DAIMLERCHRYSLER

MANUFACTURING TECHNICAL INSTRUCTIONS - SAFETY

Subject: SMI-164: ELECTRICAL SAFETY IN THE WORKPLACE

ISSUE DATE: EFFECTIVE DATE: REVIEW DATE. SERIES & NO.

12/07/05 12/07/05 10/28/05 SMI - 164
06/09/06 04/28/06

I. PURPOSE
To provide guidelines for the safe maintenance of live electrical equipment operating at 50 volts or
more.

II. REFERENCES
• M.T.I. SMI-107, "Control of Hazardous Energy (Lockout)”

• National Electrical Code (Latest Edition)

• NFPA 70E, "Standard for Electrical Safety in the Workplace" Article 130 “Working On Or Near Live Parts
Equipment Manufacturers Specifications and Trouble shooting Services Procedures

• OSHA 1910.132, “Personal Protective Equipment”

• OSHA 1910.147, "The Control of Hazardous Energy (Lockout/Tagout)"

• OSHA 1910.331, "Electrical - Safety-Related Work Practices"

III. FUNCTIONS AFFECTED

Manufacturing Engineering
Facilities Engineering
Production Engineering
Employee Safety

IV. OPERATIONS AFFECTED

DaimlerChrysler Corporation

V. DEFINITIONS
• Qualified Person – One who has skills and knowledge related to the construction and operation
of the electrical equipment and installations and has received safety training on the hazards
involved.
• Personal Protective Equipment (PPE) – For the purpose of this SMI, shall include clothing, gear
and work accessories designed to protect employees from potential arc flash / shock hazards.
• Arc Flash – Short circuit through the air where a large amount of concentrated radiant energy
explodes outwards from an electrical device or equipment.

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VI. INFORMATION

• Hazardous arc flash can occur in any electrical device, regardless of voltage, provided that the current is
high enough to sustain an arc. Examples include typical industrial equipment such as 480V motor control
centers, panel boards and switch boards. An arc of this type, while typically lasting less than a second in
duration, can reach temperatures in excess of 30,000 deg F and can result in severe burns, permanent
blindness, or death.

• The purpose of this policy is to help prevent incidents and injuries related to electrical work in our facilities
by providing direction to faculties with employees who may be exposed to live electrical hazards on the job
with the requirements for proper training, Personal Protective Equipment (PPE), tools and equipment
required to safely perform these jobs.

• In accordance with Corporate Policy, SMI 107 - Control of Hazardous Energy Lockout, employees are
required to lockout all potential sources of hazardous energy prior to commencing maintenance activities.
This policy specifically reinforces the need to fully comply with SMI 107 while providing guidance for
operations where total electrical energy shutdown is not feasible and there is subsequent potential for
contact with live voltage operating at 50 Volts or more (i.e., testing).

• Effective immediately the stabbing of any size buss plug into an energized buss system is
suspended until a detailed arc flash study can be completed. Once the arc flash study is
completed, and all engineering and labeling tasks are completed and proper PPE is worn, the only
buss plugs that will be allowed to be stabbed into hot busses are ones that pose additional
hazards if the buss is deactivated.

VII. SCOPE
This policy addresses the safe work practices requirements for employees who may be exposed to
live voltage sources operating at 50 volts or more (i.e., Electricians)

VIII. RESPONSIBILITIES

1. LEPC shall:
o Designate a Plant Subject Matter Expert (SME) to develop a Plant Specific Launch Plan and
coordinate the implementation of this policy.
o Review this policies implementation on a regular basis with the Plant SME and the Plant Local
Joint Health and Safety Committee to ensure compliance with the Plants Launch Plan.
o Commit adequate resources to insure the proper implementation of all aspects of this policy
including training, labeling, and procurement of testing meters, and arc flash / shock resistant
clothing and personal protective equipment for affected employees.

