OSHA Electrical Safety Training

and Low Voltage (<600 V.)

Safe Work Practices
(2002)

CMT-0134-EN
12/2002
 Table of Contents

Lesson Page
Cover 1
Table of Contents 2
Lesson A: Training Series Overview and How to Use Materials 3
Lesson 1(LV): Classification of Voltage and Definitions 10
Lesson 2 (LV): The Network of Regulations 15
Lesson 3 (LV): Electrical Accidents in the Work Place 21
Lesson 4 (LV): Ohm’s Law and the Physiology of Electrocution 27
Lesson 5 (LV): Other Electrical Hazards 37
Lesson 6 (LV): Six Steps to Stay Alive 47
Lesson 7 (LV): Understanding System Grounding 60
Lesson 8 (LV): Understanding Current Sources 72
Lesson 9 (LV): PPE, Risk Assessment, and Clearances 76
Lesson 10 (LV): PPE Selection and Care 104

Revision History
V1.00 (11/29/02)
1. Initial release for PGU.

11/29/02 2
Lesson A: Training Series Overview and How to Use
Materials
Objectives:
ƒ Understand the reasons for the training.
ƒ Understand the training requirements of OSHA regulations in 29CFR 1910 ...
1910.269.
ƒ Understand employee and employer responsibilities for training
ƒ Understand the layout of the lessons and activities.
ƒ Understand who should study each unit.
ƒ Understand how to use the CBT program, tests, and attached reference
materials.
ƒ Define what a qualified and unqualified person is.
Introduction
The Occupational Health and Safety Administration (OSHA) requires employers
to provide a workplace where electrical equipment is safely installed. The
National Electrical Code (NEC) provides guidance on the safe installation of
electrical service and equipment. The National Electrical Safety Code (NESC)
provides guidance on the safe installation of generating, transmission, and
distribution equipment.

General Training Requirements

OSHA makes the employer responsible for providing training, tools, equipment,
and procedures so that employees who are required to operate or service
specific equipment can do so safely.

OSHA 29 CFR 1910.269 (a)(2) spells out a general training requirement that
employees shall be trained in and familiar with safety-related work practices,
procedures, and requirements that pertain to their job assignments.

Specific Training Requirements

OSHA 1910.269 (a)(2) spells out four specific requirements for training:
1. Skills necessary to distinguish live parts from others.
2. Skills necessary to determine nominal voltages present.
3. Skills necessary to determine minimum approach distances for the voltage
present.
4. Skill necessary to properly use protective equipment, insulated tools,
shielding materials, and precautionary techniques on or near live parts.

7/22/02 3
 Monitoring and Retraining Requirements

In addition, employers are responsible to monitor employee compliance with

prescribed safe work practices and provide additional training or retraining if:
1. Employees are found to not be following safe work practices.
2. New technology, new types of equipment, or new procedures are introduced
to the work place.
3. Tasks are performed less than once per year.

Employee and Owner Responsibilities

OSHA makes the employee responsible for following safe work procedures and
using the correct tools, equipment, and protective gear to insure their own safety.

Owner’s are ultimately responsible for contractors doing work on their site.

Type of Training, Documentation, and Testing

Training can be classrooms training, on-the-job training, or a combination of the
two. Employers must document (record in employment records) when
employees received specific training to qualify them to perform assigned work.
Employers must also document that employees can demonstrate correct
application of safe procedures and practices to perform typical duties in order
to be certified to do the work.

Four Steps to Qualification and Certification

For Low Voltage (<600 V.) and
Medium Voltage Work (601-15,000 V.)
At Cummins-Onan there are four steps to becoming qualified and certified to do
electrical service work on a range of electrical service voltages from 50 volts to
15,000 volts.

Qualified means that someone has been familiarized with the construction and
operation of equipment and the hazards involved.

Certified means that a person has demonstrated hands-on skills in selecting

proper protective equipment, tools, and procedures to isolate and confirm
isolation for service.

7/22/02 4
 Four Step Training Sequence

The first step involves training in basic electrical safety when working with
voltage up to 600 VAC. This segment is for everyone who works with electrical
equipment or supervises those who do. The first module culminates in
satisfactory completion of a series of written tests of basic safety knowledge. A
passing score is 80% or better on each lesson test is necessary for qualification.

