How to build a comprehensive workplace electrical safety program

Safety program insights

• Developing an electrical safety program requires organization-wide commitment.
• Regular and effective training is crucial to making NFPA 70E’s technical standards accessible to all employees.

Engineers and facility designers routinely encounter electrical hazards associated with live equipment in their daily tasks. Without adequate knowledge of safety protocols, they could unknowingly breach NFPA 70E: Standard for Electrical Safety in the Workplace, putting themselves and their company at risk. Examples include unqualified workers entering within shock and arc flash boundaries. Securing safety is the highest priority. At the same time, companies need to mitigate risks linked to workplace incidents. The direct and indirect costs of a workplace injury can be staggering, going far beyond medical bills. So, a comprehensive, formal and integrated corporate electrical safety program is a must for any consulting-specifying engineering firm.

Such a program should be based on a recognized national safety standard. NFPA 70E provides guidance and requirements for electrical safety practices to protect personnel from electrical hazards. By fully complying with NFPA 70E, organizations can effectively reduce their risk for the types of commonly encountered electrical hazards.

While most engineering firms possess some semblance of an electrical safety program, too often these initiatives lack formality. Engineers may also mistakenly rely on their technical degree or professional licensure to navigate electrical hazards, neglecting protocols, procedures and training. When this occurs, the company’s safety and liability risks escalate.

The benefits of a formal electrical safety program extend beyond accident prevention and injury mitigation.

They include:

• Upholding reputation: Demonstrating commitment to safety enhances a firm’s image, strengthening its ability to attract and retain talent.

• Managing injury and insurance rates: Effective safety measures help control injury rates and associated insurance costs.

• Enhancing competitiveness in proposals: Clients prioritize safety records and favor firms with exemplary safety practices.

• Fostering a culture of safety: Demonstrating concern for employee well-being inspires loyalty among staff.

• Reducing litigation risks: A robust safety program could reduce the likelihood of litigation involving injuries to workers.

• Increasing productivity: Effective safety measures reduce lost time injuries and support production by helping employees do their jobs more effectively.

• Greater clarity: A clear safety “playbook” backed by executive support increases staff effectiveness.

Companies wishing to develop a corporate electrical safety program based on NFPA 70E should possess a thorough understanding of the standard. They should also have a clear framework for applying requirements to establish safe work practices and reduce exposure to potential electrical hazards.

Understanding NFPA 70E

NFPA 70E is widely viewed as the gold standard for safeguarding personnel from electrical risks in the workplace. Companies that structure safety programs in alignment with NFPA 70E guidelines can reduce the likelihood of electrical incidents, fostering the safest possible workplace environment. To gain a deeper understanding of NFPA 70E, it is beneficial to consider the historical context in which safety standards emerged and how pivotal events influenced their development.

Founded in 1896, NFPA was created with the aim of eliminating injury, death and loss from fire and electrical hazards, reflecting a growing awareness of the need for standardized safety measures. However, shortly after forming, it became apparent that electrical wiring practices lacked uniformity and consistency. Standardization was needed to create safer living and working environments. In response, NFPA developed NFPA 70: National Electrical Code (NEC) in 1897 to outline equipment and installation requirements.

Fourteen years later, in 1911, the tragic events of the Triangle Shirtwaist Factory fire in New York City served as a wake-up call for more comprehensive safety regulations in workplaces. While the catastrophic fire, which claimed the lives of 146 workers, was not related directly to an electrical issue, it exposed numerous safety deficiencies and prompted reforms to prevent similar disasters. Ultimately, the incident helped shape more comprehensive regulations for electrical safety in workplaces.

Fast forward to 1970, rising electrical-related accidents in workplaces led to the enactment of the Occupational Health and Safety Administration (OSHA) under the Nixon administration. Since the NEC already covered electrical equipment and installation requirements, OSHA adopted the code as a consensus standard.