2. Plant SME shall

o Identify employees who may be exposed to arc flash / shock hazards from working on
energized electrical circuits from 50 to 600 volts.
o Identify employees who may be exposed to arc flash / shock hazards by working on
energized electrical circuits greater than 600 volts.
o Work with the Plant Local Joint Health and Safety Committee to establish a Personal
Protective Equipment issue and maintenance program to address identified arc flash hazards.
o Coordinate labeling of equipment in accordance with this policy.
o Coordinate training of employees in the elements of this policy.

Additionally, management shall ensure that anyone (employees from other locations, or outside
contractors, etc.) who may be exposed to electrical hazards be required to comply with all provisions
of this policy..

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3. Local Joint Health and Safety Committee shall;
o Ensure, and verify that all employees impacted by this SMI receive required training.
o Become familiar with the requirements of this policy.
o Monitor progress of the Plants Launch Plan and work with the Plants SME, as required to ensure
compliance with this policy.

4, Impacted Supervisors and Employees shall;

o Attend and complete the required training, and become familiar with the requirements of this
policy.
o Ensure that only qualified employees are assigned to tasks associated with live electrical work at
50 volts or more.
o Insure that all qualified employees are issued, use, and are trained in the use of the PPE for their
work on energized electrical circuitry.
o Insure that all qualified employees utilize applicable safety procedures and tools during work on
electrical equipment.

5. Plant Manufacturing Engineering / Center Managers

Shall insure that all personnel involved in servicing or trouble shooting of live electrical circuits operating at
50 volts or more adhere to this policy.

6. Production Engineering
The Production Engineer shall incorporate into all tools and equipment designs, processes and layouts,
the necessary features and devices (in accordance with the latest version of NFPA 70E) required to
minimize arc flash / shock hazards and provide maximum protection for the safety of the operator,
electrician, or any other service person that may potentially be exposed to live electrical circuits at 50 volts
or more.

IX. INSTRUCTIONS

Immediate Actions:
1. Mitigate electrical hazards by issuing arc- flash resistant clothing and PPE to employees
potentially exposed to arc- flash hazards from live circuits operating at 250 volts or more. At a
minimum, Hazard Category Level 2 arc-flash resistant clothing and approved safety glasses
with side shields (see Attachment #1) must be worn by any employee working within the flash
protection boundary of an exposed, energized circuit (see Graphic # 3). Under no
circumstances shall Unqualified Persons come in contact with live electrical circuits. Additional
protective equipment may be required, dependant upon work activities to be performed. See
Attachment # 1 for details. Hazard Category Level 2 garments shall meet the following minimum
specifications;
• Approved for Hazard Category (HC) Level 2 Operations
• Indura Ultra Soft Garments
• Coveralls – Minimum 7.0 oz. w/ HC Level 2 Label on right front pocket
• Shirt – Minimum 7.0 oz. w/ HC Level 2 Label on right front pocket
• Pants – Minimum 9.0 oz. w/ HC Level 2 Label on right rear pocket
.
2. Provide training to employees affected by this SMI via the NFPA 70E, E-Learning Program..
Additionally, training on the proper use of required PPE shall be conducted (Refer to Attachment #
1 for detailed use requirements) and a copy of the electrical work “Task List” describing the types
of protective equipment to be utilized when working within the flash protection boundary shall be
provided to all affected employees..

3. Provide properly rated tools and equipment for use when testing live voltage. Multi meters
used for testing live voltage during indoor work , shall have a minimum rating of CAT III, 1000V..
Non-conductive tools shall be used when working on live electrical circuits.

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 4. A BASIC label shall be applied to electrical enclosures that may have arc flash energy
exposure potential such as main control enclosures, motor control centers, and switchgear, which
contains components operation at 250 volts or more. An example label is shown in Graphic #1
below. NPM Code # 78-359-4410 (Brady Part # 94914 – 5”x 7” Label,
NPM Code 78-359-4412 (Brady Part Number 94913 – 3”x5”). See attachment #2 for placement
of arc flash labels

Graphic # 1

! WARNING
Arc Flash Hazard.
Appropriate PPE Required.
Failure To Comply Can Result in Death or Injury.
Refer to NFPA 70E.

