Page 1 of 4 2016-PSEC-0679

Electrical Safety Inspections in Industrial Facilities

Dennis K. Neitzel, CPE, CESCP

Senior Member, IEEE
AVO Training Institute, Inc.
4271 Bronze Way
Dallas, Texas 75237
dennis.neitzel@avotraining.com

Abstract - Industrial facility's often have very complex
electrical systems and equipment. Much of this equipment was
installed many years or even decades ago and therefore may
have deteriorate into an unsafe condition.
equipment covers are left off or are not properly fastened in
place, there are unused openings that have not been effectively
closed, and listing and labeling requirements are not adhered to.
Another major issue is that sufficient access and working space
is not maintained about all electric equipment to permit ready
and safe operation and maintenance of such
Regularly scheduled electrical safety inspections can assist in
identifying these deficiencies, as well as other electrical safety
issues that may put personnel at risk from electrical hazards.
The Occupational Safety and Health Administration (OSHA)
and the National Fire Protection Association
developed regulations and standards that, if adhered to, can
reduce the hazardous conditions that are identified through
electrical safety inspections or assessments.
Index Terms - safety inspections, electrical hazards, risk
assessment, electrical safety, procedures, training, and personal
protective equipment (PPE).
I. INTRODUCTION
II. ELECTRICAL SAFETY INSPECTION PROGRAM
The OSH Act of December 29, 1970, requires the employer
All too often
toassure safe and healthful working conditions for working
men and women. Section 5 of this Act, titled Duties, generally
known as the "General Duty Clause," paragraph (a)(1),
requires each employer to furnish to each of his employees
employment and a place of employment which are free from
equipment. recognized hazards that are causing or are likely to cause
death or serious physical harm to their employees and to
"comply with occupational safety and health standards
promulgated under this Act. All electrical hazards are
"recognized hazards" and therefore must be identified and
(NFPA) have
corrected in order to provide safe and healthful working
conditions. Paragraph (b) of Section 5 requires each
employee to comply with occupational safety and health
standards and all rules, regulations, and orders issued
pursuant to the aSH Act which are applicable to his own
actions and conduct. [1]
To assist in accomplishing the requirements of Section 5 of
the OSH Act, the employer should implement a self­
inspection program. This can help ensure that the electrical

Electrical safety inspections, often referred to as audits or systems and equipment are properly designed, installed,

assessments, must be conducted in order to identify operated, and maintained in a safe and reliable condition. The

potentially hazardous conditions that may exist with electrical inspection program can also ensure that employees are using

systems and equipment installed in industrial and commercial the electrical safety-related work practices and PPE when

facilities. Safety inspections can be instrumental in identifying working on or interacting with electrical equipment.

most workplace hazards, including any potential hazards that Electrical safety inspections must be conducted in order to

could affect worksite conditions or work practices. verify full compliance with OSHA electrical safety

Conducting electrical safety inspections on a regular basis can regulations that include 29 CFR 1910.302-.308 for the
provide valuable information for managing electrical systems minimum requirements for design and installation of
and equipment, and to maintain them in a safe and reliable electrical equipment and systems [3], 1910.331-.335 for
condition. identifying electrical safe work practices [4], 1910.137 that
Electrical safety inspections must also be conducted to identifies the electrical PPE requirements [6], 1910.269
verify full compliance with OSHA electrical safety (where applicable) for all power generation, transmission, and
regulations, as well as industry consensus standards. distribution systems and equipment [8], and 1910.132 [5] that
Verifying compliance with these regulations and standards, identifies the general requirements for determining the need
through regularly scheduled safety inspection, can help to to use PPE. To further emphasize the requirements for hazard
ensure that employers are maintaining electrical systems and assessments (inspections) the following OSHA requirement is
equipment in a safe and reliable working condition, as well as provided from 1910.132 which states:
verifying each employee's use of safe work practices and the (d) Hazard assessment and equipment selection.
appropriate PPE. (1) The employer shall assess the workplace to determine if
hazards are present, or are likely to be present, which
necessitate the use of personal protective equipment (PPE).