After OSHA adopted the NEC, NFPA established the NFPA 70E committee in 1976. Three years later, in 1979, the first publication of NFPA 70E: Standard for Electrical Safety in the Workplace was released. Since then, updates to NFPA 70E have been released every three years to incorporate changes in technology, regulations and industry best practices.

Those wishing to stay informed about future NFPA 70E changes or to obtain their own copy can visit nfpa.org. Additionally, electrical safety consulting firms knowledgeable of NFPA 70E can help organizations develop and implement their own electrical safety program and train staff on electrical safety best practices.

Figure 1: Employees coordinate with facility teams to verify electrical equipment is in safe condition so they can perform assessments to better support facility teams during construction and commissioning of new electrical equipment. Courtesy: Dewberry

The NFPA 70E standard is organized into three chapters, each addressing distinct aspects of electrical safety:

Chapter 1: Safety-related work practices:

Chapter 1 delineates the roles and responsibilities of both employers and employees concerning electrical safety. Employers are mandated to eradicate electrical hazards and establish electrically safe working conditions for their personnel. The chapter emphasizes the importance of developing a written electrical safety program tailored to the specific risks associated with electrical hazards in the workplace. The program should cover risk assessment procedures, job safety planning, inspections, lockout/tagout (LOTO) programs, audits, training, electrical safety principles and other electrical safety procedures.

Article 120 within Chapter 1 provides guidance on establishing electrically safe work conditions through a written LOTO program to ensure the safety of workers when performing maintenance, repair or testing activities on electrical systems. This program should encompass procedures for identifying energy sources, equipment shutdown, verifying absence of voltage and establishing grounding methods if necessary.

Article 130 of Chapter 1 addresses work involving electrical hazards and prescribes practices aimed at mitigating exposure to such hazards. It emphasizes the importance of conducting shock and arc flash risk assessments to delineate safe work boundaries, restricted access areas, limited approach and arc flash boundaries. Article 130 also provides guidance on selecting suitable personal protective equipment (PPE) based on the nature of the task and the associated electrical system.

Notably, Chapter 1 distinguishes between qualified and unqualified personnel. It defines qualified individuals as those possessing requisite skills and knowledge related to the construction and operation of electrical equipment, including safety training, to identify and mitigate hazards. Employers are tasked with providing qualified employees with appropriate training and verifying their competence for performing qualified tasks. Conversely, unqualified employees lack the necessary training and knowledge to safely work on or near energized electrical equipment. Employers have the responsibility to identify unqualified employees and make sure they do not perform any tasks that could expose them to electrical hazards, which should be accomplished through awareness-level training

Some companies may even choose to establish intermediate or hybrid classifications for electrical workers beyond these two designations. This could be necessary if the unqualified classification is overly limiting for certain electrical field tasks, while the qualified classification may impose excessive training requirements and PPE mandates. Supervisors are urged to develop a clear understanding of the distinctions between each type of personnel, along with the respective requirements for each designation, and promote education related to the designation level for each employee. Lastly, promoting awareness among all employees regarding their roles and responsibilities is crucial for reducing incidents and fostering a safe work environment.

Chapter 2: Safety-related maintenance requirements:

Comprising 11 articles, Chapter 2 outlines practical safety-related maintenance requirements for various electrical equipment and installations in workplaces. This includes substations, switchgear, switchboards, panelboards, motor control centers, disconnect switches, controller equipment, fuses, circuit breakers, rotating equipment, hazardous locations, batteries and portable electrical equipment. Adhering to these guidelines during maintenance operations can reduce the risk of electrical incidents.

Chapter 3: Safety requirements for special equipment:

This chapter delineates the best practices employers should adhere to when working with or on special equipment. Emphasis is placed on the responsibility of employers to train employees in safe practices when working with special equipment such as electrolytic cells, batteries, lasers, power electronic equipment, research and development laboratories or capacitors. Employers who implement these safe work practices can help eliminate or mitigate the risks associated with these types of equipment.