Additionally, facilities which elect to perform a detailed Arc-Flash analysis of existing equipment
shall also utilize the detailed label. (Black letters on white background with Orange
background on header). An example label is shown in Graphic #2 below. Additional
information on placement of labels is included as “Attachment #2”.

Graphic #2

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X. APPLICATION

Personal Protective Equipment (PPE) Requirements

When working around exposed, energized electrical circuit conductors and components, there is a potential risk of
injury due to arc flash. Exposure to this potential hazard is inherent to such tasks as voltage testing. Arc flash is a
dangerous condition produced by an electric arc that can cause severe burns and other injuries to persons within
specific distances to the flash. The extent of damage or injury as a result of arc flash is a function of Incident
Energy Density that is a function of distance from the source. Other variables include voltage, current and
duration of the arc. To help ensure that our employees are properly protected, specific distances (Boundaries)
from live circuits have been established to keep persons from accidental contact with these circuits to minimize the
effects of any potential arc flash, see the graphic below.

Graphic # 3 Must wear appropriate PPE (See Attachment #1)

Energized Source

1-inch 1-foot 4-feet

Prohibited Approach

Restricted Approach
Only
Qualified Only Qualified Person wearing
Unprotected,

Flash Protection
Persons Qualified Hazard Category 2 PPE or
unqualified
wearing Persons
persons
Unqualified Person wearing
Boundary

wearing
Boundary

Boundary
Haz. Cat. 2
PPE, Haz. Cat. Hazard Category 2 PPE
assume 2 PPE accompanied by a Qualified
contact Person in Haz. Cat. 2 PPE

Flash Protection Boundary (distance of the employee from an arc source for a curable burn) of the
system is set at 4-feet. This is the closest that unprotected, unqualified employees without an escort
may approach to uncovered, live electrical circuits.

Restricted Approach Boundary is set at 1-foot from live electrical circuits. This is the closest that
protected, unqualified employees may approach to uncovered, live electrical circuits. Additionally,
unqualified persons who are between the Flash Protection Boundary and the Restricted Approach
Boundary must be escorted by a qualified person.

Prohibited Approach Boundary is set at 1-inch from a live, uncovered electrical circuit. Any activity
within this boundary is considered the same as making contact with the live part.

Note : Unqualified Persons within the Flash Protection Boundary assumes panel is equipped with
required suitable permanent, substantial partitions (i.e. plexa glass panel) arranged so that only
qualified person have access to reach the live parts. In the absence of these partitions, all Unqualified
Persons shall remain outside the Flash Protection Boundary.

The vast majority of electrical work in DaimlerChrysler facilities is performed inside of these boundaries.
Consequently, protective equipment requirements, as defined by NFPA 70E, Article 130 must be enforced when
working or testing within the Flash Protection Boundary. A complete listing of task examples can be found in
NFPA 70E Article 130. The minimum PPE requirements for employees who are working with energized electrical
circuits over 50 volts are listed in Attachment # 1 and are intended to protect employees from an arc flash / shock
hazards.

Facilities which have verified their available short circuit current is below 65kAIC, and a 2-cycle fault clearing time
fuse is upstream, can apply the Hazard Category 0 label to the disconnect. This allows the operation of a closed
cover disconnects without need for PPE beyond regular work attire. A sample of the Hazard Category 0
disconnect label is shown in Attachment 4.