The second step involves completion of a supervised hands-on test

demonstrating that you can follow safe procedures and use the correct tools,
protective gear, and test equipment in securing, testing, and preparing equipment
up to 600 V for service. Technicians working on generator sets up to 600 V
should demonstrate hands-on proficiency. Passing this test is necessary for
certification by Cummins-Onan.

The third step involves training in special safety considerations that apply to
working with voltages between 600V and 15KV. Technicians working on
equipment over 600 volts should take study this medium voltage section. This
module culminates in satisfactory completion of a series of written tests of
advance safety concepts and procedures. A passing score is 80% or better on
each lesson test is necessary for qualification.

The fourth step involves completion of a supervised hands-on test

demonstrating that you can follow safe procedures and use the correct tools,
protective gear, and test equipment in securing, testing, and preparing equipment
from 600V to 15KV for service. Technicians working on generator sets over 600

7/22/02 5
V should demonstrate hands-on proficiency. Passing this test is necessary for
certification by Cummins-Onan.

Steps 1 and 3 in the process can be completed on-line through the Power-Gen
University. Materials have been broken up into small lessons so you don’t have
to commit large blocks of time. Downloadable text files will be available for
reference. All lesson tests must be passed before proceeding to the next lesson
and may be repeated until you are successful.

A designated mentor or provider at your job site can help you complete hands-on
certification in steps 2 and 4 of the process. Information will be provided on how
to complete the hands-on certification when you have successfully completed the
preceding on-line training step.

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 Suggested User Interface for On Line Training
The interface bar on the left of your screen will provide status information and
navigation buttons.

Status and Lesson Screen

Navigation Bar

The status indicator at the top of the interface bar will inform
Page 1 of 15 Pages
you about where you are in the lesson.
☼ Back
☼ Forward (Example: Page 1 of 15) This tells you that you are on the
☼ Menu first page of the lesson and that there are 14 more pages to
☼ Exit complete the lesson.
☼ Next Lesson
The buttons below it will give you active choices for moving
around within the lesson.

☼ Back ... Clicking this button will take you back one slide
☼ Forward ... Clicking this button will take you to the next
slide.
☼ Menu ... Clicking this button will take you to the whole
list of lessons in this training module.
☼ Exit ... Clicking this button will terminate the lesson and
take you to the Power Gen University menu to log off or
move to another course.
☼ Next Lesson ... Clicking this button will take you to the
next lesson in this training module.

Additional buttons or underlined text may appear on a

screen to take you to another link or download.

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 Lesson A: Overview Test Questions w/Suggested Format
Click on the letter to select the answer to each question that you think is correct. Once
you have selected the first answer, you will not be able to leave the page until the
whole lesson test is completed. You can change your mind by simply clicking on a
different answer. Once you click the submit button at the bottom of the page, your
answers will be frozen and scored. Quizzes may be repeated until you get a passing
score. Passing scores will be recorded in your Power Gen University account for
credit.

1. OSHA requires that the employer A. provides the proper tools and equipment and
documents training to use them. B. follow NEC codes to the letter. C. determine
the nominal voltage present. D. utilizes dead front grounding.

2. OSHA requires that the employee A. pass tests with a score of 80% or better. B.
supply the proper tools. C. follow procedures and select the proper tools and
protective equipment. D. document that they have been trained.

3. Becoming qualified means A. taking a self-study course. B. becoming familiar with

equipment construction, operation, and hazards. C. demonstrating hands-on
proficiency. D. getting a score of 70% or better.

4. Becoming certified by Cummins-Onan means A. becoming familiar with equipment

construction, operation, and hazards. B. getting a score of 80% or better. C.
taking a self study course. D. demonstrating hands-on proficiency.

5. Which of the following statements is not one of the four basic OSHA employee
training requirements? A. Knowing which parts are live. B. Knowing the safe
approach distance to live parts of known voltage. C. Knowing what protective
equipment and procedures to use when working on live parts. D. Checking for
voltage at exposed parts to confirm lockout.

