Among all industries that make up the U.S. industrial sector, manufacturing is by far the biggest consumer of electricity. With high voltage equipment frequently in use, manufacturing businesses of all kinds have to pay careful attention to the various aspects of electrical safety.
From strictly implementing lockout tagout protocols to ensuring that your electrical enclosure boxes have the right ratings, it’s critical to know and use industry best practices in implementing electrical safety procedures. Failure to do so can result in costly disruption or even a tragic loss of life.
Here, we’ll take a quick look at five basic safety rules for implementing electrical safety systems in the day-to-day activities of your manufacturing workplace.
- Understand the relevant sections of the NFPA 70E code.
NFPA 70E is the most important electrical safety standard for most businesses, including manufacturers. This industry standard establishes comprehensive electrical safety rules. It’s not technically a law but, since it’s a consensus industry standard, it’s generally equivalent to a law in the eyes of OSHA.
Some key concepts from NFPA 70E you might want to review include calculating incident energy, creating energized work permits and plans, and selecting the correct electrical PPE. Remember that the 70E standard gets regular updates every three years, so make sure that your workplace is using the latest version. The new regulations include changes to PPE standards, so don’t delay in getting familiar with them.
- Conduct periodic audits of electrical safety procedures to identify and evaluate risks.
When was the last time your facility audited its electrical safety procedures? You can’t spot safety issues if you’re not aware of them, so a thorough electrical safety audit will help ensure that everyone’s up to speed on workplace electrical safety.
Typically, an electrical safety audit begins with a review of safety procedures and relevant standards like NFPA 70E. Compare the standard with current procedures and identify any areas that may require changes. Key areas for most workplaces will include training and electrical qualification processes, arc flash hazard management, maintenance schedules, and PPE.
Once you’ve reviewed procedures, it’s also important to conduct on-site inspections that determine how well your procedures are being followed. Review safety records and investigate any areas of concern. Interview employees and managers, and make sure everyone has an opportunity to express their full opinions.
- Ensure that employees are trained to implement lockout tagout procedures correctly.
Lockout tagout procedures are a core element of electrical safety. These procedures prevent equipment from being accidentally activated and energized while workers are performing maintenance or repairs. Workers apply safety locks to equipment controls that make them impossible to operate until the keyholder unlocks them when work on the equipment is complete.
OSHA and NFPA 70E standards should be your guide as you design and implement lockout tagout procedures in your workplace. Making sure that lockout tagout kits are available when and where workers need them is crucial—it’s easy to skip safety protocols when you can’t find the tools you need.
Lockout tagout also requires training to execute correctly, so consider holding refresher training sessions on your facility’s procedures. A study of several hundred accident investigations found that, in many cases, workers didn’t even try to lock out machinery, so be sure you’re emphasizing the life-and-death importance of these systems.
- Only use components that have been certified by standards organizations such as UL.
Standards organizations like UL play a key role in electrical safety. These independent laboratories test electrical components for compliance with the most important safety standards. Using UL-certified components is particularly important in any environment in which electrical equipment can potentially be subject to environmental hazards, including outdoor environments.
For example, NEMA- and IP-rated outdoor weatherproof electrical enclosures are a common requirement for workplace electrical safety. However, these standards rely on self-certification by manufacturers—so if you’re not using enclosures with ratings certified by UL, you might not know whether they’ll perform under pressure.
When specifying electrical enclosures for projects, make sure that only UL-certified enclosures make it onto your bill of materials. Get familiar with the major UL marks and know which ones to look for. UL Listed is the most common, but other marks such as UL Recognized Component and the new UL Enhanced Certification badge may also be important for your applications.
- Ensure that employees have the right arc-rated PPE, and that they’re using it consistently.
First, determine whether you’ve provided sufficient PPE for all of your employees. Remember, it’s the employer’s responsibility to purchase and maintain the appropriate PPE. If your PPE is uncomfortable, inaccessible, or in bad condition, don’t be surprised if workers try to avoid wearing it whenever possible.
Arc-rated PPE is another critical element of electrical safety for facilities in which workers might be exposed to an arc flash hazard, so pay especially close attention to the needs of workers whose job brings them in contact with high-voltage parts. Understand the NFPA 70E CAT rating system thoroughly, and ensure that workers are always wearing clothing with the correct CAT rating.
PPE, of course, has to be worn consistently and correctly to be effective. Now is the time to tighten up compliance and make sure employees know the consequences for PPE violations. In addition, inspect PPE in use on the job to ensure that it’s in good condition, and keep track of how many times various pieces have been washed to know how close they are to needing replacement.
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The goal for every manufacturer should be to develop a safety culture that’s thoroughly woven into the fabric of daily operations. In a truly robust safety culture, workers choose the safe path consistently and with a clear understanding of its importance. Getting there isn’t always quick or easy, but it’s indispensable.