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Clothing for wear under all arc flash resistant clothing is 100% cotton. Synthetic materials shall not be worn
over or under the uniform. Untreated synthetic fabrics (such as polyester) can melt onto the skin or ignite.
The type of uniform (shirt / pants or coveralls) to be utilized at each facility must, at a minimum, meet the
requirements of Hazard Risk Category 2 and have the Risk Category of the garment easily visible on the outside
of the garment (i.e. a tag with the Hazard Risk Category attached to the pocket). A selection of approved Code
Group 78 garments is available in the Restricted Parts Access System (RPAS) code catalog and shall be provided
to impacted employees as required by this SMI.

DaimlerChrysler approved, nonconductive eye wear must be worn while performing electrical work to protect
employees from eye injuries resulting from electrical arcs, flashes, or from flying objects resulting from electrical
explosions. Arc Flash Resistant clothing shall consist of long-sleeve shirt providing full-arm protection to the
employee’s wrist and pants providing full leg protection to the employee’s ankle, or equal coveralls.

Voltage rated, rubber insulated gloves, and voltage rated tools in compliance with NFPA 70E, shall be used when
there is a danger of hand and arm injury from electric shock and burns due to contact with live parts. Reference
Attachment # 1 and NFPA 70E Article 130.7 (C) (13) (c) Hand Protection and NFPA 70E Article 130 Table 130.2
(C) Approach Boundaries to Live Parts for Shock Protection.

Reference attachment #3 for the pocket card developed to assist qualified employees.

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 Attachment # 1
Initial Arc Voltage Incident Hazard Minimum Arc Labels Specific Protective Equipment Required
Flash Hazard (Note # 6) Energy @ 18” Category Thermal FR Glove Eye Face & Foot Flash
Potential (cal / cm2) Protection Clothing Type Wear Head Protection Suit
(See Note #3) Value (ATPV) (See (See
Note #2) Notes, #5)
None 0-50 0 0 NA No No N/A N/A N/A N/A N/A
(Zero Energy
State)
Low 50-250 0 0 0 No N/A Class 00 Yes N/A N/A N/A
Medium >250 and <= >0 and <= 8 1-2 8 Yes Yes Class 00 / Yes Note #1 Note #4 N/A
600 0
High >600 and <= >8 and <= 40 3-4 25-40 Yes Yes Class 2/ 3 Yes Yes Note #4 Yes
26.5kV
Note 1: Arc-rated face shield, electrical rated hard hat
Note 2: FR Clothing required depends upon Hazard Category.
HC 0 = Untreated Cotton
HC 1-2 = Cotton Underwear Plus FR Shirt and FR Pants or FR Coverall
HC 3 -4 = Cotton Underwear Plus Double Layer Switching Hood, Coat and Pants
Note 3: Task / Equipment Description Examples by Arc Flash Hazard Potential
None = Work on de-energized plant floor or facilities equipment (electrical energy removed and locked out and tested to ensure no voltage present)
Low = Work on energized electrical equipment at 250 volts or below (assumes circuit is fed from less than a 125kva step down transformer)
Medium = Removing or installing circuit breakers or fused switches (>250 volts), Voltage testing(>250 volts), Working on control circuits with energized parts
exposed, Appling safety grounds, Racking circuit breakers, Racking starters, Removing bolted covers, Work on energized electrical equipment that meets ALL of
the following conditions:

•(250< Voltage < 600), • (Over-current Protection is “Current Limiting” )

This task category includes operation of a bus plug-in device disconnect with the doors closed and under “NORMAL OPERATING CONDITIONS”
As arc fault incidents are most prevalent when inserting units in Motor Control Center (MCC) buckets and bus plugs and racking decries, it is highly recommended
this be done only on de-energized equipment.
High = Work on energized electrical equipment that meets one of the following conditions:
• Voltage >600V • Substation or Switchgear Equipment, • Sourced Directly from Unit Substation power circuit, • Voltage > 120 V and over current protection
is not a current limiting device
Note 4: Foot Protection. Heavy-duty leather work shoes provide some arc flash protection to the feet and shall be used in all tasks in Hazard Category 2 and higher.
Note 5: Rubber insulating gloves are available in the following voltage classes (“00”-0-500V, “0”- 0V-1000V, “2”-7500V-17kV, “3” – 17kV – 26.5kV) as these classes allow
us a minimum number of products that are expected to cover all currently known internal maintenance operations. In all cases, the Plant shall be responsible to ensure
employees are provided with the appropriately rated gloves based upon expected hazards to be encountered. Leather protector gloves should always be worn over rubber
insulating gloves to protect against cuts, abrasion and punctures to the rubber insulating gloves.
Note 6: Voltage levels from 50-250 are defined as low risk, and will be categorized as such as long as the transformer supplying the system is less than 125kva as per IEEE
1584.

