MEGGER GettingDownToEarth

PCP-650
Electrical Safe Practices For Personnel and Equipment
Index
1. Scope
2. Electrical System Owner
3. Electrical Safety Program
4. Electrical Safety Program Principles
5. Hazards of Electricity
6. Electrical Qualification Program
7. Qualified Person
8. Clear Work Space
9. Job Planning
10. Energized Electrical Work
11. Energized Work Defined
12. Energized Work Examples
13. Energized Work Permit
14. Work Not Requiring an EWP
15. Prohibited Work
16. Approach Boundaries
17. Shock Protection Boundaries

18. Flash Hazard Boundary
19. Flash Hazard Protection
20. Electrical PPE
21. General Lockout/Tag out Guidelines
22. Contractor LOTO Procedures

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23. Safety Grounding
24. Detailed Safety Grounding Procedure
25. Temporary Wiring
26. Portable Cords
27. Ground Fault Protection for Portable Tools
28. Portable Electrical Equipment
29. Electrical Power Tool Safe Practices
30. Appendix A, Table 1 – Hazard/Risk Category Classifications

31. Appendix B, Figure 1 –Approach Distances
32. Appendix C - Ground Fault Circuit Interrupter Use
33. Appendix D – Example Electrical Outage Planning CBA
34. Appendix E – Example Electrical Outage Job Plan
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1. Scope
1.1. This practice, PCP-650, provides minimum standards for Electrical Safe Practices at all Procter &
Gamble Co. sites and applies to employees and contractors engaged in work at P&G sites. This
standard is to be followed by all sites, unless the local laws and/or electrical codes require more
stringent standards.
2. Electrical System Owner (ESO)

2.1. The site Electrical System Owner (ESO) has responsibility for all electrical systems at the site, down to
50 Volts, (the shock hazard threshold), including the following deliverables:
2.1.1. The site electrical qualification program
2.1.2. The site electrical safety program
2.1.3. Electrical equipment maintenance and reliability
2.1.4. Electrical power quality and reliability
2.1.5. Electrical system master-planning
2.1.6. Short circuit and fault coordination studies
2.1.7. Flash hazard protection
2.2. The ESO may delegate as appropriate to accomplish the work, but is the single point of contact and is
accountable for the deliverables. The ESO responsibilities may be shared between multiple persons
allowing the site to retain staffing flexibility.
3. Electrical Safety Program

3.1. All P&G sites will implement and maintain an Electrical Safety Program intended to protect all
personnel from the hazards of electricity, electric shock, electrical arc flash, and arc blast.
4. Electrical Safety Program Principles

4.1. The Site Electrical Safety Program shall follow these principles:
4.1.1. All employees will be trained to recognize, avoid and report specific electrical hazards as
may exist in their work location.
4.1.2. Employees performing electrical work will be qualified by the site to perform that work
safely.
4.1.3. Electrical work is to be planned such that the need for “energized work” is minimized.
4.1.4. The integrity of electrical enclosures, insulation systems, bonding and grounding will be
maintained.
4.1.5. A Risk Assessment shall be completed before executing any electrical work and safety
measures applied as per the result of that analysis.
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5. Hazards of Electricity
5.1. Shock Hazards:
5.1.1. The hazards of electric shock are due to the fact that electric current can flow through the
human body. The severity of the injuries will vary based upon the path that the current takes
through the body, and the level of that current flow. Minor shocks, while potentially painful,
are short duration and usually cause no injury. As the duration of the shock incident or the
level of current flow increases, the likelihood of a serious injury also increases.
5.1.2. Shock injuries are in the form of surface and internal burns, and heart fibrillation.
Fibrillation is a condition where the heart is rapidly twitching, but not pumping, and will be
fatal unless interrupted by the use of a medical defibrillator. Surface burns can be easily
evaluated, while internal burns can initially go undetected and can potentially show up later as
internal medical problems. For this reason it is important to P&G and the affected employee
that all instances of electrical shock be reported as an incident and that the employee’s
condition be evaluated by competent medical personnel. Shock injuries are prevented by
proper grounding and bonding of electrical systems and avoiding contact with energized
circuits or components.
5.2. Flash Hazards
5.2.1. Flash hazards result from the flame and radiant heat (over 19,000 Deg C. - 35,000 Deg F.)
that is generated during an arcing fault. An arc is electric current flowing through the air.
Arcing faults occur when contact is made between energized phases or an energized phase and
ground, initiating very high current which can then sustain itself through the air. Arc faults can
be initiated by faulty equipment, birds, rodents, insects, or human error. The incident energy of
the flash is measured in Joules or Calories /sq. cm., and will vary, depending upon the fault
current available from the upstream electrical distribution equipment, and clearing times of the
circuit protective devices.
5.2.2. Arc flash injuries can be burns ranging from 1st degree to severe 3rd degree. Clothing and
hair can be instantly set on fire during arc flash incidents. Flash injuries are prevented through
the proper use of the correct PPE for the hazard.
5.3. Blast Hazards
5.3.1. Blast hazards result from arcing faults and to some degree, always accompany the flash
hazard. The blast results from the rapidly expanding gas generated during the arc flash and the
force of the resulting pressure wave. The force can be strong enough to destroy electrical
enclosures, knock people down, or off of ladders, and propel shrapnel and molten metal
droplets great distances through the air. Blast injuries include cuts, bruises, etc. from flying
debris and potential falls, as well as potential sound induced hearing loss. Blast injuries to the
face are mitigated by safety glasses and face shields. Protective equipment does not exist that
will completely protect personnel from the potential effects of blast hazards. Blast incidents are
best eliminated through effective switchgear maintenance, proper operational procedures, and
safe practices.
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6. Electrical Qualification Program

6.1. All P&G sites are required to have an electrical qualification program that documents the qualification
of all persons authorized by the site to perform electrical tasks. The program must list the level of
qualification and the standard by which the qualification was awarded. The intention is to ensure
that only persons who have received training and successfully completed a performance
demonstration are authorized to perform electrical tasks. The site Electrical Qualification Program,
should follow the principles of HSE CBA 8016 Electrical Safety Qualification of Employees
Working on Electrical Systems, which includes the following five levels of qualification:
6.1.1. General Awareness Training: All Employees
6.1.2. Task Qualifications: Specific Tasks
6.1.3. Low Voltage Qualification: Up to 1KV
6.1.4. Medium Voltage Qualification: 1KV to 36KV*
6.1.5. High Voltage Qualification: Above 36 KV
*38kV would be the natural choice because of the MV equipment configuration of using metal enclosed
switchgear, however, this safe practice originally used 15kV as the upper MV limit. The U.S. distances for two
of the boundaries are more lax than the European boundaries. Many sites had labels up with distances for
Limited Approach Boundary, Restricted Approach Boundary, and Prohibited Approach Boundary that were
consistent with >38kV in the U.S. but not in Europe. Two of the three distances would have had to be extended
beyond what was currently used had 38kV been used. The decision was made to use 36kV so the labeling on so
many panels would not need to be changed knowing that there were a couple of plants that use 38kV. For those
sites the Global Electrical Safety Leader can work with them individually as needed to provide them with the
correct boundary distances for their region and they may also consider 38kV as MV or they may use the longer
boundary distances provided for High Voltage systems.
7. Qualified Person
7.1. A qualified person shall be trained and knowledgeable of the construction and operation of equipment
or a specific work method, and be trained to recognize and avoid the electrical hazards that might be
present with respect to that equipment or work method. Such persons shall also be familiar with the
proper use of special precautionary techniques, PPE (personal protective equipment), insulating and
shielding materials, and insulated tools and test equipment. A person can be considered qualified
with respect to certain equipment and methods but still unqualified for others.
8. Clear Work Space

