs• Eight Operations Specialists• Upper Managers & Duty Assistant• Crews & Crew Chiefs work 5-week rotating
shift schedules – the schedules are different
so that each Crew Chief works with everycrew.

Operator’s Primary Responsibilities• Search & Secure of enclosures• Powering on/off the accelerators• Establishing and tuning beam as needed• Monitoring utility and emergency systems• Preserving the Beam Budget Monitor• First responders to all failures, fires, and floods

Floods?
Yes, floods.

Search & Secure,Radiation & Electrical Safety• Search & Secure:– A well established training program is in place:• Multiple visits, participation and leads for eachenclosure prior to qualification• Detailed maps & procedures for Ops to use during S&S• Radiation Safety:– Radiation Worker – Retrained every two years– Radiation Work Permits (RWP)– ALARA as a Cultural NormHistorical Approach to Electrical Safety• Single course (renewal not required) in Lock-Out
Tag-Out (LOTO)• Singular (renewal not required) training for group
LOTO (13.8-KV) procedures• In terms of day-to-day work there was littledirection. Mainly we relied upon “commonsense.”• Lab-wide this led to near misses and theinfrequent serious accident.
• Such events served as motivation…

Failure of a 480-V Switch ata Nation Laboratory (not Fermi)• Undamaged switch• Damaged switch

NFPA-70E• In 2005 Fermilab moved to be in-line with thestandards set forth by the National Fire
Prevention Association.
• Employees undertook a day-long training
session that was primarily focused on thepower distribution side as opposed to theutilization side.

In Other Words…

The Need for an Operations-Specific
NFPA-70E Program• My bosses felt the Ops Department needed todo more to not only stress electrical safety,
but to teach good techniques as well.
• They also felt the Laboratory’s NFPA-70E could
and should be made more specific forOperations.
• My task was to create and implement such aprogramOperations-Specific NFPA-70E• Strong Leadership: Operations & Division
management strongly required Ops to follow
rules – this was and is a crucial factor!
• Keep it Simple– There are many different power supplies andconfigurations –> develop simple categories.
– Limit unnecessary, but relatively risky activities.
• e.g. “Hot” jobs are not permitted.

– Provide easy access to personal protective and test
Equipment

Arc-flash Hazard Risk Categories
Defined by NFPA-70E
Arc-Flash Hazard/Risk Categories - Required Clothing - Required PPE
Fermilab Summary for NFPA 70E
Calculated Exposure
from Prospective Arc-FlashHazard/Risk
Category

Minimum
Required
ATPVClothing Requirements

Additional PPE

Zero up to 1.2 cal/cm2-1

NACotton Tee Shirt and Pants

Safety Glasses

Zero up to 1.2 cal/cm2

0NALong Sleeve Cotton Shirt and Pants

Safety Glasses

More than 1.2 and up to 4 cal/cm2

14 cal/cm2

FR Coverall

Hard Hat, Safety Glasses

228 cal/cm

Cotton Clothing Under FR Coverall

Hard Hat, Safety Glasses,
Face Shield,
Hearing Protection, Leather Gloves,
Leather Work Shoes

2*2Cotton Clothing Under FR Coverall

Hard Hat, Safety Glasses,
Double-Layer Switching Hood,Hearing Protection, Leather Gloves,
Leather Work Shoes

3225 cal/cm

Cotton Clothing Under 2 x FR Coveralls

Hard Hat, Safety Glasses,
Flash Suit Hood,
Hearing Protection, Leather Gloves,
Leather Work Shoes

42Cotton Clothing Under FR Coverallplus Multilayer Flash Suit Jacket & Pants

Hard Hat, Safety Glasses,
Flash Suit Hood,
Hearing Protection, Leather Gloves,
Leather Work Shoes