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If such hazards are present, or likely to be present, the 2. Why did it happen?
employer shall: 3. What will be done to prevent it in the future?
(i) Select, and have each affected employee use, the types A root cause analysis is essentially a method of problem
of PPE that will protect the affected employee from the solving used for identifying the root causes of incidents,
hazards identified in the hazard assessment; faults, or problems. Hazards identified during an inspection,
(ii) Communicate selection decisions to each affected recommended changes or corrections in processes, and safe
employee; and, work practices and procedures should be analyzed to help
(iii) Select PPE that properly fits each affected employee. prevent a reoccurrence.
(2) The employer shall verifY that the required workplace Any deficiencies identified in the inspection, along with
hazard assessment has been performed through a written lessons learned, should be communicated to all potentially
certification that identifies the workplace evaluated; the affected personnel in the organization that may benefit from
person certifYing that the evaluation has been performed; the the information.
daters) of the hazard assessment; and, which identifies the
document as a certification of hazard assessment. [5] II. MANAGEMENT'S ROLE
Industry consensus standards such as NFPA 70, National
Electrical Code [10], NFPA 70B, Recommended Practice for OSHA concluded that effective management of worker's
Electrical Equipment Maintenance [11], and NFPA 70E, safety, which includes electrical safety inspections, was a
Standard for Electrical Safety in the Workplace [9] are also decisive factor in reducing the extent and the severity of
needed for conducting electrical safety inspections. work-related injuries.
Electrical safety inspections should be conducted by a Management ultimately bears the burden of effectively
trained and electrically qualified person in order to more administering an electrical safety inspection program.
effectively identify deficiencies in electrical equipment or Management's involvement in the development and
systems, as well as to provide corrective action and to implementation of the inspection program is vital to the
properly document any deficiencies found. This will also help success of the program.
ensure that the inspection program is on target. Another There are several areas that must be considered when
option is to contract a third party electrical safety inspector or developing the inspection program, which includes but is not
inspection agency. Using an inspector from outside the limited to; 1) hazard assessments, 2) inspections, 3) safety
facility will often lead to discovery of issues and deficiencies training, and 4) evaluation of the existing safety management
that may be overlooked by in-house, self-inspection system.
programs. To assist employers in developing an effective safety
The documented electrical safety inspection program management system, OSHA published Safety and Health
should be reviewed on a periodic basis, by qualified persons, Program Management Guidelines (Federal Register 54(16):
to ensure that the check-lists and procedures are based on 3904-3916, January 26, 1989). These voluntary guidelines
current standards and that they are being utilized by can be applied to all places of employment covered by
personnel. A review of the entire electrical safe work program OSHA.
for energized and deenergized work should also be included The guidelines identify four general elements that are
in the program. Written work practices, PPE requirements, important to the development of a successful safety
and all electrical equipment and systems should be included management system, as follows:
for inspection and compliance. Inspections should also • Management leadership and employee involvement,
include an audit of the electrical safety program as required
• Worksite analysis,
by NFPA 70E, 110.1(1)(1), as well as "work in progress", as
• Hazard prevention and control, and
required by 110.1(1)(2) to ensure that each worker
• Safety and health training. [12]
understands and is implementing safe work practices and
PPE.
III. ELECTRICAL SAFETY INSPECTION

I. ROOT CAUSE ANALYSIS GUIDELINES

The electrical safety inspection program should also Employers (management) should institute a self-assessment

include a Root Cause Analysis of the deficiencies identified. or inspection program in order to determine the adequacy of

A root cause analysis is a systematic approach for identifying their existing written electrical safety inspection program, safe

the underlying causes of why an incident or accident occurred work procedures, PPE, and training programs, to ensure that

so that the most effective solutions can be identified and they are being implemented. The program should also include

implemented. Within any industrial or commercial an inspection of the facility electrical systems and equipment

organization problem solving, incident investigation, and root to ensure compliance with the installation and maintenance

cause analysis are all fundamentally connected by three basic regulations and standards.

questions: The list below identifies OSHA Electrical Self-Inspection

1. What is the problem? Checklist items. These questions are typically asked by an
OSHA inspector when conducting an electrical safety