Submit

7/22/02 8
 Lesson A: Overview Test Questions w/Suggested
Format
(Answers Highlighted)

Click on the letter to select the answer to each question that you think is correct.
Once you have selected the first answer, you will not be able to leave the page
until the whole lesson test is completed. You can change your mind by simply
clicking on a different answer. Once you click the submit button at the bottom of
the page, your answers will be frozen and scored. Quizzes may be repeated until
you get a passing score. Passing scores will be recorded in your Power Gen
University account for credit.

1. OSHA requires that the employer A. provides the proper tools and equipment
and documents training to use them. B. follow NEC codes to the letter. C.
determine the nominal voltage present. D. utilizes dead front grounding.

2. OSHA requires that the employee A. pass tests with a score of 80% or
better. B. supply the proper tools. C. follow procedures and select the
proper tools and protective equipment. D. document that they have been
trained.

3. Becoming qualified means A. taking a self-study course. B. becoming

familiar with equipment construction, operation, and hazards. C.
demonstrating hands-on proficiency. D. getting a score of 70% or better.

4. Becoming certified by Cummins-Onan means A. becoming familiar with

equipment construction, operation, and hazards. B. getting a score of 80%
or better. C. taking a self study course. D. demonstrating hands-on
proficiency.

5. Which of the following statements is not one of the four basic OSHA
employee training requirements? A. Knowing which parts are live. B.
Knowing the safe approach distance to live parts of known voltage. C.
Knowing what protective equipment and procedures to use when working on
live parts. D. Checking for voltage at exposed parts to confirm lockout.

7/22/02 9
Lesson 1(LV): Classification of Voltage and Definitions
Objectives:
ƒ Understand the different classifications of electrical voltage by a variety of
standards organizations.
ƒ Understand the magnitude of hazards posed by different system voltages.
ƒ Become familiar with the definition of basic electrical terms, quantities, and
relationships.

Voltage Classifications
There are lots of ways to classify voltage. The National Electrical Code classifies
everything under 600 volts as low voltage.

Most circuits and equipment operate at voltages less than 600 volts phase to
phase or phase to ground including common household circuits (110/120 volts),
commercial and industrial lighting (277/480 volts), industrial machinery (480
volts), and pumps(240-480 volts).

The National Electrical Code classifies everything over 600 volts as high voltage.
OSHA uses the same break point between low and high voltage. Circuits and
equipment operating at voltages over 600 volts phase to phase are less common
in residential and most commercial buildings. Industrial sites and manufacturing
facilities where there are heavy industrial motors (more than 200-300
horsepower) and special equipment like arc furnaces and electrostatic
precipitators operate that equipment at higher voltages for practical reasons.

Voltages of less than 15,000 V (15 kV) carry power from substations to
neighborhoods, between buildings in industrial plants and large building
complexes, and to pieces of large industrial equipment in plants. The electrical
industry generally refers to voltages between 601volts and 15,000 volts as
“medium voltage circuits”.

Voltages more than 15 kV are common on lines carrying power from generation
plants to distribution substations. Installations in generation plants and
distribution systems are more commonly regulated by the National Electrical
Safety Code (NESC), which guides utilities. The electrical industry commonly
refers to these voltages as “high voltage circuits”.

A good way to think about installation guidelines is that the NEC applies to
everything on a utility customers site from the electric meter on and the NESC
applies to everything on the utility’s side of the meter. Of course, it is really not
that simple in an industry where there is a network of regulatory and standards
organizations.

11/29/02 10
The Institute of Electronic and Electrical Engineers, which sets standards for the
manufacture of switch gear, transformers, breakers, fuses, and protective relays
used in distribution systems, breaks down the classifications a little differently.