More than 4 and up to 8 cal/cm22

More than 4 and up to 8 cal/cm

More than 8 and up to 25 cal/cm22

More than 25 and up tp 40 cal/cm

8 cal/cm

40 cal/cm

Breakdown of Hazard/RiskCategories & Personal Protective
Equipment (PPE)• HRC-0: Most frequently encountered by Ops –PPE is fairly minimal & comfortable• HRC-1: Almost never encountered by Ops• HRC-2: Occasionally encountered by Ops
Examples will follow…

Hazard/Risk Categorical Criteria as Interpreted by
the FNAL Electrical Safety Subcommittee• Hazard/Risk Category 0 (HRC-0):– Most frequently encountered by Ops:
• Circuit breaker (CB) or fused switch less than 240-V;
enclosed (covered) or not• Enclosed CB or fused switch greater than 240-V and lessthan 600-V• Enclosed Motor Controller Center (MCC) up to 600-V• PPE Requirements:
 Safety glasses
 Long sleeve shirt & pants both made from untreated natural
fiber (e.g. cotton, wool)
 Leather work gloves are optional (but encouraged)

Examples of HRC-0:
Main Injector Corrector
Bulk Power Supply Disconnect

Linac RF Main BreakerMore Examples of HRC-0:
Klystron Solenoid
Panel Breaker

MI Service Building
House Power SafetyDisconnect

Hazard/Risk Categorical Criteria• H/R Category 2:– Enclosed CB or fused switchgear rated greater than 1-KV
– NFPA-70E details many other combinations of hardware
and activities in this H/R category, however, Ops (byorder of Mau) do not undertake these activities. Instead
we call FESS electricians.

• Required PPE:Hard hat, hearing protection & arc-rated face shield
Fire-retardant Cover-alls over HRC-0 clothing
Leather gloves & leather work shoes

Examples of Category 2:
Booster Gradient Magnet Power Supply
Utility Yard Disconnects

HRC-2 Activity in Action(Note the PPE)FNAL Electrical Safety Sub-committee
Shock/Electrocution Hazard PPE Guidelines
Shock Protection Boundaries and PPE
Fermilab Summary for NFPA 70E
System Voltage Range
Phase to Phase

50 to 300
Including 120, 277 and 120/208

301 to 750
Including 480/277

751 to 15K
Including 13.8K

345K to 362K

LimitedApproach
Boundary(Fixed Parts)

Restricted
Approach
Boundary

Prohibited
Approach
Boundary

Shock Protection
Insulating PPE

3 Ft 6 In

Avoid
Contact

Avoid
Contact

LAB - None
RAB - Wear/Use if Contact Likely
PAB - Wear/Use if Contact Likely

3 Ft 6 In

1 Foot1 InchLAB - None
RAB - Must Wear
PAB - Must Wear

5 Feet2 Ft 2 In

7 Inches

LAB - None
RAB - Must Wear
PAB - Must Wear

15 Ft 4 In

8 Ft 6 In

8 Feet

LAB - None
RAB - Must Wear
PAB - Must Wear

Within the
Limited Approach Boundary

Non-Qualified Worker Allowed Within Only if Advised and Escorted.
Insulated Equipment/Tools if Contact Likely.

Within theRestricted Approach Boundary

Only Qualified Worker Allowed Within.
May Not Cross Into with Conductive Objects Prohibited.
Body Parts Must be Insulated.

Within theProhibited Approach Boundary

Consider Activity as Same as Working On.

Keeping It Simple• 25 years ago Ops were as likely to be graduates oftechnical school as University• Today most Ops have degrees in Physics but
minimal or no experience working with highpower circuits.
• Given these considerations we do not allow Ops
to open power supplies with multiple powersources or high stored capacitive energy unlessthey have equipment specific LOTO.