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inspection. Some questions have been updated to current • Are all disconnecting switches and circuit breakers
standard's requirements. [2] labelled to indicate their use or equipment served?
• Do you specify compliance with OSHA for all contract • Are disconnecting means always opened before fuses are
electrical work? replaced?
• Are all employees required to report as soon as • Do all interior wiring systems include provisions for
practicable any obvious hazard to life or property grounding metal parts of electrical raceways, equipment
observed in connection with electrical equipment or and enclosures?
lines? • Are all electrical raceways and enclosures securely
• Are employees instructed to make preliminary fastened in place?
inspections and/or appropriate tests to determine what • Are all energized parts of electrical circuits and
conditions exist before starting work on electrical equipment guarded against accidental contact by
equipment or lines? approved cabinets or enclosures?
• When electrical equipment or lines are to be serviced, • Is sufficient access and working space provided and
maintained or adjusted, are necessary switches opened, maintained about all electrical equipment to permit
locked-out and tagged whenever possible? ready and safe operations and maintenance?
• Are portable electrical tools and equipment grounded or • Are all unused openings (including conduit knockouts)
of the double insulated type? in electrical enclosures and fittings closed with
• Are electrical appliances such as vacuum cleaners, appropriate covers, plugs or plates?
polishers, and vending machines grounded? • Are electrical enclosures such as switches, receptacles,
• Do extension cords being used have a grounding and junction boxes, provided with tight fitting covers or
conductor? plates?
• Are multiple plug adaptors prohibited? • Are disconnecting switches for electrical motors in
• Are ground-fault circuit-interrupters (GFCI) installed on excess of two horsepower, capable of opening the
each temporary 15, 20, or 30 ampere, 125 volt AC circuit when the motor is in a stalled condition, without
circuit at locations where construction, demolition, exploding? (Switches must be horsepower rated equal to
modifications, alterations or excavations are being or in excess of the motor hp rating.) Is low voltage
performed? protection provided in the control device of motors
• Are all temporary circuits protected by suitable driving machines or equipment which could cause
disconnecting switches or plug connectors at the probable injury from inadvertent starting?
junction with permanent wiring? • Is each motor disconnecting switch or circuit breaker
• Do you have electrical installations in hazardous dust or located within sight of the motor control device?
vapor areas? If so, do they meet the National Electrical • Is each motor located within sight of its controller or the
Code (NEC) for hazardous locations? controller disconnecting means capable of being locked
• Is exposed wiring and cords with frayed or deteriorated in the open position or is a separate disconnecting
insulation repaired or replaced promptly? means installed in the circuit within sight of the motor?
• Are flexible cords and cables free of splices or taps? • Is the controller for each motor in excess of two
• Are clamps or other securing means provided on flexible horsepower, rated in horsepower equal to or in excess of
cords or cables at plugs, receptacles, tools, equipment, the rating of the motor it serves?
etc., and is the cord jacket securely held in place? • Are employees who regularly work on or around
• Are all cord, cable and raceway connections intact and energized electrical equipment or lines instructed in the
secure? cardiopulmonary resuscitation (CPR) methods?
• In wet or damp locations, are electrical tools and • Are employees prohibited from working alone on
equipment appropriate for the use or location or energized lines or equipment over 600 volts?
otherwise protected? The list below contains discrepancy items typically found
• Is the location of electrical power lines and cables during inspections of industrial and commercial facilities. [2]

(overhead, underground, under floor, other side of • Operating one-line diagrams (up-to-date)
walls) determined before digging, drilling or similar • Training of qualified personnel
work is begun? • Training of unqualified or non-electrical personnel
• Are metal measuring tapes, ropes, handlines or similar • De-energized work procedures (establishing an
devices with metallic thread woven into the fabric electrically safe work condition)
prohibited where they could come in contact with • Electrical safety program
energized parts of equipment or circuit conductors? • Energized safe work procedures
• Is the use of metal ladders prohibited in areas where the • Deenergized safe work procedures
ladder or the person using the ladder could come in • Grounding and bonding of electrical equipment
contact with energized parts of equipment, fixtures or • Corrosion
circuit conductors?