IEEE Classification
Voltage Class Voltage Range
Low Voltage (LV) 0-1,000 volts
Medium Voltage (MV) 2,400-72,500 volts
High Voltage (HV) 121,000 to 242,000 volts
Extra High Voltage (EHV) 362,000-800,000 volts
Ultra High Voltage (UHV) 1,000,000 volts and
above
Typical System Voltages
120, 208/120, 240/120,
480/277
2.3, 4.16, 7.2, 12.47, 13.2,
13.8, 20.8, 34.5, 69kV
115, 138, 230 kV
345, 500, 765 kV
1,100 kV

In the course work to follow, voltages below 600 volts will be classified as low
voltage and voltages from 601V - 15 kV will be classified as medium voltage.
To avoid confusion when communicating across trade lines on the job site
consider simply identifying the voltage of the equipment ... “I am working on 480,
3 phase, I am working on 13.8 kV, etc.”

Voltage over 50 volts is generally regarded as life threatening. As voltage

increases there is greater potential for current to arc and jump across gaps and
greater potential for more current to flow across a given amount of resistance.

In general, higher voltage is more hazardous to work with and commands greater
respect. Lower voltage often proves fatal when people do not respect the hazard
and take greater risks when working with it.

Definitions
Refreshing your familiarity with some basic terms used when talking about
electricity and electrical service in buildings where you will be working by
reviewing the tables on the next pages may be helpful.

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 Electrical Terms and Quantities

Term Definition
Alternating Current is electricity that flows back and forth in a conductor in a
rising and falling cycle and is caused by the south and
north poles of rotating magnets in a generator as they
approach and retreat from the coils that they induce
current in.
Hertz(Hz), Cycles is the rate at which the AC current changes
Per Second (cps) direction and is determined by the speed and
number of coil poles in a generator.
Direct Current is electricity that flows in a single direction.
Polarity applies to the negative (-) or positive (+) charge at a
terminal. Like charges repel and opposite charges. This
is normally applied to direct current and also applied to
the north and south poles of a magnet.
Resistance (R) is to electricity as restriction or friction is to liquid flow. It
is measured in ohms. It is analogous to a pinch in a
hose.
Voltage (E) or (V) the fundamental force that pushes electrons along a
conductor and overcomes resistance. It is measured in
volts. It is analogous to pressure in a hose.
Current (I) or (A) is the volume of electrons flowing in a stream. It is
measured in amperes or amps. It is analogous to the
number of gallons per minute flowing through a hose.
Power (P) or (W) is a measure of electricity’s capacity to do work. It is
measured in watts and is the product of voltage and
current. This is the way we are billed for power by the
utility. This is analogous to the shaft output from water
falling on a mill wheel.
Ohm’s Law says the voltage in a circuit is the product of the amount
(E = I*R) or (V=A*R) of current and the resistance in a circuit. What it really
says is that the greater the voltage supplying a circuit,
the more current will flow across a given resistance.
When any two values are known for a circuit, the third
can be calculated with Ohms Law.
Watt’s Law says the power is equal to the product of the current and
(P = E*I) or (W=V*A) voltage flowing in a circuit. A 120 watt, 120 volt light
bulb, will require 1 amp of current flow to light it.

11/29/02 12
 Terms Used When Talking About
Electrical Service and Wiring

Term Definition
Conductor is a wire carrying current that has a potential above
ground. It is usually insulated and any color but green,
white, or gray.
Ground is the potential reference of the earth.
Ground Electrode is usually a copper rod driven deep into the ground.
(Shiny)
Grounded is a wire that carries current but has no potential
Conductor difference from the earth. This is sometimes called a
neutral in an AC circuit and is usually a white or gray
wire. This may be a black wire in a DC circuit.
Grounding is a wire that normally does not conduct electricity but
Conductor provides an alternate path to ground for stray currents. It
is usually a green wire but may not be insulated.

Bonded refers to a bolted connection between parts of frames,

enclosures, and conduit enclosing live conductors.

Bonding Conductor is a wire connecting separate parts of enclosures to form

a common current carrying structure or between the
grounding conductor and the grounded conductor at a
single point in the service panel.

11/29/02 13
System Drawing Showing Examples of Bonding

System Drawing with All Terminology

11/29/02 14
Lesson 2 (LV): The Network of Regulations
Objectives:
ƒ Link standards organizations with the equipment and safety gear that they
establish standards for, regulate, or certify.
ƒ Reinforce the four basic OSHA training requirements.
ƒ Make clear when training or retraining is required.