8.1. A minimum clear work space of 0.9 meter (3 feet) must be maintained in front of, and /or beneath all
electrical cabinets, MCC’s, switchboards or panelboards containing circuits energized at greater than
50 volts. This is a minimum distance and may need to be increased based upon the voltage level, the
proximity to other electrical equipment or grounded surfaces, and the authority having jurisdiction.
Refer to local and country codes and regulations for specific clarifications. This area may not be
used to store materials or equipment of any kind. The clear work space must be maintained.
9. Job Planning
9.1. Developing a Job Plan
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9.1.1. See Annex D for an example job planning system (CBA 101)
9.1.2. See Annex E for an example job plan
9.2. Job Safety Analysis and Potential Problem Analysis
9.2.1. A job safety analysis must be prepared for all medium or high voltage work.
9.2.2. A Potential Problem Analysis should be conducted for all medium or high
voltage work.
9.2.3. The JSA and PPA can be combined into one document. Please see Annex F
for an example.
9.3. Job Breifing
9.3.1. Before starting each job, the employee in charge shal conduct a job briefing
with the employees involved. The briefing shall cover such subjects as hazards
associated with the job, work procedures involved, special precautions, energy
source controls, and personal protective equipment requirements.
9.3.2. If the work or operations to be performed during the work day or shift are
repetitive and similar, at least one job briefing shall be conducted before the
start of the first job of the day or shift. Additional job briefings shall be held if
changes that might affect the safety of employees occur during the course of the
work.
9.3.3. A brief discussion shall be satisfactory if the work involved is routine and if
the employee, by virtue of training and experience, can reasonably be expected
to recognize and avoid the hazards involved in the job. A more extensive
discussion shall be conducted if either of the following apply:
9.3.3.1. the work is complicated or particularly hazardous.
9.3.3.2. The employee cannot be exptedcte to recognize and avoid the hazards
involved in the job.
10. Energized Electrical Work

10.1. Each site must have a written policy governing work performed on or near energized equipment.
The policy should require that all persons, authorized by the site to perform energized electrical
work, be qualified according to the intent of Procter & Gamble Co. HSE CBA-8016 Qualification.
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11. Energized Work Defined
11.1. At P&G sites, energized work is governed by HS&E CBA 8015. HS&E CBA 8015, Part IV
Paragraph C states: “Energized work involves working inside the Prohibited Approach Boundary as
defined in NFPA 70E, or repairing, replacement, or installation of energized electrical equipment.
Specific safety actions must be taken to ensure the task can be performed safely. If at any time the
person(s) doing the work, a supervisor, or person signing the permit determine that the task cannot be
performed safely, stop the work.”
12. Energized Work Examples
12.1. Making or breaking splices in energized wiring
12.2. Connecting or disconnecting energized wires on terminal strips
12.3. Making or breaking plug-in connections to energized bus bars, MCC buckets, bus-ducts, etc.
12.4. Adjusting or aligning energized parts
12.5. Using hand tools to tighten, remove, or replace energized components
12.6. Pulling wire or cable into conduits containing energized circuits
12.7. Removing or replacing fuses in energized circuits
12.8. Crossing the LV Prohibited Approach Boundary for any reason including during troubleshooting.
13. Energized Work Permit (EWP)

13.1. HSE CBA-8015 Energized Work Permit defines the official P&G policy governing EWP’s and
should be followed whenever considering any energized electrical work on a P&G site. All work on
or near energized electrical equipment is to be avoided where possible due to the inherent dangers
involved. Most instances of proposed energized work can be temporarily postponed and
accomplished at a time when the power can be turned off without causing additional risk to the
business, and thereby eliminate the risk to the employees. In cases where it is not possible to wait, or
when waiting could actually increase the risk of a serious incident occurring, work may proceed by
following the EWP process.
13.2. The EWP Process:
13.2.1. requires a permit for all work on circuits or components energized above 50 Volts
13.2.2. limits the work to systems operating at 600 Volt or less The selection of 600 V as the limit for
an EWP is based on the types of injuries seen when shocks occur at these voltages. At about 600V
the skin no longer offers significant protection and we begin to see penetration wounds at the
locations of where the current enters and leaves the body. In addition, the wounds continue through
the individual forming a burn track with relatively low impedance and significant damage. This is the
reason why EWP is limited to 600V. It is not based on either equipment or the voltages normally seen
or used in any region of the world.
13.2.3. documents sufficient cause
13.2.4. documents the job specific hazards, safe practices, work procedures, personal protective
equipment, limited approach, restricted approach, prohibited approach, and flash
boundaries(Appendix B), special precautions, and tools required to ensure the work will be
performed in a safe manner.
13.2.5. requires proper authorization
13.2.6. insures proper communication
13.2.7. identifies those to perform the work
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14. Work Not Requiring an EWP
14.1. Routine maintenance activities by persons qualified to the level required for the work, often require
that certain tasks (troubleshooting, voltage and/or current measurements, etc.) be completed with the
circuit energized. These activities do not normally require an Energized Work Permit, although sites
may choose to require a permit for such activities if they deem it necessary. All proper PPE and
tools approved for the hazard must be used. Examples of these tasks are given below:
14.2. Visually inspecting components (no disassembly required).
14.3. Using approved test equipment to measure voltage, current, etc.
14.4. Troubleshooting using ground fault detection equipment.
14.5. Taking IR Scan measurements.
14.6. M.V. or H.V. Switching operations, (manually actuating switchgear) where the enclosures are intact
and closed.
15. Prohibited Work

15.1. In all cases, work on energized electrical equipment, systems or components above 600 Volts is
prohibited by the Procter & Gamble Co. EWP’s (Energized Work Permits) may only authorize work
on circuits energized up to 600 Volts.
15.2. Energized Work Permits vs. Circuit Voltages
0-50 V. No permit required

51-600 V. Energized work requires a Permit
600 V. & Higher Not authorized by P&G
16. Approach Boundaries (Working Near Exposed, Energized Equipment)

16.1. There are 4 approach boundaries intended to protect workers from electrical hazards. Three are
dedicated to shock protection and one is dedicated to flash protection. These boundaries are intended
to limit access to areas of high hazard to electrically qualified personnel, specify when PPE is
required, specify when an energized work permit is required, or prohibit access
16.2. In IP-20 or “finger-safe” panels, where all energized components are fully enclosed, the enclosure is
intact, and all guards are in place, and direct contact is not possible, there is therefore no exposure,
and the “approach boundaries” do not need to be considered unless the worker is interacting with the
equipment. An example of an individual interacting with the equipment would be taking voltage
measurements.
16.2.1. The “clear work space” requirements in front of the IP-20 panel would apply.
17. Shock Protection Boundaries