Configuration Control Lockout List:
LINAC Configuration Control Updated 2/23/2006
LOCKED-OUT name/date/time......................................................................................LPSLUNLOCKED name/date/time .....................................................................................
Approved by ..................................................................................................................... Safety Officer
LOCKEDOFF

SUPPLYTYPE[ ] MH1
POWERTEN[ ] LAM
POWERTEN[ ] QD4
POWERTEN[ ] QD3
POWERTEN[ ] Q2POWERTEN[ ] Q5POWERTEN[ ] MV1
POWERTEN[ ] B:CEP400 FERMILABCONTROL
AT ENCLOSURE
POINT
LG-1 LINAC
LG-1 LINAC
LG-1 LINAC
LG-1 LINAC
LG-1 LINAC
LG-1 LINAC
LG-1 LINAC
BG24 LINAC/BOOSTERWALL BREAKERWALL BREAKERWALL BREAKERWALL BREAKERWALL BREAKERWALL BREAKERWALL BREAKERWALL BREAKERNFPA 70E
UNHAZ. CAT. LOCKED
00000000[[[[[[[[]]]]]]]]

Developing an Electrical Safety OJT• Ops have about ~15 different electrical safety
procedures• Some require additional training and some donot• We felt a need to formalize the processGroup Lock-Out
Tag-Out (LOTO)• Before Access to enclosures Ops
perform 13.8-KV LOTO
• Historically:• Procedures were read &training was done by a qualifiedoperator• No expiration for the training• Today:• Only Crew Chiefs may train• New Ops must perform theLOTO three (3) times before
being qualified• Training must be renewed
annually• Created Electrical Safety OJT tocomplete documentation

New Operator
Electrical Safety OJTExample• Ops must complete both FNAL
& Departmental NFPA-70E• Once NFPA-70E is complete
Ops may begin training forindividual procedures• The Operations Department
Head is only allowed to provide
the final signature1.

_______________
Trainer
Date
NFPA-70E Training_____ Operators must complete the Fermilab NFPA-70E electrical safety training.
_____ Operators must complete the Accelerator Operations Departmental NFPA70E training.
_____ Once both NFPA-70E training sessions are complete the Deputy Department
head will issue the operator fire retardant coveralls.
________________DH or DDH
Date
2. Master Substation (MSS) 13.8-KV LOTO Procedure_____ Operator must read and sign ADSP-05-1211_____ Introduction to the MSS LOTO field checklist_____ Operator should understand that Feeder 23 powers all Tevatron bend andquad magnets, low beta power supplies and the C0 shunt_____ Operator must visit the substation and get a demonstration of theprocedure by a Crew Chief. This may be a mock exercise done by the back-up
CC if necessary_____ Operator must then visit the substation with a Crew Chief or his/her
designee and lead the procedure; this may be a mock exercise;_____ Operator must flawlessly perform an actual LOTO procedure with a Crew
Chief present_____ Once these steps and all NFPA-70E training have been complete an operator
will be approved by the Department Head (DH) or the Associate DH or theDeputy DH to perform MSS LOTO

LOTO Field Check-List
for Trainers• In order to make training
more uniform we provide thischecklist to the Crew Chiefs• Since Crew Chiefs areultimately responsible forOperations it makes sense forthem to be the trainers

Example of LOTO
Field Form
• Check lists are used in
the field to ensure thewritten procedure isconsistently followed.
• Use of checklist
eliminates reliance upon
human memory• A corresponding form is
attached to the lockbox inMCR. The Crew Chiefmust sign-off that theprocedure was followed.

Continued Training• Training Videos– Ops created several demonstrative videos thatexist on a web server and can be reviewed at anytime.

• Annual Renewal:– Operations NFPA-70E– All Group LOTO procedures (High Voltage)Migration to Electronic Record Keeping• Historically our procedures were kept in books(three-ring binders).
• Over the past two years these procedures now
exist on a secure server.
• Operations has recently implemented anelectronic system record keeping.

Summary• Electrical safety training is much more formal.
• A department specific NFPA-70E program is inplace. The Ops Department lead the Accelerator
Division in adopting these guidelines.
• Vital LOTO training has been made more uniform
and requires annual renewal.
• An electronic database gives CC & Ops quick
access to training records and procedures.

Thank You for your Time. Here a
Gratuitous Picture of Lighting at Fermilab.