Creating a successful safety program

As companies develop a thorough knowledge of the tenets of NFPA 70E and prepare to embark on their electrical safety program journey, it’s crucial they are first aware of key criteria that are essential for a successful program. To begin with, companies should put an organization wide commitment to safety in place. This commitment should involve executives, safety advocates, operational managers and employees. Buy-in across all company strata is necessary for the program’s effectiveness.

Moreover, companies should recognize that developing an electrical safety program transcends the implementation of rules and procedures. Instead, it must integrate electrical safety practices into the company’s ethos. This integration requires active support and involvement from operational leadership who must champion electrical safety to make it a core principle. Without such backing, the investment of resources into program development risks being lost.

Companies are also advised to investigate the regulatory requirements applicable to their industry. These requirements can be found in NFPA 70E guidelines. Discussions with peers from other firms in their industry who have successfully developed similar programs can also be helpful.

Companies should analyze the tasks performed by their employees to identify the hazards and risks they routinely encounter. An effective program should address and mitigate the hazards specific to employees’ roles and activities without including provisions for hazards they never encounter. For instance, a program that extensively mitigates hazards associated with working on high voltage transmission lines for a group that never works with equipment operating above 600 volts would not only waste resources in program development but also lead employees to question the program’s effectiveness upon implementation.

Figure 2: Employees inspect electrical equipment and verify breakers settings with electrical equipment in safe working condition. Courtesy: Dewberry

Developing and implementing a safety program with NFPA 70E

With preparations made and the groundwork laid, a company should be poised to begin developing the relevant policies and procedures of a program within the framework of NFPA 70E.

To start, Chapter 1 of the standard recommends that any electrical safety program include the following:

• Guiding principles upon which the program is based: For guiding principles, Annex E of NFPA 70E provides some suggestions, such as using the correct job tools, assessing staff abilities, identifying hazards and protecting employees from them.

• Controls for measuring and monitoring a program: Risk management controls provide companies with a means to determine the effectiveness of their safety program. In the context of electrical safety, controls primarily revolve around mitigating electrical hazard risks through proper training, principles, policies and procedures. They should focus on identifying and evaluating the sources of risks and then determining a mitigation strategy for each one.

• Safety procedures to follow before performing electrical work: Safety procedures must be developed in alignment with at least the minimum NFPA 70E standards and include both policies and methodologies intended for individuals in the field to safeguard themselves and others. The procedures are manifold and should be focused on managing risks before work is started, such as LOTO procedures.

• Methods for performing an electrical risk assessment: Risk assessment training is fundamental to the development of a comprehensive electrical safety program. NFPA 70E, Annex F offers guidance on electrical risk assessment protocols. The assessment process should include identifying sources of risk, analyzing them for risk level and determining appropriate measures for mitigation. These risks include both arc flash and electric shock hazards. Understanding work boundaries such as limited approach and arc flash boundaries, being aware of the operating voltage present and heeding warning labels are crucial elements in effectively managing these risks.

• Job safety planning or briefing requirements: An essential prework assessment includes job safety planning, which may involve completing a daily risk assessment form. For more complex and hazardous electrical work, safety briefings should be held before initiating tasks. Ideally, this planning should be scaled to the level of risk and the certification level of the workers involved.

• Incident investigation steps, even for close calls or near misses: By examining incidents, close calls and near misses, organizations can pinpoint areas where additional training or program modifications are needed, such as emergency response training. This process reinforces the program’s principles through corporate stewardship.

• Program compliance auditing: Programs should also incorporate auditing conducted by internal or third-party safety advocates. These audits, typically conducted every three years, aim to verify that the program’s principles and procedures, including the auditing of fieldwork safety, align with the chosen safety standard and corporate safety mandates.

Once a program is developed, a three-pronged approach can help with implementation:

• Executives endorsing the program: Nothing cements the importance of a safety program across an organization more than public endorsement by corporate executives. But a one-time endorsement is not enough. No program will have a lasting impact without an executive-level champion to periodically monitor its implementation and create accountability. An executive champion can make necessary changes to the program, resulting in proper outcomes.