17.1. Shock Protection Boundaries must be observed whenever personnel are in the vicinity of exposed,
energized conductors at 50 Volts or more. This includes times when an electrical enclosure door is
opened, a cover or panel is removed that exposes un-insulated energized components or non-finger
safe terminals. Also, anytime work is to be done on or near open power distribution lines such as
pole mounted feeders or switchgear. Any proposed work within these areas should be reviewed by
the site ESO, or their designee, before beginning work.
17.2. Low Voltage, 50 – 1000 Volt Approach Boundaries are identified as follows:
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Limited Approach Boundary; for fixed conductors 1.2 meters (4 feet), for movable
17.2.1.
conductors 3 meters (10 feet). Only qualified personnel may enter within this boundary. This
means that before a qualified person opens an MCC compartment door, exposing un-
insulated terminals or bus bars, the limited approach boundary must be established, to keep
passers-by from unknowingly entering a hazardous area.
17.2.2. Restricted Approach Boundary; 0.3 meter (1 foot). Only qualified personnel wearing
proper shock protection PPE may enter within this boundary. Electrically insulated blanket
may also be required as a means of protecting the worker from contact with phase or ground
potential.
17.2.3. Prohibited Approach Boundary; 2.5 Centimeters (0 ft. 1 in.). Up to 600 Volts, only
qualified personnel with an approved “Energized Work Permit”, wearing proper shock
protection PPE, and using insulated tools may enter within this boundary. Electrically
insulated blanket may also be required as a means of protecting the worker from contact with
ground/earth potential or phase potential from other sources in the vicinity of the energized
electrical work.
17.3. Medium Voltage, 1kV-36kV Approach Boundaries are identified as follows:-
17.3.1. Limited Approach Boundary; for fixed conductors 1.8 meters (6 feet), for movable
conductors 3 meters (10 feet). Only qualified personnel may enter within this boundary. An
example of a movable conductor is an overhead line which can be moved by the wind.
17.3.2. Restricted Approach Boundary, 1.0 Meter (4 feet) only qualified personnel wearing proper
shock protection PPE may enter within this boundary.
17.3.3. Prohibited Approach Boundary, 0.3 meter (1 foot). No access is permitted above 600 volts.
Individuals within the Prohibited Approach Boundary are considered to be in direct contact
with the energized conductors. The limitation is based on the fact that the severity of shock
incidents becomes much worse above 600 volts. In addition to the possibility of cardiac
arrest, present for any shock incident, common injuries resulting from shock at voltages in
excess of 600 volts also includes: entry and exit wounds, destruction of internal tissue and
organs along the path of current flow, blood cell, vein and artery destruction as the blood
typically provides the lowest resistance path, and increased current levels through the heart.
These levels of tissue damage commonly result in the body becoming overwhelmed with the
byproducts from destroyed cells resulting in renal (kidney) failure.
17.4. High Voltage, >36 kV-115kV Approach Boundaries are identified as follows;
17.4.1. Limited Approach Boundary: For systems up to these voltage levels typically movable
conductor distances are appropriate. 3.6M (12 feet)
17.4.2. Restricted Approach Boundary: 2.4M (8 feet) – No access allowed. (No shock protection
PPE available.)
17.4.3. Prohibited Approach Boundary: 1.2M (4 feet) – No access allowed.
Note: Appendix B, Figures 1 & 2, of this document show graphical representations of the approach and flash
hazard boundaries relative to exposed energized components, the PPE to be used, and the procedures to be
followed when working within those boundaries.
18. Flash Hazard Boundary

18.1. The flash hazard boundary, also known as the “curable burn distance”, is the minimum distance from
the arc source that a person who is not wearing flash protection PPE must be to insure that any burn
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received will not cause permanent tissue damage. This occurs at incident energies of 1.2 calories per
square centimeter. Persons within that boundary must be protected from the potential arc flash by
flash protection PPE. Flash hazard studies are required at all P&G sites. As a minimum, the
following flash hazard boundaries shall be observed:
18.1.1. >600 volt systems – as determined by an Arc Flash Study.
18.1.2. 50 to 600 volt systems down to and including MCCs - As determined by an Arc Flash
Study.
18.1.3. 50 to 600 volt systems below the MCCs. - 1.2 meters (4 feet) (when using the table method
from Appendix A)
19. Flash Hazard Protection

19.1. Preferred Method
The preferred method of determining the proper protection is to have a complete and detailed flash
hazard study for the site power distribution system. IEEE-1584 is the Procter & Gamble Co.
standard methodology for conducting a detailed flash hazard analysis, and should be used for all
flash hazard studies at P&G sites. Engineering contractors hired to complete Short Circuit,
Coordination and Flash Hazard studies must be listed as approved engineering resources in PCP-
1502. Flash hazard studies calculate the available incident energy (in calories per square centimeter),
which allows the site to define the flash hazard boundary to be observed at each bus in the system.
Further, this information allows qualified persons to determine the proper minimum PPE to be worn
while working at specific points in the electrical system.
19.2. Power System Study software packages are available to assist with calculating via the IEEE-1584
method.
19.3. Alternate Method
Some sites, such as a new acquisition site, may not have completed the required flash hazard study.
Also, a site’s power system computer model, used to perform the short circuit, coordination, and
flash hazard studies will have a lower equipment limit. For example the computer model may not
extend below the motor control center level. In these situations the site may choose to follow the
guidance of Appendix A to select PPE for protecting their personnel from flash hazards.
19.3.1. Appendix A - Table 1 defines the Hazard/Risk Category classifications for various
electrical tasks on energized equipment at specific voltages, and specifies the default
category of PPE to be used for flash hazard protection while performing those tasks.
19.3.2. Appendix A - Table 2 defines the specific PPE items to be worn to provide adequate
protection for each Hazard/Risk Category.
19.4. P&G Default Flash Hazard Category 0
Based upon documented testing conducted by the IEEE, P&G now recognizes a default Hazard Risk
Category 0 for all portions of electrical systems which operate at less than 240 Volts 3 phase, and
that have less than 10 KA 3 phase symmetrical fault current available. Typically, fault currents of
this level are found in smaller electrical systems supplied by transformers less than 125 KVA. The
IEEE-1584 testing found that, given these system limitations, arcing faults cannot be sustained.
Therefore, sites may eliminate the Flash Hazard calculations in areas of their electrical system where
these system limitations exist, and simply label them as Category 0 Flash Hazard with a 4 foot (1.2
meter) Flash Protection Boundary. Electrical systems with voltages of 240 and higher or with
available fault currents of 10KA or higher, must continue to have their flash hazard level calculated
by following one of the methods outlined in other portions of this document.
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19.5. P&G Default Flash Hazard Category 2*
19.5.1. For 50-1000 volt exposed energized conductors sites may default to Flash Hazard
Category 2* PPE. This allowance is based on Annex H of NFPA 70E-2009.
19.5.2. The following low voltage tasks require higher levels of PPE per Appendix A Table 1. As
a result individuals are not allowed to perform these tasks using Default Flash Hazard
Category 2* PPE:
19.5.2.1. Insertion or removal of low-voltage motor starter “buckets,”
19.5.2.2. Insertion or removal of power circuit breakers from switchgear cubicles or
19.5.2.3. Removal of bolted covers from switchgear, motor control centers, or power
distribution panels.
19.6. Equipment Interaction/Operation With Enclosure Doors Closed
19.6.1. For MCCs PDPs (Power Distribution Panel)Hazard/Risk Category 0 is adequate for
interaction/operation of the electrical equipment with the enclosure doors closed. (This is
based on Appendix A table method for determination of Flash Hazard PPE.)
19.6.2. Above the MCC/PDP level interaction/operation of electrical equipment, with the
enclosure doors open or closed, the PPE specified by the Flash Hazard Study must be
utilized. When the enclosure door is closed and the Flash Hazard Study states that the hazard
risk category is “Dangerous” a maximum PPE level of Category 4 is required. When
possible, additional administrative or engineering controls should be used to reduce or
eliminate the risk of an incident. (In cases where the required Flash Hazard study has not
been completed the Appendix A Table Method must be used and the Flash Hazard Study
must be completed.)
20. Electrical PPE (Personal Protective Equipment)