Primary Sources
The two primary sources of guidance on electrical safety for electrical workers
are OSHA 29CFR Part 1910 and NFPA 70E. The OSHA document establishes
the requirements for employers and NFPA 70E translates these requirements
into practical guidelines to use on the job.

Who Sets What Standards

11/29/02 15
The capsules that follow are designed to help you navigate through the
maze of regulations that govern safety, safe work practices, equipment
design, safe system design, safe installation, protective safety equipment,
and its care.

OSHA 29CFR Part 1910

The Occupational Safety and Health Administration addresses electrical safety in
Subpart S of 29CFR 1910.302 through 1910.399 of the General Industry Safety
and Health Standards.

Subpart K of 29 CFR 1926.402 through 1926.408 of the Construction Safety and

Health Standards contains installation safety and health standards for
installations providing power and lighting on the jobsite. These regulations apply
to both temporary and permanent installations.

Subpart R 29 CFR (1910.269, 1910.302, 1910.332-.335) covers what

qualifications are required to handle specific duties on generation, transmission,
and distribution equipment.

In general, OSHA (1910.269 (a) (2) establishes four training requirements for
persons to become qualified for their job assignment:

1. Persons must be trained to distinguish live parts from other electrical

components.
2. Persons must be trained to determine the nominal voltages present.
3. Persons must be trained on the minimum approach distance corresponding to
the voltage.
4. Persons must be trained on the proper use of precautionary techniques and
personal protective equipment when working on or near exposed parts.

This includes knowing what to do to protect yourself and demonstrating how

to do it.

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Classroom, on-the-job training, or a combination of the two can meet the initial
requirement of knowing what to do and how to do it safely. Retraining or
refresher training is only required if:

1. Supervision finds someone is not following safe practices.

2. New technology, equipment, or techniques are introduced.
3. If procedures not normally used are required by a job.
4. If the task is performed less than once per year.

From these guidelines, you can infer that people performing electrical work would
initially receive training at the time of hire or assignment and if something
changes in their job performance or assignment.

NFPA 70E
NFPA 70E available from the Nation Fire Protection Association translates
OSHA requirements into recommended safe work practices that meet those
requirements. NFPA 70E provides specific help in analyzing the level of risk
posed by performing specific jobs and guidance in selecting proper protective
equipment to be used to do that job. This is a more practical guide for
technicians and their employees to use.

NFPA 70E addresses:

■ Safe Work Practices
■ Shock and Arc Hazards
■ Boundary Requirements
■ Personal Protective Equipment

Installation Standards

NEC
The National Electrical Code provides regulations and standards for the safe
installation of electrical service to work site buildings. It is the basis for
electrical building codes. In a nutshell, the code spells out how things must be
wired to prevent them from starting a fire or electrocuting someone. These
regulations principally apply to the customer’s side of the utility meter. The NEC
guides electricians.

NESC
The National Electrical Safety Code contains rules necessary for the
installation, operation, or maintenance of electric supply. The NESC also
contains work rules and principally applies to the utility’s side of the electrical
service and utility workers. Since Cummins-Onan sells, installs, and services

11/29/02 17
backup power generation equipment at the customer’s site service personnel
may perform functions of both utility workers and electricians. NEC and NESC
regulations may apply to what you do in each of those roles.

NECA
The National Electrical Contractors Association is a national organization serving
the management interests of the entire technical contracting industry. NECA
keeps members updated on current regulations and works with other groups
drafting installation standards.

IEC
The International Electrotechnical Commission (IEC) is the leading global
organization that prepares and publishes international standards for all electrical,
electronic, and related technologies. These serve as a basis for national
standardization and as references when drafting international tenders and
contracts.

Product Standards

NEMA
The National Electrical Manufacturers Association sets standards for equipment
such as what enclosures are appropriate for different classifications and service
applications. NEMA standards also sets design codes for motors or other
equipment.

IEEE
The Institute of Electrical and Electronics Engineers set standards for the
manufacture of switch gear, transformers, breakers, fuses, and protective
relays.

UL
Underwriters Laboratories tests and certifies plug connected equipment and
user interfaces. An example of this is a motor controller since most motor
controls have a human interface at the operator or start-stop station.