• Safety advocates overseeing the program: Someone in the organization must own the program. Whether safety duties are a primary profession or a secondary responsibility assignment, this role is the driving force for implementing and maintaining the program. The advocate should lead the roll-out of the program, schedule training sessions, perform the necessary safety training (if certified and authorized) and periodically report to executives on the health and outcomes of the program. Regularly scheduled safety training videos with accountability measures are an excellent way to compel, remind, refresh and instruct new and existing employees of the program’s goals and practices. While in-person training for larger organizations can be time-consuming, they’re important for soliciting feedback and answering questions. This training also allows managers and executives to reinforce the importance of the program and show their support.

• Engineers executing the program: Mid-level managers who supervise the engineering staff at risk must be the ones who understand, support and execute the day-in, day-out safety program requirements. No executive or cadre of advocates can adequately supervise the regular, on-site work where these best practices should be implemented. Executives holding their managers accountable and those same managers holding their staff accountable is the key to program implementation success.

Essential safety program components

Among the most important approaches that can be incorporated, training stands out as fundamental for the success of any program. However, the inherent challenge of a training program that centers on NFPA 70E is the technical complexity of the standard, much of which focuses on compliance. Communicating this information to hundreds or thousands of employees, many of whom lack electrical training, can be exceedingly challenging. Therefore, the primary goal of training is to translate this technical content into easily understandable terms for a broad audience, so that the information is not only effective but also readily comprehensible. Here, a team-based approach often proves useful. It should involve safety advocates with subject matter expertise who possess a deep understanding of corporate risk.

A training program must also prepare employees to prioritize safety as a top-of-mind awareness when they go out in the field. They need to be empowered to make wise decisions when it comes to practicing safety. In the field, there may not always be direct supervision when it comes to safety practices. However, if they understand expectations during training and have all their questions answered, they will be well-prepared for success when they transition to fieldwork. This readiness includes situations and conditions with inherent risks or exposures.

Figure 3: Verifying breaker settings will allow for the future safe operation of electrical equipment by the facilities team. Courtesy: Dewberry

Additionally, training should not be treated as a singular event but rather as an ongoing journey and continual process. It requires a commitment to learning every single day and breaking bad habits. It also serves to reinforce safer actions and decisions. Training should be consistent, with regular refreshers. Throughout their careers, employees should undergo knowledge checks to verify that the information is retained.

For many legacy engineering professionals, adapting to a new way of conducting their work can be a difficult undertaking. Some may have been operating without a structured program for 20 or 30 years. A corporate electrical safety program should also relate to all technical personnel working in the field and not solely to electrical engineers. This is because electrical hazards can exist in any construction site or operational facility, even though the risk to non-electrical staff may be comparatively lower. To support this transition, leaders who are closely connected with their teams and able to address questions, while certifying compliance, are invaluable. They play a crucial role in guiding and supporting employees through the necessary changes.  Those leaders may identify who is trained and certified as qualified or unqualified electrical workers based on the program’s certification definitions.  Hybrid safety certifications that exist somewhere between NFPA 70E qualified and unqualified are options and need to be clearly defined in the program, with careful consideration given the lack of NFPA 70E guidance.

A successful corporate electrical safety program is not only about compliance, mitigating risks or avoiding accidents. It’s also about cultivating an environment where electrical safety becomes a shared value. This is where a program lays the groundwork for an enduring electrical safety culture across the organization. A culture of electrical safety emerges when employees recognize their well-being is a top priority—instilling a sense of responsibility and loyalty among them. Such a culture, underpinned by strong safety performance, plays a vital role in upholding positive corporate morale and reputation, and, ultimately, building a resilient foundation for long-term success.

Do you have experience and expertise with the topics mentioned in this content? You should consider contributing to our WTWH Media editorial team and getting the recognition you and your company deserve. Click here to start this process.