20.1. Electrical PPE includes, but is not limited to; safety glasses, arc rated face shields, flash hoods w/ arc
rated face shields, hearing protection, rubber gloves with leather covers, insulating mats, hard hats,
fire retardant clothing, safety shoes, insulated hand tools, etc. Anytime that tools or test equipment
are used to make contact with energized circuits, at or above 50 Volts, PPE rated to provide
protection from the existing hazards must be worn. This includes IP-20 touch safe equipment. PPE is
used to provide protection from both the shock hazards and the flash hazards. Both hazards must be
considered when defining the proper PPE for a task.
20.2. Electrical insulating PPE, such as rubber gloves, mats and sleeves are voltage rated and must be used
only on voltages of that rating or less. Leather protectors (gloves) shall be worn over rubber
insulating gloves at all times. Rubber insulating mats should be used as needed to provide additional
protection when the work is in close quarters with grounded or energized surfaces.
20.3. Rubber gloves are required to be inspected before each use and tested every 6 months. In cases
where testing facilities are not available in the region or country purchasing new gloves every 6
months is acceptable with proper tracking.
20.4. Arc flash PPE, such as flame resistant (FR) clothing and face shields, are rated in Calories per square
centimeter. Appendix A of this document lists arc flash, and shock protection, PPE for specific tasks
where personnel are exposed to those hazards. FR clothing shall be rated to provide protection from
the known flash hazard, or as a minimum, be selected according to Appendix A, section 18.4, or
section 18.5 of this document. All personnel within the flash hazard boundary (curable burn
distance) must be protected from the known arc flash hazard.
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20.5. Properly utilized PPE provides protection to the level indicated by the rating of that specific PPE
item. PPE cannot provide adequate protection in situations where the level of voltage or the
available incident energy is beyond their rated capability. For example; rubber gloves are available
rated up to 36 KV (Class 4, 36,000Volts), but no higher, and the maximum rating currently available
for arc resistant clothing is 100 cal/cm sq. Hazard levels may exist at some sites that are beyond the
level of protection that PPE can provide.
20.6. Working Distance
20.6.1. As a worker approaches an arc source the incident energy increases. For example, at a
great distance from a strong arc source no PPE is needed while very near to a strong arc
source adequate PPE is not commercially available or recommended, i.e. > 40 calories/square
cm. Flash hazard studies dictate the minimum required PPE to protect an individual at a
specific distance from the arc source. The distance is measured from the arc source to the
individual’s head/chest. This distance is provided by IEEE 1584 as follows:
20.6.1.1. Meduim-voltage switchgear 910mm (36 inches)
20.6.1.2. Low-voltage switchgear 610mm (24 inches)
20.6.1.3. Low-voltage MCCs and panelboards 455mm (18 inches)
20.6.1.4. Cable 455mm (18 inches)
20.6.1.5. Other To be determined in the field.
20.6.2. These distances are based on the typical distances a person’s head and chest should be
from the arc source while working on that equipment. For most low voltage equipment the
distance is based on the length of a person’s arm and was set by IEEE 1584 at 455mm (18
inches). In the case of low-voltage substation switchgear, i.e. power circuit breakers, the
distance is based on arm’s length plus 155mm (6 inches). The additional 155mm is because
the arc source for a low voltage power circuit breaker is about this far behind the front of the
breaker. In the case of medium-voltage switchgear a person is expected to use a hot stick
while voltage testing and applying temporary protective safety grounding and this results in
910mm (36 inches).
20.6.3. If an individual is working with their head or chest closer to the equipment than the
distance used in the arc flash study and a fault occurs the amount of incident energy will be
higher than predicted by the study and the flash hazard PPE specified by the study may not
be adequate. The working distance for each piece of equipment should be on the flash hazard
labeling and workers are expected to observe the working distance. In cases where this is not
possible special precautions and procedures must be employed. An example is the application
of clamp type safety grounds to medium voltage switchgear prior to the installation of ground
balls. In this instance the following are examples of effective techniques to control the risk:
20.6.3.1. increasing the PPE level,
20.6.3.2. increased vigilance when voltage testing, and
20.6.3.3. using a hot stick/ground cluster combination, while observing the required working
distance, to strike down the phase conductors prior to installing, by hand, a clamp
type safety grounding cluster.
21. General Lockout/Tag out (LOTO) Guidelines
21.1. All sites must have documented LOTO guidelines in place for personnel to follow whenever work is
to be done on electrical systems, powered equipment, or equipment with stored energy.
21.2. Always follow the site specific or Global HSE guidelines for LOTO procedures.
21.3. Always use a unique padlock and keep the key in your personal control.
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21.4. Never trust anyone else’s padlock for your safety.
21.5. Always inform the machine owner or customer that you have a LOTO in place and why.
21.6. The implementation details may vary from region to region, or site to site, but all LOTO procedures,
for P&G employees and contractors, must have the following features:
21.6.1. The ability to isolate all forms of potential energy, electrical, pneumatic or hydraulic,
mechanical, or stored energy.
21.6.2. A system of identifying who placed the lock on the isolator and why.
21.6.3. A deliberate, documented process for removing a lock in the event that one is mistakenly
left in place and the originator is not available for removal.
21.6.4. All individuals working on a system or machine must have a personal lock and tag in place
on the isolating device until their portion of the work is completed or they leave the site.
21.7. Electrical equipment must be maintained in an electrically safe work condition at all times. This
means that when exposed electrical conductors exist, either a lock out and appropriate safety
grounding is in place or, in the case of troubleshooting or energized electrical work, effective
boundaries have been established including the Limited Approach Boundary.
Note: For reference see PCP-345and HSE CBA 2052.
21. Construction (contractor) LOTO Procedures

21.1. During Construction the contractor is responsible for all switching and LOTO’s until the involved
equipment is turned over to P&G ownership and control. Disconnects used to isolate power from
circuits under construction must be locked and tagged with a lock that remains under the control of
the contractor's representative.
21.2. During commissioning activities, all P&G personnel working on a given circuit must add their
personal lock and tag to the disconnect switch even though the contractor may still have a lock in
place. Commissioning personnel must remove their locks when finished with their work or
whenever leaving the site.
21.3. Construction Completion. When all commissioning work is completed and the machine or process is
accepted by P&G, a formal hand off must occur during which all contractor locks and tags are
removed, and the start-up team and plant personnel are informed that P&G has complete control and
ownership of the machine or process. After the ownership transfer, the normal P&G plant LOTO
procedures shall be followed.
22. Safety Grounding (temporary protective grounds)
22.1. Simply following LOTO procedures alone, does not insure safety during power outage maintenance
activities. “Safety Grounding” is the practice of connecting all three phases of a power circuit to
ground (earth) after testing and confirming them to be de-energized. This is done primarily to
prevent inadvertent re-energizing, but also to ensure that all capacitively stored or induced voltages
are dissipated, and the circuit remains at ground potential while the work is underway. Safety
grounding protects personnel who otherwise would be at great risk as they climb in and on normally
energized surfaces to clean, inspect, test and repair power circuit components.
22.2. During scheduled maintenance power outages, there is a very real risk of circuits being energized or
retaining hazardous energy from:
22.2.1. re-energization from the normal feed.
22.2.2. “back feeds” from portable generators used to provide local lighting and portable tool power.
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PCP-650
22.2.3. capacitively stored electrical charges that remain on recently de-energized circuits. If of
sufficient length, circuit conductors can retain energy sufficient to deliver serious shocks due
to inter-electrode capacitance or capacitance to ground/earth. Capacitively stored charge is
direct current (DC) and typical medium voltage testing equipment is capable on testing for
alternating current only. The result is that capacitively stored charge cannot be detected using
this equipment and temporary protective grounding is required to ensure safety.
22.2.4. magnetic coupling with nearby energized circuits can induce voltages onto de-energized
conductors.
22.3. Proper application of safety grounds eliminates the hazards listed above, and is a requirement for
establishing a safe working condition on systems with nominal voltages over 1000 volts. Safety
grounding is accomplished either by using integral grounding switch mechanisms, or by installing
temporary protective grounds or “ground clusters”. Ground clusters are an assembly of clamps and
cables manually attached to ground and all three-phase conductors. Ground clusters are not required
when using grounding switch mechanisms provided the grounding switch mechanism is rated for the
available short circuit current. In rare cases where it is not possible to install temporary protective
safety grounds the specific hazards in Section 22.2 must be addressed and it must be shown that there
is no possibility for induced voltage. These cases sometimes occur during the installation/removal of
a feeder or when working with some MV motor starters.
Note: Many substation transformer installations at P&G do not include secondary protection. In such
cases the incident energy available at the low voltage bus can be extremely high, often over 150 Cal/cm2.
This makes measuring the secondary voltage a very hazardous task that should never be undertaken when
the equipment is known to be energized. When it is necessary to verify the absence of voltage at the
secondary bus, the following procedure should be followed to minimize the risk.
23. Detailed Safety Grounding Procedure