11/29/02 18
CSA

Canadian Safety Association is the Canadian equivalent of UL and tests and

certifies similar equipment including equipment enclosures.

ANSI

American National Standards Institute rates and labels safety equipment like
insulated gloves, hard hats, safety glasses, shields, flash hoods, flash jackets,
and hot sticks. This includes many of the pieces of equipment like fuses whose
standards may also be set by the IEEE. They also prescribe how safety gear
should be labeled and taken care of.

ASTM
American Society for Testing of Materials sets standards for the materials that
safety gear is made of, such as fire resistant clothing.

IEC/ISO/DIN
The International Electrotechnical Commission (IEC), the International
Organization for Standardization (ISO), and Deutsches Institut für Normung (DIN)
are the international organizations covering a similar range of product standards
to IEEE, ANSI, ASTM, NEMA, UL, and CSA in the US and Canada.

11/29/02 19
Match the Acronym of the Agency or Organization to the
Area of Regulation or Standards Application
Function Agency or Standards
Organization
Sets training requirements for people exposed to electrical
hazards.
Would rate fire protective clothing or the materials circuit
breakers are made of.
Would certify a panel or enclosure.
Would classify a panel or enclosure for use outside.
Establishes safe work practices like when and what PPE to
wear.
Would establish standards for over current protection
devices.
Two organizations who both deal with PPE standards.
Sets installation and operating standards for utility
companies and power generators.
Would be involved in labeling safety gear.
Establishes requirements for grounding services.
Establishes requirements of disconnects and over current
protection.
Would set standards for transformers, switches, and switch
gear.
Would set standards for equipment or installations outside
of the United States.

11/29/02 20
Lesson 3 (LV): Electrical Accidents in the Work Place
Objectives:
ƒ Familiarize people with the profile of who typically gets killed.
ƒ Familiarize people with the profile of what hazards kill.
ƒ Familiarize people with when and where accidents take place.
ƒ Familiarize people with NIOSH recommendations for electrical accident
reduction.
ƒ Point out the only two reasons OSHA permits working on energized
equipment.

Background of Electrocution in the Workplace

Electricity kills, maims, disfigures, and at the very least causes extreme
discomfort every time it gets out of control . Every year in the US there are 600
electrical fatalities, 2000 people hospitalized for serious electrical burns, and
30,000 non-fatal electric shocks. Electricity ranks as the 4th leading cause of
traumatic industrial injuries.

According to the National Institute for Occupational Safety and Health (NIOSH),
between 1980 to 1992 electricity killed 5,348 people on the job site and
accounted for 7% of all traumatic occupational fatalities. The average is more
than one fatality per calendar day or 411 per year. Electrocutions ranked as the
fifth leading cause of death on the job in that 12-year period.

A detailed investigation by NIOSH of 224 electrical accidents that killed 244

workers between November of 1982 and December of 1994 looked at three
dimensions of the incidents:

1. The mode of energy exchange

2. The worker involved
3. The environment

11/29/02 21
Who died?
About 85% of the fatalities were white males, about 65% were under 35, and
only one was a woman.
The construction trades accounted for about half of all the fatalities.
Utility workers who typically receive extensive safety training had the
highest number of fatal injuries as a group.
Laborers who generally receive little or no electrical training had the next
highest number of fatalities as a group.

What killed them?

Almost all events involved AC or AC arcs.
Two thirds of the fatalities were from contact with voltages over 600 V. Three
quarters of those were voltages above 7200 V.
Over half of the incidents under 600 V. were at household voltage levels.
Accidents were divided among five scenarios in order of reducing occurrence:
direct contact with power lines, direct contact with energized equipment,
boomed vehicle contact with power lines, improperly installed or damaged
equipment, and conductive equipment coming in contact with power lines.
Lots of the incidents involved inadvertent contact with power lines,
intentional contact with parts thought to be safe, failure to lock out
equipment, and inadvertent restoration of power during service work.

When and where did the accidents take place?

There were substantially more incidents during the warmer months where
more outside activity was common. Fatalities were much more common in
June through August and minimal in December through February.

What characterized the situations?