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 2016-PSEC-0679 Page 4 of 4

• Electrical equipment maintenance programs and Safety Standards for Electrical Systems, Federal Register Final Rule
February 14,2007
procedures
[4] Occupational Safety and Health Administration (OSHA), 29 CFR,
• Identifying exposed energized parts - covers off or not Part 1910,Subpart S Electrical Standards, 1910.331-.335 Electrical
properly secured, or equipment doors left open or not Safety-Related Work Practices, Final Rule August 6,1990
properly secured [5] Occupational Safety and Health Administration (OSHA), 29 CFR,
Part 1910, Subpart T Personal Protective Equipment, 1910.132
• Unused openings not effectively closed
General, Final Rule June 30,1993
• Working space around electrical equipment not [6] Occupational Safety and Health Administration (OSHA), 29 CFR,
provided and maintained, 600-volts or less Part 1910, Subpart 1 Personal Protective Equipment, 1910.137
Electrical Protective Equipment, Final Rule April 11,2014
• Working space around electrical equipment not
[7] Occupational Safety and Health Administration (OSHA), 29 CFR,
provided and maintained, over 600-volts
Part 1910
• Identification of disconnecting means - circuit [8] Occupational Safety and Health Administration (OSHA), 29 CFR,
breakers and disconnect switches Part 1910, Subpart R Special industries, 1910.269 Electric Power
Generation, Transmission, and Distribution, Final Rule April 11,
• Improper or unapproved extension cords
2014
• Damaged extension cords National Fire Protection Association (NFPA), NFPA 70E Standard
[9]
• Damaged cord- and plug-connected equipment for Electrical Safety in the Workplace, 2015 Edition
• Lack of ground-fault circuit-interrupters (GFCI) [10] National Fire Protection Association (NFPA), NFPA 70 National
Electrical Code (NEC),2014 Edition
(installed or portable as required)
[II] National Fire Protection Association (NFPA), NFPA 70B,
• Availability, use, and condition of rubber insulating Recommended Practice for Electrical Equipment Maintenance, 2013
gloves and other insulating PPE Edition
• Availability, use, and condition of arc-rated clothing [12] Occupational Safety and Health Administration (OSHA) Safety and
Health Program Management Guidelines (Federal Register 54(\6):
and PPE
3904-3916,January 26,1989)

IV. CONCLUSIONS
VII. VITA

Electrical safety inspections of industrial facilities are

Dennis K. Neitzel, CPE, CESCP, Director Emeritus of
necessary in order to verify compliance with regulations and
AVO Training Institute, Inc., Dallas, Texas, has over 48 years
standards, as well as to help ensure that electrical installations
in the electrical industry in various capacities, specializing in
and equipment are maintained in a safe and reliable condition.
electrical equipment and systems maintenance, testing,
Compliance with the OSHA regulations and NFPA standards
engineering, inspection, and safety. He is a past Chair of the
will provide a means to help reduce electrical accidents,
IEEE-lAS Electrical Safety Workshop (2012). He is an IEEE
injuries, and fatalities in all segments of industry.
Senior Member, and is also a member of ASSE, AFE, IAEI,
As identified, there are requirements for identifying
electrical hazards, performing risk assessments, developing SNAME, and NFPA. Mr. Neitzel is a Certified Plant

and implementing safety programs and safe work procedures, Engineer (CPE), Certified Electrical Safety Compliance
providing training for all employees who may be exposed to Professional (CESCP), and a Certified Electrical Inspector­
the identified electrical hazards, and providing all required General. He is a Principle Committee Member as a Special
PPE, in order to help protect all personnel who may be Expert for the NFPA 70E, Standard for Electrical Safety in
exposed to electrical hazards. the Workplace; Working Group Chair of IEEE Std. 3007.1-
This paper addressed the electrical safety inspection 2010 Recommended Practice for the Operation and
requirements needed to identify electrical hazards associated Management of Industrial and Commercial Power Systems,
with working around electrical equipment and systems. This 3007.2-2010 Recommended Practice for the Maintenance of
is necessary in order to help protect personnel who perform Industrial and Commercial Power Systems, 3007.3-2012
maintenance or operations of electrical equipment associated Recommended Practice for Electrical Safety in Industrial and
with industrial facilities. Adherence to the requirements stated Commercial Power Systems, and IEEE Std. 45.5-2014
in this paper can help save lives.
Recommended Practice for Electrical Installations on
Shipboard-Safety Considerations; and is a co-author of the
VI. REFERENCES
Electrical Safety Handbook, McGraw-Hili Publishers. Mr.
Neitzel earned his Bachelor's degree in Electrical
The references below are used in the paper as reference
Engineering Management and his Master's degree in
documents and are not directly quoted.
Electrical Engineering Applied Sciences. He has authored,
published, and presented numerous technical papers and
[I ] The OSH Act, Public Law 91-596,91st Congress,S.2193,December
29,1970. magazine articles on electrical safety, maintenance, and
[2] D.K. Neitzel,ESW-2009-11,Industrial Electrical Safety Inspections technical training. Mr. Neitzel can be contacted at
[3] Occupational Safety and Health Administration (OSHA), 29 CFR,
dkneitzel@ieee.org.
Part 1910, Subpart S Electrical Standards, 1910.302-.308 Design

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