23.1. Always confirm, as much as possible, that the switchgear is unloaded before opening the transformer
primary (medium or high voltage) switch.
23.2. Wear the proper PPE for the hazard involved.
23.3. Open the primary switch and lock and tag.
23.4. Select the proper test equipment for the system voltage.
23.5. Test all voltage testers, glow sticks, etc. on a known energized source just prior to use.
23.6. Maintain the maximum practical distance while working.
23.7. Test all phases of the circuit for any voltage indication to verify that there is no voltage.
23.8. After the tester shows no voltage, retest the voltage tester to confirm proper functionality.
23.9. Once it is verified that there is no voltage on the circuit, connect one end of the ground cluster to an
effective ground connection, ideally this would be a grounding point specifically provided for such
use.
NOTE: Use only ground clusters designed for the purpose and of sufficient wire size to safely carry the
fault current available at that point in the system. The P&G standard minimum size is AWG 4/0 or 95 mm2.
To order proper ground clusters for your site, go to the Salisbury Grounding Configurator at
www.whsalisbury.com.
23.10. Using the hot stick, touch each phase with the ground cluster to discharge any residual energy
stored by the line capacitance.
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PCP-650
23.11. Using the hot stick, individually connect the three phases to the ground cluster.
23.12. Remove PPE as desired and begin maintenance work.
23.13. When removing protective grounds, first disconnect the phase leads and then disconnect the
ground connection last.
24. Temporary Wiring

NOTE: Insubstantial or unsafe wiring cannot be considered safe or acceptable because it is temporary.
24.1. At P&G sites temporary wiring is subject to the following limitations:
24.1.1. 90 days maximum installation lifetime or the duration of the associated construction effort.
24.1.2. Must be installed by qualified person(s).
24.1.3. All connections, other than those made with approved plugs and receptacles, must be made
inside electrical enclosures.
24.1.4. The installation must meet all applicable codes and standards.
24.1.5. All components used must be listed and approved for the purpose as used.
24.1.6. Each end of temporary feeder cables must be tagged indicating the anticipated date of
removal, date of installation, project name, and the project contact’s name.
24.1.7. All temporary electrical equipment must meet the requirements of HS&E CBA 8018.
24.1.8. The ESO is responsible to review temporary wiring plans and ensure timely removal.
25. Portable Cords

25.1. HS&E CBA 8018 establishes the expectations for inspections of portable cords.
25.2. Type SO (heavy duty oil resistant) cords are not acceptable for permanent wiring except as power
cords for portable equipment, extension cords, push button pendants, or drops from bus ducts. The
jacket of SO cord is rubber which is flammable and therefore not approved for use in conduit, cable
tray, or air return plenums. SO cord may be used for single phase and 3-phase circuits up to 600
volts. Do not install or use portable cords on circuits operating at over 300 volts potential to ground.
The recommended maximum length is 50 feet (15 m). Limit the length of all portable cords to as
short as practical for the need.
25.3. Do not expose portable cords to vehicle traffic, or other forms of mechanical damage. Route cords
in a manner to protect them from mechanical damage, moisture and chemicals. Install cords such
that the strain and wear will be minimized.
25.4. For 3 phase systems, use a 4 conductor cord to maintain the safety ground. 3-phase, 480 volt, plug
connected equipment must not be plugged-in or un-plugged under load. A means of de-energizing
must be provided at or near the receptacle to allow safe connecting and disconnecting.
26. Ground Fault (Earth Leakage ) Protection for Portable Tools

26.1. HS&E CBA 8018 establishes the expectations for ground fault protection of portable tools. An RCD
(Residual Current Device) rated at 30 mA or less is considered equivalent protection when compared
to a GFCI.
26.2. All portable, hand held electrical tools used by personnel during construction, remodeling,
maintenance, repair or demolition of buildings, structures, equipment or similar activities must be
protected by GFCI’s (Ground Fault Circuit Interrupters) or ELCB’s (Earth Leakage Circuit
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PCP-650
Breakers). This includes drill motors, grinders, circular saws, soldering irons, cord lights, and the
like.
26.3. The P&G preferred method of protecting personnel from electric shock when using portable hand
held tools is the use of portable GFCI’s to supply power whenever the tools are used. Portable
GFCI’s for personal shock hazard protection should be a standard issue item for every employee
who is expected to operate portable electric tools when ground fault or earth leakage protection is
not available as part of the site wiring system.
27. Portable Electrical Equipment

27.1. HS&E CBA 8018 establishes the expectations for inspections of portable electrical equipment.
27.2. Portable (plug and cord connected) electrical equipment includes appliances and unit-operations
which, are not permanently wired to the building electrical system, and that by their design, can be
easily moved or relocated. Office equipment, such as lamps, PC’s, printers, copy machines, etc. that
are rated and approved for their use by the local authority, (CE in the EU, U/L in the USA, CSA in
Canada, etc.) are not included in this definition.
27.3. All portable, plug and cord connected, electrical devices, equipment, and appliances with exposed
conductive surfaces, must have those surfaces properly and adequately bonded to ground. Normally
this is accomplished by the manufacturer using a three conductor power cord and three prong
polarized plug, but may in some cases require an additional grounding conductor. Unless marked as
“double insulated” by the manufacturer, all portable electrical equipment must have an equipment
grounding conductor and a three-prong attachment plug. The grounding conductor in the power
cord is an important safety feature than must remain intact to insure the safety of those who come in
contact with the equipment. At most P&G sites this includes equipment such as; space heaters, floor
fans, portable lights, electronic scales, lab ovens, mixers, etc. Such equipment should be powered by
a GFCI’s where possible.
27.4. Portable, plug and cord connected, three phase electrical equipment, not protected by GFCI’s, must
be inspected visually prior to each use and tested periodically to verify the continuity of the
equipment grounding conductor. The visual inspection should verify that the cord and plug are in
good, serviceable working condition, and that the electrical enclosure on the equipment is intact.
Departments that rely upon such portable equipment for their day to day operation should document
the periodic testing of that equipment and track the equipment to insure that the safe working
condition does not degrade over time. The test results should be documented and made available to
electrical system auditors. Such equipment includes portable welders, air compressors, production
unit-operation’s, or similar equipment and machines. When such equipment has been placed in
storage, it should be electrically tested and inspected before returning it to service.
28. Electrical Power Tool Safe Practices

When using hand held power tools:
28.1. Always use a Ground Fault Circuit Interrupter (GFCI) to supply power, and test it before use.
28.2. Always minimize your contact to ground while using power tools.
28.3. Avoid allowing any part of your body to become a current path, between the tool and ground.
28.4. Avoid laying down on the earth, damp concrete, or any grounded metallic surface. When you must
do so, use a dry insulating mat.
28.5. Never use an aluminum (or any metallic) ladder. Fiberglass safety ladders are the P&G standard.
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PCP-650
28.6. Never use power tools while standing in water or the rain.
28.7. Never stand barefoot on the soil, metal structures, or concrete, always wear proper footwear in good
dry condition.
28.8. Never use 3-prong to 2-prong adapters. These devices eliminate the safety ground connection.
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PCP-650
PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications

Tasks Performed on Energized Equipment HRC Rubber Insulated and
Insulating Insulating
Gloves Hand Tools
Panelboards or Other Equipment Rated 240 V and Below – Note 1
Perform infrared thermography and other non-contact inspections outside the 0 N N
restricted approach boundary
Circuit breaker (CB) or fused switch operation with covers on 0 N N
CB or fused switch operation with covers off 0 N N
Work on energized electrical conductors and circuit parts, including voltage 1 Y Y
testing
Remove/install CBs or fused switches 1 Y Y
Removal of bolted covers (to expose bare, energized electrical conductors and 1 N N
circuit parts)
Opening hinged covers (to expose bare, energized electrical conductors and 0 N N
circuit parts)
Work on energized electrical conductors and circuit parts of utilization 1 Y Y
equipment fed directly by a branch circuit of the panelboard

Gloves Hand Tools
Panelboards or Switchboards Rated >240 V and up to 600 V
(with molded case or insulated case circuit breakers, Note 1)
CB or fused switch operation with covers on 0 N N
CB or fused switch operation with covers off 1 Y N
Work on energized parts, including voltage testing 2* Y Y
Work on energized electrical conductors and circuit parts of utilization 2* Y Y
equipment fed directly by a branch circuit of the panelboard or switchboard
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PCP-650
PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications (continued)