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 Attachment # 2

No Is the voltage of the equipment 250

volts and above?

Yes

Is the step down transformer Yes Has the plants detailed arc flash
feeding the equipment larger study been performed?
than 125kva

No Yes No

No Arc Flash Warning Label is Install detailed Install generic

required. HRC-0 to be arc flash label arc flash label
recognized.

Install generic and detailed labels on the

following pieces of equipment:

All 480 and 240 volt buss All substation feeder breakers
plugs and primary voltage equipment

The first disconnect on the The first door nearest the

shop floor fed from a disconnect on a multi door
substation or buss plug. panel installation.

The above flow chart is based on the following:

IEEE-1584
2005 NEC 110.16
NFPA 70e 130.7(16)(e)

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 Attachment # 3
(Side 1)

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 Attachment # 3
(Side 2)

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 Attachment 4

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 Attachment 5
Document Change History

Original Issue Date: 12/07/05, Initial Effective Date: 12/07/05, Initial Review Date: 10/28/05

Revision: 4 Date of Latest Revision: 6/30/2006 Latest Revision Approval Date: 6/30/2006
Document Author: Process Owner/Document Manager:
DaimlerChrysler DaimlerChrysler

Revision: Sec/ Para Changed Change Made: Date

1 V- Definitions Reference to “Unqualified Person” removed 6/09/06
VIII – Responsibilities Calories designation for voltages removed
– Plant SME
VIII – Responsibilities - “Affected” employees changed to “Impacted” employees to
LJHSC avoid confusion with SMI 107
VIII - Responsibilities “Affected” employees changed to “Impacted” employees and
“Authorized” changed to “Qualified” to avoid confusion with SMI
107 requirements
IX – Instructions – Increased voltage level from 50 volts to 250 volts
Immediate Actions –
(1)
IX – Instructions – Removed requirement for CAT IV, 600 volt rating on test meters
Immediate Actions – and retained CAT III 1000 volt rating
(3)
IX – Instructions – Removed detailed label description and added new Brady part
Immediate Actions – numbers with reference to new Attachment #2 (Label
(4) Application Flow Chart)
- Reference to “any enclosure” removed to ensure consistency
with labeling flow chart and changed 50 V to 250 V reference
X – Application Changed “amperes” to “current” in background data
X- Application Added reference to new Attachment # 3 (Pocket Card)
X- Application Added reference to new Hazard Category 0 Label
- Deleted second and third paragraph of page 6 with PPE
discussion to new language referencing this SMI’s requirements
only
X- Application (Graphic Added reference to Hazard Category 2 PPE on graphic and
#3) added “Energized Source” text
Attachment #1 - Changed voltage of concern from 50 to 250
- Changed ATPV clause to 0 from “Low” and “None” arc
potential hazard columns
- Removed old “Note 1”
- Removed reference to shirt and pants in Note 3
- Changed 50 to 250 volts in Note 4 and removed
reference to circuit supply rated at 400A or less
- Added new “Note 6”
Attachment # 2 Added “Arc Flash :Label Application flow chart”
Attachment # 3 Added “Arc Flash Pocket Card”
Attachment # 4 Added “Hazard Category 0 Label”
Attachment # 5 Added “Document Change History”

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