Over one third of the incidents took place where there was no safety program
or written safe work procedures. Poor enforcement of safety policies and use
of personal protective equipment characterized some of the incidents.
Supervisors were present in more than half of the incidents and comprised
more than one third of the fatalities when present.
80% of the victims had some electrical safety training ... mostly OJT, 20% had
no training whatsoever, and more than 40% had been on the job less than a
year.

Many workers were unaware of the potential electrical hazards present in their
work environment that made them more vulnerable to electrocution.

11/29/02 22
Newer OSHA’s guidelines focused on reducing worker vulnerability by making
sure workers are made aware of potential electrical hazards in their work
environment and provided with the knowledge, tools, and equipment to protect
themselves.

NIOSH figures indicate that electrocution rates decreased 50% in the 12-year
period studied above. NIOSH made the suggestions below to continue the
improvement.

What are NIOSH Recommendations for Prevention?

Develop and implement a comprehensive safety program and periodically
update it.
Ensure compliance with provisions of OSHA 29CFR Subpart S, K, and R.
Train workers to identify and control electrical hazards.
Provide specialized training to those who work with circuits and exposed
components.
Develop written procedures to control hazards including lock out tag out.
Provide testing or detection equipment to workers who work directly with
electrical energy.
Follow the NEC and NESC codes.
Conduct regular safety meetings.
Conduct scheduled and unscheduled safety inspections.
Encourage workers to be actively involved in workplace safety.
Conduct jobsite surveys to identify electrical hazards and control measures
before starting construction projects.
Make sure proper personal protective equipment is worn by workers.
Conduct job hazard analyses of tasks that might expose workers to hazards.
Identify potential electrical hazards and appropriate safety interventions for
maintenance projects.

11/29/02 23
 Selected (LV) Case Examples from
NIOSH Study of 224 Incidents
The examples below occurred below 600 V. They were selected because the
bulk of the victims were electricians or service personnel who should have known
better. These examples were also chosen because they illustrate specific errors
in judgment. They demonstrate the risk of not following safe practices
recommended by OSHA or failure to use good common sense. (The first 2 digits
indicate the year the incident happened.)

85-25 Electrician electrocuted at coal-fired power plant while replacing limit

switch on coal sampler. Lockout procedures not followed. Contact with
220 V. line.

85-28 Maintenance worker electrocuted when he attempted to turn off a

welder. Exposed cable, broken insulation, water on the floor.

85-36 Electrical worker electrocuted when he slipped and fell into a 7200 V,
240/120 V single-phase, step-down transformer he was wiring.

86-01 Electronic technician electrocuted as he demonstrated how feeders were

connected to bus bars. Contact with 380 volts.

86-47 Electrician electrocuted while repairing airport runway lights. Co-worker

misinterpreted signal, re-energizing circuit before electrician finished.

86-50 Meter technician, working as a lineman, electrocuted while attempting to

repair a fallen 120 V. power line. Power line splice caught victim’s glove,
exposing his arm to direct 120 V current.

87-14 Stagehand electrocuted when he contacted an exposed electrical wire

protruding from a junction box. Victim was lying on a metal catwalk
reaching out to replace a ceiling tile when the incident occurred.

87-68 Electrician electrocuted after contacting a 110 V conductor while working

in a crawlspace to install a furnace in a cottage.

.
OSHA Injunctions on Working Hot

The number of fatal incidents above underscore the perils of working on

energized equipment. OSHA 1910.333 (a)(1) and NFPA 70E 2-1.1.1 stresses
that no one should ever work on energized equipment except to take diagnostic
measurements or if termination of power would introduce greater risk like in the
case of disabling ventilation in a hazardous area.

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 Chart 1

Facilities Under and Over 600 V

NIOSH FACE 1982-1994

33%

67%

Fatalities Under 600 Volts

Fatalities Over 600 Volts

11/29/02 25
 Chart 2

Breakdown of Fatalities Under 600 V

NIOSH FACE 1982-1994

600 Volts 110-120

440-480
Volts Volts

270-277 220-240
Volts Volts

110-120 Volts 220-240 Volts 270-277 Volts

440-480 Volts 600 Volts

11/29/02 26