Gloves Hand Tools
600 V Class Motor Control Centers (MCC’s)
Note 2 (except as indicated)
CB or fused switch or starter operation with enclosure doors closed 0 N N
Reading a panel meter while operating a meter switch 0 N N
CB or fused switch or starter operation with enclosure doors open 1 N N
Work on energized electrical conductors and circuit parts, including voltage 2* Y Y
testing
Work on control circuits with energized electrical conductors and circuit parts 0 Y Y
120 V or below, exposed
Work on control circuits with energized electrical conductors and circuit parts 2* Y Y
>120 V, exposed
Insertion or removal of individual starter “buckets” from MCC – Note 3 4 Y N
Application of safety grounds, after voltage test 2* Y N
circuit parts) – Note 3
Opening hinged covers (to expose bare, energized electrical conductors and 2* N N
circuit parts) – Note 3
Work on energized electrical conductors and circuit parts of utilization 2* Y Y
equipment fed directly by a branch circuit of the motor control center

Gloves Hand Tools
600 V Class Switchgear
(with power circuit breakers or fused switches) – Notes 4
CB or fused switch operation with enclosure doors closed 0 N N
CB or fused switch operation with enclosure doors open 1 N N
Work on energized electrical conductors and circuit parts including voltage 2* Y Y
testing
Work on control circuits with energized electrical conductors and circuit parts 2* Y Y
>120 V, exposed
Insertion or removal (racking) of CBs from cubicles, doors open or closed 4 N N
Application of safety grounds, after voltage test 2* Y N
Removal of bolted covers (to expose bare energized electrical conductors and 4 N N
circuit parts)
Opening hinged covers (to expose bare energized electrical conductors and 2 N N
circuit parts)
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PCP-650

Gloves Hand Tools
Other 600 V Class (277 V through 600 V nominal)
Lighting or small power transformers (600V, maximum)

Removal of bolted covers (to expose bare, energized electrical conductors and 2* N N
circuit parts)
circuit parts)
testing
Application of safety grounds after voltage test 2* Y N
Revenue meters (kW-hour, at primary voltage and current) 2* Y N
Insertion or removal
Cable trough or tray cover removal or installation 1 N N
Miscellaneous equipment cover removal or installation 1 N N
testing
Application of safety grounds after voltage test 2* Y N
Insertion or removal of plug-in devices into or from busways 2* Y N

Gloves Hand Tools
NEMA E2 (fused contactor) Motor Starters, 2.3kV Through 7.2kV
Contactor operation with enclosure doors closed 0 N N
Contactor operation with enclosure doors open 2* N N
testing
>120 V, exposed
Insertion or removal (racking) of starters from cubicles, doors open or closed 4 N N
Application of safety grounds, after voltage testing 3 Y N
circuit parts)
Opening hinged covers (to expose bare energized electrical conductors and 3 N N
circuit parts)
Insertion or removal (racking) of starters from cubicles of arc-resistant 0 N N
construction, tested in accordance with IEEE C37.20.7, doors closed only
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PCP-650

Gloves Hand Tools
Metal Clad Switchgear 1kV Through 38kV
CB operation with enclosure doors closed 2 N N
CB operation with enclosure doors open 4 N N
testing
>120 V, exposed
Insertion or removal (racking) of CBs from cubicles, doors open or closed 4 N N
Application of safety grounds, after voltage test 4 Y N
circuit parts)
Opening hinged covers ( to expose bare energized electrical conductors and 3 N N
circuit parts)
Opening voltage transformer or control power transformer compartments 4 N N
Arc-Resistant Switchgear Type 1 or 2 (for clearing times of <0.5 sec with

a perspective fault current not to exceed the arc resistant rating of the
equipment)
CB operation with enclosure door closed 0 N N
Insertion or removal (racking) of CBs from cubicles, doors closed 0 N N
Insertion or removal of CBs from cubicles with door open 4 N N
Insertion or removal (racking) of ground and test device with door closed 0 N N
Insertion or removal (racking ) of voltage transformers on or off the bus door 0 N N
closed
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PCP-650
Other Equipment 1 kV Through 38 kV
Metal clad load interrupter switches, fused or unfused
Switch operation of arc-resistant-type construction, tested in accordance with 0 N N

IEEE C37.20.7, doors closed only
Switch operation, doors closed 2 N N

testing
circuit parts)
circuit parts)
Outdoor disconnect switch operation (hook stick operated) 3 Y Y
Outdoor disconnect switch operation (gang-operated, from grade) 2 N N
Insulated cable examination, manhole or other confined space 4 Y N
Insulated cable examination, in open area 2 Y N
General Notes (applicable to the entire table):

(a) Rubber insulating gloves are gloves rated for the maximum line –to-line voltage upon which work will be
done.
(b) Insulated and insulating hand tools are tools rated and tested for the maximum line-to-line voltage upon
which work will be done, and are manufactured and tested in accordance with EN 60900 or ASTM F 1505,
Standard Specification for insulated and Insulating Hand Tools or similar standard appropriate for the country.
(c) Y = yes (required), N = no (not required).
(d) For systems rated less than 1000 volts, the fault currents and upstream protective device clearing times are
based on an 18 in. working distance.
(e) For systems rated 1kV and greater, the Hazard/Risk Categories are based on a 36 in. working distance.
(f) for equipment protected by upstream current limiting fuses with arcing fault current in their current limiting
range(1/2 cycle fault clearing time or less), the hazard/risk category required may be reduced by one number.
Specific Notes (as referenced in the table):
1. Maximum of 25 kA short circuit current available, maximum of 0.03 second (2 cycle) fault clearing
time.
2. Maximum of 65 kA short circuit current available, maximum of 0.03 second (2 cycle) fault clearing
time.
3. Maximum of 42 kA short circuit current available, maximum of 0.33 (20 cycle) fault clearing time.
4. Maximum of 35 kA short circuit current available, maximum of up to 0.5 second (30 cycle) fault
clearing time.
For clarification “Lighting and small power transformers” refers to transformers which are 500kVA or less. It
does not refer to distribution transformers such as those used in substations.
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PCP-650
PCP-650, Appendix A, Table 2
Protective Clothing and Personal Protective Equipment (PPE) Matrix
Hazard/Risk Category Protective Clothing and PPE
Hazard /Risk Category 0
Protective Clothing, Nonmelting (According to ASTM F 1506-00 Shirt (long sleve)
or equivalent standard) or Untreated Natural Fiber Pants (long)
FR Protective Equipment Safety glasses or safety goggles (SR)

Hearing protection (ear canal inserts)
Leather gloves (AN) (Note 2)
Hazard /Risk Category 1
FR Clothing, Minimum Arc Rating of 4 (Note 1) Arc-rated long-sleeve shirt (Note 3)
Arc-rated pants (Note 3)
Arc-rated coverall (Note 4)
Arc-rated face shield or arc flash suit hood
(Note 7)
Arc-rated jacket, parka, or rain wear (AN)
FR Protective Equipment Hard hat

Safety glasses or safety goggles (SR)
Leather gloves (Note 2)
Leather work shoes (AN)
Hazard/Risk Category 2
FR clothing, Minimum Arc Rating of 8 (Note 1) Arc-rated long-sleeve shirt (Note 5)
Arc-rated face shield or arc flash suit hood
(Note 7)

Hazard/Risk Category 2*
FR clothing, Minimum Arc Rating of 8 (Note 1) Arc-rated long-sleeve shirt (Note 5)
Arc-rated arc flash suit hood (Note 10)
Hard hat
FR Protective Equipment Safety glasses or safety goggles (SR)
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PCP-650
PCP-650, Appendix A, Table 2 (continued)
Hazard/Risk Category Protective Clothing and PPE

