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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=1184">Inspection of Newly Transitioned Electrical System May Have Prevented an Arc Flash - Richland Operations - Hanover</a></td>
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<h2 style="white-space:nowrap">Statement of Lessons Learned</h2>
<pre>While performing circuit verifications in a newly transitioned Boiler Annex facility, an electrician heard a bang/pop and saw a flash of light come from behind a panel door. The electrician, who was cycling a 480-volt breaker, reported ringing in the right ear, was immediately transported to the onsite medical provider, and then released back to work with restriction. The electrician was wearing required Personal Protective Equipment (PPE) in accordance with the Electrical Risk Assessment (ERA) [safety glasses, silicon fitted hearing protection, voltage rated gloves, long sleeves, long pants, and work boots]. </pre>
<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>On Friday, January 28, 2022, four Washington River Protection Solutions (WRPS) electricians and an engineer were verifying and documenting the electrical distribution system circuits in a newly transitioned Boiler Annex facility to update and support Lockout/Tagout (LOTO) and electrical as-built drawing configurations. Two electricians and the engineer were in the immediate area of the electrical distribution panel at the time of incident.
The event investigation discovered that a screw, meant to secure the interior dead front panel, had penetrated through a single phase 1/0 THHN (thermoplastic high heat nylon) AWG (American Wire Gauge) 480-volt conductor (wire) inside the electrical distribution panel (DP-242A). (See Photo 1)
<img src=" https://misportal.jlab.org/ll/downloadAttachment?attachmentId=6548" width="400px">
Engineering and the WRPS' Authority Having Jurisdiction (AHJ) performed a review and calculations of the event and determined that the fault resulted in a phase to ground fault from one of the cabinet's cover retaining screws contacting the "C" phase conductor (wire). Incident Energy on the load side of #2 breaker with covers off was calculated to be 0.19 cal/cm² at 18" and an Arc Flash Boundary of 6".
</pre>
<h2 style="white-space:nowrap">Analysis</h2>
<pre>Oversight of the installation and testing of the new electrical system had been performed prior to the Boiler Annex facility's transition. However, only minimal documentation of the identified potential NEC electrical deficiencies was provided to WRPS.
WRPS did not perform an inspection to assess risk prior to performing verifications on the energized system on the electrical distribution panels.
Damage to the cabinet was limited to the load side of breaker #2 specifically to one of the branch circuit conductors at the cabinet cover retaining screw located in the cabinet's lower right corner.
</pre>
<h2 style="white-space:nowrap">Recommended Actions</h2>
<pre>Evaluate whether more conservative vision and hearing PPE should be implemented for work done when there is potential for an arc flash.
Replace breaker #2 [cycled at the time of the arc flash event].
Inspect and repair/replace deficient line side conductors, mounting hardware, grounding/bonding wires, and branch circuit wires/panel connections [includes replacing the damaged conductor and resolving the condition of the bundled and wedged wires behind the screw hole].
The location of the conductors (wires) that were bundled and wedged behind the screw hole was less than adequate and would likely result in another event. The electrical subcontractor is to locate the wires further away from the location of the screw hole.
Replace multiple splices throughout the electrical distribution panel where conductors need extending for the installation of the new panel.
Correct the ground conductor splice and the grounding electrode conductor to conform with NEC electrical code.
Perform an NEC Inspection once all identified deficiencies are corrected. The NEC inspection will include both electrical distribution panels that were installed for the new Air Gap Water System.
</pre>
<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre></pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">8/10/2022 9:56:03 AM by Bailey, Mary Jo</h5>
<pre>Submitted to those current in:
GEN020: TR Training
ESC001: Basic Electrical Safety (for Electrical Workers)</pre>
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<legend>Summary</legend>
<table>
<tr class="row">
<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">1184</td>
</tr>
<tr class="row">
<td class="label" nowrap>Status:</td>
<td class="dataval">OK</td>
</tr>
<tr class="row">
<td class="label" nowrap>Doc ID:</td>
<td class="dataval">2022-JLAB-1184</td>
</tr>
<tr class="row">
<td class="label" nowrap>Priority:</td>
<td class="dataval">Best Practice</td>
</tr>
<tr class="row">
<td class="label" nowrap>Safety Related:</td>
<td class="dataval">YES</td>
</tr>
<tr class="row">
<td class="label" nowrap>Originator:</td>
<td class="dataval">Bailey, Mary Jo</td>
</tr>
<tr class="row">
<td class="label" nowrap>Issued:</td>
<td class="dataval">8/10/2022 9:35:49 AM</td>
</tr>
<tr class="row">
<td class="label" nowrap>Approved By:</td>
<td class="dataval">Bailey, Mary Jo</td>
</tr>
<tr class="row">
<td class="label" nowrap>Approved On:</td>
<td class="dataval">8/10/2022 9:56:03 AM</td>
</tr>
<tr class="row">
<td class="label">Source:</td>
<td class="dataval">
DOECRD
</td>
</tr>
<tr class="row">
<td class="label" nowrap>Location:</td>
<td class="dataval">Other</td>
</tr>
<tr class="row">
<td class="label" nowrap>Cost Savings:</td>
<td class="dataval"></td>
</tr>
<tr class="row">
<td class="label" nowrap>Contact:</td>
<td class="dataval">Mike Hay, Maintenance / Craft Support Manager, (509)373-5206 or james_m_mike_hay@rl.gov</td>
</tr>
<tr class="row">
<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">520</td>
</tr>
<tr class="row">
<td class="label" nowrap>Sent Emails:</td>
<td class="dataval">0</td>
</tr>
<tr class="row">
<td class="label" nowrap>Viewings:</td>
<td class="dataval">1 times</td>
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<li><a target="_blank" href="https://misportal.jlab.org/ll/downloadAttachment?attachmentId=6546">OPEXShare Hanford - Post-Transition Inspection Needed.pdf</a></li>
<li><a target="_blank" href="downloadAttachment?attachmentId=6548">Photo 1 - 1184.JPG</a></li>
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<li>Subcontracts</li>
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<li>GEN020: TR Training</li>
<li>ESC001: Basic Electrical Safety (for Electrical Workers)</li>
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