FR clothing, Minimum Arc Rating of 25 (Note 1) Arc-rated long-sleeve shirt (AR) (Note 8)
Arc-rated pants (AR) (Note 8)
Arc-rated coverall (AR) (Note 8)
Arc-rated arc flash suit jacket (AR) (Note 8)
Arc-rated arc flash suit pants (AR) (Note 8)

FR Hard Hat Liner (AR)
Arc-rated gloves (Note 2)
FR clothing, Minimum Arc Rating of 40 (Note 1) Arc-rated long-sleeve shirt (AR) (Note 9)
Arc-rated pants (AR) (Note 9)
Arc-rated coverall (AR) (Note 9)
Arc-rated arc flash suit jacket (AR) (Note 9)
Arc-rated arc flash suit pants (AR) (Note 9)

FR Hard Hat Liner (AR)
Arc-rated gloves (Note 2)
AN = As needed (optional)
AR = As required
SR = Selection required
Notes:
1. See Appendix A, Table 3. Arc ratings for garments are expressed in cal/cm2.
2. If rubber insulating gloves with leather protectors are required by Appendix A, Table 1, additional
leather or arc-rated gloves are not required. The combination of rubber insulating gloves with leather
protectors satisfies the arc flash protection requirement.
3. The FR shirt and pants used for Hazard/Risk Category 1 shall have a minimum arc rating of 4.
4. Alternate is to use FR coveralls (minimum arc rating of 8) instead of FR shirt and FR pants.
5. FR shirt and FR pants used for Hazard/Risk Category 2 shall have a minimum arc rating of 8.
6. Alternate is to use FR coveralls (minimum arc rating of 8) instead of FR shirt and FR pants.
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PCP-650
7. A face shield with a minimum arc rating of 4 for Hazard/Risk Category 1 or a minimum arc rating of 8
for Hazard/Risk Category 2, with wrap-around guarding to protect not only the face, but also the
forehead, ears, and neck (or, alternatively, and arc_rated arc flash suit hood), is required.
8. An alternate is to use a total FR clothing system and hood, which shall have a minimum arc rating of 25
for Hazard/Risk Category 3.
9. The total clothing system consisting of FR shirt and pants and/or FR coveralls and/or arc flash coat and
pants and hood shall have a minimum arc rating of 40 for Hazard/Risk Category 4.
10. Alternate is to use a face shield with a minimum arc rating of 8 and a balaclava (sock hood) with a
minimum arc rating of 8 and which covers the face, head and neck except for the eye and nose areas.
PCP-650, Appendix A, Table 3 – Protective Clothing Characteristics
Category 0
Flash hazard protective clothing is categorized according to the table below. Only clothing that has been tested
for arc flash (thermal) resistance will have an ATPV (arc thermal protection value) rating assigned by the
manufacturer. Category 0 clothing is not FR (flame resistant), and carries no ATPV from the manufacturer.
They are considered acceptable for Category 0 use only because they are non-melting and will protect against
minor burns such as would be received in a minor arc flash incident.
Category 1and Higher

For Category 1 and higher arc flash hazards, FR PPE with certified ATPV ratings are required to provide
adequate protection when doing exposed, energized electrical work. FR clothing can be layered to provide an
increased level of protection.
Flash Hazard PPE Category vs. Incident Energy
HRC (Hazard Risk Category) Required Minimum ATPV (arc
thermal protection value)
0 N/A
1 4 Cal/cm2
2 8 Cal/cm2
3 25 Cal/cm2
4 40 Cal/cm2
The threshold incident energy level for a second degree burn on bare skin is 1.2 Cal/cm2.
Caution: In Europe, when tested per standard ENV 61482-1-2, Class 1 is 3.2 Cal/cm2 and Class 2 is 10.1
Cal/cm2. Please note that the term Category 1 means 4 Cal/cm2 and is based on IEEE 1584 and NFPA
70E while the term Class 1 means 3.2 Cal/cm2 and is based on ENV 61482-1-2. In every case, adequate
arc flash hazard protection is required based on the Cal/cm2 rating of the clothing when compared to the
arc flash study hazard identified.
Notes:
 FR means Flame Resistant. To be considered FR, the clothing must meet the requirements of ASTM F 1506-02a.
 Arc rating or ATPV (arc thermal protection value) is the maximum incident energy resistance demonstrated by a
material or layered system of materials, prior to “break open”, that point at which one or more holes are formed
through the innermost layer of FR clothing, that allow flame to pass through the material, or at the onset of a 2nd
degree burn based on the Stoll curve. Arc ratings are normally expressed in Calories per square centimeter.
 100% cotton clothing provides only minimal protection, up through Category 0 only. In addition, Cotton will
ignite and continue to burn in an arc flash incident!
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PCP-650
 Injuries resulting from arc flash incidents are usually minimal if workers are wearing proper FR PPE!
 Eyes and face are protected by safety glasses and face shields, and the body is protected by clothing unless the
clothing ignites. Serious burn injuries will usually result if the clothing is ignited.
 Error! Objects cannot be created from editing field codes.
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PCP-650
PCP-650, Appendix B
Procter & Gamble Co. Global Electrical Safety Program
Approach Boundaries
Graphical Representation of Approach Boundaries
(From NFPA 70E, Figure C.1.2.4 – 2009 Edition)
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PCP-650
PCP-650, Appendix B, Figure 1 – Low Voltage Approach Distances
This figure specifies safe approach distances to be observed at all P&G sites by persons exposed to circuits
energized at 50-1000 volts, and further specifies the default Flash Hazard Boundary to be observed in all
cases unless a flash hazard study identifies a different flash hazard boundary. All persons working on low
voltage equipment must be LVQ (low voltage qualified) or supervised by a LVQ person.
Prohibited Restricted Limited Approach

Approach Approach and Flash Protection
Boundary Boundary Boundaries
1. LVQ or 1. LVQ or 1. LVQ or supervised

supervised Supervised 2. Flash Protection PPE
2. Wearing Flash and 2. Shock and
shock PPE Flash Non-LVQ
3. Energized Work Permit Protection person or those
PPE not wearing
flash protection
Energized PPE
surface
2.5 cm (1 in)
0.3 m (1 ft)
1.2 m (4 ft)
These distances are P&G Standards and exceed those specified by EN 50110-1 and NFPA 70E Article 130.
PCP-650, Appendix B, Figure 2 – Medium Voltage Approach Distances
energized at 1,000-36,000 volts. The flash hazard boundary is not included and must be determined using
the facility’s flash hazard study. All persons working on medium voltage equipment must be MVQ
(medium voltage qualified) or supervised by a MVQ person.
Prohibited Restricted Limited Approach

Approach Approach
Boundary Boundary
Energized MV work 1. MVQ or 1. MVQ or supervised

is not permitted! Supervised 2. Flash Protection PPE
2. Shock and
Flash Non-MVQ
Protection personnel
PPE
Energized 1-36
kV surface
0.3 m (1 ft)
1.2 m (4 ft)
1.8 m (6 ft) fixed conductor or
3.0 m (10 ft) movable conductor
Flash hazard boundary and flash PPE per the flash hazard study.
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PCP-650
PCP-650, Appendix B, Figure 3 – High Voltage Approach Distances

energized at 36,000-115,000 volts. The flash hazard boundary is not included and must be determined using
the facility’s flash hazard study. All persons working on high voltage equipment must be HVQ (high voltage
qualified) or supervised by a HVQ person.
Prohibited Restricted Limited

Approach Approach Approach
Boundary Boundary Boundary
Energized 1. HVQ or 1. HVQ or

HV work is Supervised supervised
not 2. Shock PPE 2. Flash
permitted! 3. Flash PPE PPE per Non-HVQ
per the the flash person
flash hazard
hazard study.
Energized 36 to study.
115kV surface
1.2 m (4 ft)
2.4 m (8 ft)
3.6 m (12 ft)
Flash hazard boundary and
flash PPE per the flash hazard
study.
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PCP-650
PCP-650, Appendix C
Ground Fault Circuit Interrupter use in P&G N.A. Corporate Buildings
Background:
Dwelling Units
GFCI’s (ground fault circuit interrupters) are widely used in residential applications to provide shock hazard
protection for people using 125 volt receptacles in and around the home where it is likely that moisture or
water will present an increased shock hazard. The NEC, in Art. 210.8(A) lists eight specific locations in
dwelling units where GFCI’s are required. They include; bathrooms, garages, outdoors, crawl spaces,
unfinished basements, kitchens, laundry or utility rooms and boathouses.
Commercial Buildings
The GFCI requirements for commercial or industrial applications are very different, even though some
workplace applications are very similar to those we are familiar with at home. This is because the code
recognizes that at home electrical devices are often operated by children or others with little or no
understanding of the hazards electricity around water. At work there are requirements for General Electrical
Awareness Training to provide employees with the knowledge they need to work safely.
In commercial buildings, the NEC (Art. 210.8(B) ) requires GFCI’s to be installed only in these clearly
defined areas. They include; bathrooms, kitchens, rooftops, sinks, and outdoor locations.
NEC Art. 210.8 (B) (5) requires GFCI protection for receptacles within 6 ft of a sinks including laboratory
sinks. The 6 Foot distance is derived from the U/L standard 6 ft cord length for appliances that effectively
prevents devices from being accidentally placed in the sink while still connected. We will follow this
guidance relative to receptacle outlets near wet locations.
Safety Showers
According to NEC Art. 406.8, receptacles in damp or wet locations, Section C states: A receptacle shall not
be installed within a bathtub or shower space. Therefore, all receptacles within 6 feet of Safety Shower
spaces must be removed. This can be done simply and inexpensively by replacing the outlets with blank,
gasketed covers.
Eyewash Stations
Use of Eyewash Stations creates an increased hazard when in the close proximity of electrical outlets. This
is due to the intentional flushing and splashing that will occur, and the fact that the person using them is
temporarily sight impaired, and likely to reach blindly for a towel or tissue with wet hands and face. For
these reasons receptacles located within 6 feet of Eyewash Stations must be removed or protected by a
GFCI. Again, this is not an expensive task.
5/21/2015 Page 30 of 35
PCP-650
Laboratory Sinks (without eyewash stations)

The 2008 NEC requires all sink receptacles to be GFCI protected. This was not found in the code prior to
the 2008 revision. As a result, the P&G lab space owner will need to decide which of the following three
options is appropriate for existing installations. All new installations must meet the 2008 NEC requirement.
Also, changes to the existing installation must also meet requirements of the 2008 NEC.
1. Remove all receptacles within 6 ft. of a sink. This will remove the hazard, but also remove the
capability of using electrical devices at all, in that location. This option involves minimal costs.
2. Install GFCI protection for all receptacles within 6 ft. of a sink in accordance with the 2008 NEC.
This will provide shock hazard protection for the lab personnel, and allow the continued use of
electrical devices close to the sink. However, GFCI’s installed in your space need to be tested monthly
to insure proper operation. It would be the responsibility of the space owner to test and document
monthly and forward the documentation to the site ESO annually. GFCI’s should not be used to supply
power to long term experiments, CT rooms, freezers, or any device that cannot handle being
temporarily powered down. This option involves moderate costs of purchasing and installing one or
two GFCI’s per sink.
3. Provide portable GFCI’s, for use in the lab, whenever electrical devices are used within 6 ft. of a sink.
Portable GFCI’s must be tested before each use. This option involves minimal costs, but, requires
developing and delivering training and periodic testing per HS&E CBA 8018.
5/21/2015 Page 31 of 35
PCP-650
PCP-650, Appendix D
Example Electrical Outage Planning CBAs
Electrical Outage Pwr Maint Planning

Planning Timeline.doc CBA.doc
5/21/2015 Page 32 of 35
PCP-650
PCP-650, Appendix E
Example Electrical Outage Plan
The following documents are part of an actual job plan that took place in 2004.
1) The switching notification is used to notify the utility of the plant’s intentions and request their support in advance of the plant’s
electrical outage.
Switching Notification
to GPU, 4-29-04.doc
2) The Job Plan is very detailed including the names of the persons who will perform the tasks.
2004 Memorial Day Memorial Day 2004

outage plan.doc Lines 1-2 ppa-jsa .doc
3) The Job Briefing is held 30 minutes prior to the beginning of the shutdown.
Job Briefing July

2004.doc
4) The lockout lists show the lockout tagout locations.
lock out list line lock out list#2 line

1&2.xls 1&2.xls
5) The Power-Down and Power–Up Notifications are administrative tag-out documentation required because it is not possible to
use a lock on the hook-stick operated utility switches which isolate power from the plant. As a result, these two documents are
used to ensure the system is in an electrically safe work condition prior to work commencing and to ensure all work is completed
and all workers are clear from the power system before procedures for the restoration of power begin.
Power-down Power-up
notification.1&2-2004notification.1&2-2004
6) Some of the checklists and reports used to document findings. Checklists for switchgear cleaning, breaker testing, etc. also are
required.
INCOMING LINE INCOMING LINE Job Report lines

1.doc 2.doc 1&2,2004 Memorial D
Glen Knox
Procter & Gamble Co.
Global Electrical Safety Leader
5/21/2015 Page 33 of 35

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PCP-650

Electrical Safe Practices For Personnel and Equipment

2. Electrical System Owner

3. Electrical Safety Program

4. Electrical Safety Program Principles

6. Electrical Qualification Program

8. Clear Work Space

10. Energized Electrical Work

11. Energized Work Defined

12. Energized Work Examples

13. Energized Work Permit

14. Work Not Requiring an EWP

15. Prohibited Work

16. Approach Boundaries

17. Shock Protection Boundaries

19. Flash Hazard Protection

20. Electrical PPE

21. General Lockout/Tag out Guidelines

22. Contractor LOTO Procedures

24. Detailed Safety Grounding Procedure

25. Temporary Wiring

26. Portable Cords

27. Ground Fault Protection for Portable Tools

28. Portable Electrical Equipment

29. Electrical Power Tool Safe Practices

30. Appendix A, Table 1 – Hazard/Risk Category Classifications

2. Electrical System Owner (ESO)

3. Electrical Safety Program

4. Electrical Safety Program Principles

6. Electrical Qualification Program

8. Clear Work Space

9.1.2. See Annex E for an example job plan

9.2. Job Safety Analysis and Potential Problem Analysis

9.3. Job Breifing

9.3.3.1. the work is complicated or particularly hazardous.

10. Energized Electrical Work

13. Energized Work Permit (EWP)

15. Prohibited Work

0-50 V. No permit required

16. Approach Boundaries (Working Near Exposed, Energized Equipment)

17. Shock Protection Boundaries

18. Flash Hazard Boundary

19. Flash Hazard Protection

20. Electrical PPE (Personal Protective Equipment)

Note: For reference see PCP-345and HSE CBA 2052.

21. Construction (contractor) LOTO Procedures

23. Detailed Safety Grounding Procedure

24. Temporary Wiring

25. Portable Cords

26. Ground Fault (Earth Leakage ) Protection for Portable Tools

27. Portable Electrical Equipment

28. Electrical Power Tool Safe Practices

PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications

Tasks Performed on Energized Equipment HRC Rubber Insulated and

Tasks Performed on Energized Equipment HRC Rubber Insulated and

Tasks Performed on Energized Equipment HRC Rubber Insulated and

Tasks Performed on Energized Equipment HRC Rubber Insulated and

Lighting or small power transformers (600V, maximum)

Tasks Performed on Energized Equipment HRC Rubber Insulated and

PCP-650, Appendix A, Table 1 – Hazard/Risk Category Classifications (continued)

Tasks Performed on Energized Equipment HRC Rubber Insulated and

Arc-Resistant Switchgear Type 1 or 2 (for clearing times of <0.5 sec with

Other Equipment 1 kV Through 38 kV

Metal clad load interrupter switches, fused or unfused