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Saudi Aramco 7180 (5/89)

G.I. NUMBER Approved


SAUDI ARABIAN OIL COMPANY (Saudi Aramco)
GENERAL INSTRUCTION MANUAL
2.721
ISSUE DATE REPLACES
ISSUING ORG. POWER SYSTEMS ENGINEERING DEPARTMENT
03/08/2016 10/05/2009
APPROVAL PAGE NUMBER
SUBJECT: ELECTRICAL ARC FLASH HAZARD MITIGATION
AFW 1 of 23

CONTENTS:
1.0 PURPOSE
2.0 APPLICABILITY
3.0 RESPONSIBILITIES
4.0 DEFINITIONS
5.0 REFERENCES
6.0 GENERAL REQUIREMENTS
7.0 SAFE OPERATING AND MAINTENANCE PROCEDURES
8.0 PERSONAL PROTECTIVE EQUIPMENT (PPE)
9.0 OTHER PROTECTIVE EQUIPMENT
10.0 TRAINING AND CERTIFICATION

*SUPPLEMENT 2.721-1, SPECIFIC EXAMPLES OF ARC FLASH HAZARD MITIGATION


CONTROLS
*SUPPLEMENT 2.721-2, ARC FLASH PPE REQUIREMENTS
*SUPPLEMENT 2.721-3, ARC FLASH RATED CLOTHING AND PPE SPECIFICATIONS
*SUPPLEMENT 2.721-4, ARC RATED CLOTHING – GENERAL LAUNDERING GUIDELINES
*SUPPLEMENT 2.721-5, FIELD OPERATOR – EHR CERTIFICATE

1.0 PURPOSE

*This General Instruction (GI) provides minimum safe work requirements for protection of personnel
against electrical arc flash hazards in the workplace in accordance with NFPA 70E (2015 Edition),
Standard for Electrical Safety in the Workplace.

2.0 APPLICABILITY

*All Saudi Aramco departments shall apply this instruction to construction, commissioning, start-up,
operation, maintenance, and demolition activities at electrical installations whenever there is a
possibility that an electrical arc flash may occur, such as during electrical isolation, operating
breakers, switches or starters, racking breakers in/out, testing electrical circuits, applying safety
grounds, etc. Unless otherwise specified in Project Contract Language, this GI covers all Saudi
Aramco and contractor personnel working within Saudi Aramco (SA) facilities and project sites, as
well as contractor camps and temporary facilities covered under a Saudi Aramco Land Use Permit
(LUP).

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The Arc Flash Mitigation Program includes an evaluation process, whereby electrical equipment
owners will undergo an on-site evaluation, by Power Systems Engineering Department, to ensure they
are meeting the requirements of stated company Arc Flash Mitigation KPI’s.

3.0 RESPONSIBILITIES

Department managers, division heads, and unit heads are responsible for ensuring compliance with this
GI. Contractors and workers shall comply with the safe work methods and use of protective equipment
in this GI.

4.0 DEFINITIONS

Arc Flash – A rapid release of electrical energy due to an arcing fault between electrical phases, neutral
or ground, resulting in a plasma arc through the adjacent surrounding air. An arc flash is sometimes
inappropriately called a “flashover.”

*Arc Flash Hazard – A dangerous condition associated with the release of energy caused by an electric
arc. An arc flash hazard may exist when energized electrical conductors or circuit parts are exposed or
when they are within equipment in a guarded or enclosed condition, provided a person is interacting
with the equipment in such a manner that could cause an electrical arc.

*Arc Flash Risk Assessment– determines the level of risk associated with an Arc Flash Hazard. If a
hazard exists, the risk assessment shall determine; appropriate safety-related work practices, the arc
flash boundary, and PPE to be used within that boundary. (terminology changed in NFPA 70e -2015
from “Arc Flash Hazard Analysis”)

*Arc Flash Suit – A complete arc-rated clothing and equipment system that covers the entire body,
except for the hands and feet. An arc flash suit may include pants or overalls, a jacket or a coverall, and
a beekeeper-type hood fitted with a face shield.

*Arc Rating – The value attributed to a material that describes its performance during exposure to an
electrical arc discharge. The arc rating is expressed in calories per centimeter squared (cal/cm2) and is
derived from the determined value of the arc thermal performance value (ATPV) or energy of
breakopen threshold EBT (should a material system exhibit a breakopen response below the ATPV
value). Arc rating is reported as either ATPV or EBT, whichever is the lower value. Arc-rated clothing
or equipment indicates that it has been tested for exposure to an electric arc. Flame-Resistant (FR)
clothing without an arc rating has not been tested for exposure to an electric arc.

*Arc Thermal Performance Value (ATPV) – ATPV is defined in ASTM F1959-06 as the incident
energy on a material or a multi-layer system of materials that results in a 50 percent probability that
sufficient heat transfer through the tested specimen is predicted to cause the onset of a second degree
skin burn injury based on the Stoll curve, cal/cm2.

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Balaclava (Sock Hood) – An arc-rated hood that protects the neck and head except for the facial area
of the eyes and nose.

*Boundary, Arc Flash – When an arc flash hazard exists, an approach limit at a distance from a
prospective arc source within which a person could receive a second degree burn if an electrical arc
flash were to occur. A second degree burn is possible by an exposure of unprotected skin to an electric
rc flash above the incident energy level of 5 J/cm2 (1.2 cal/cm2).

Boundary, Limited Approach – An approach limit at a distance from an exposed energized electrical
conductor or circuit part within which a shock hazard exists.

Boundary, Restricted Approach – An approach limit at a distance from an exposed energized


electrical conductor or circuit part within which there is an increased likelihood of shock, due to
electrical arc over combined with inadvertent movement, for personnel working in close proximity to
the energized electrical conductor or circuit part.

**Breakopen Threshold (EBT) – EBT is defined in ASTM F1959-06 as the incident energy on a material
or a material system that results in a 50 percent probability of breakopen. Breakopen is defined as a
hole with an area of 1.6 cm2 (0.5 in2) or an opening of 2.5 cm (1.0 in.) in any dimension.

*Electrical Equipment – A general term, including fittings, switchgear, transformers, control gear
(motor control centers [MCCs]), machinery, and the like used as a part of, or in connection with, an
electrical installation. This includes DC systems and batteries.

Electrical Safety – The recognition of hazards associated with the use of electrical energy and the
precautions to be taken so that hazards do not cause injury or death.

**Electrically Safe Work Condition – A state in which an electrical conductor or circuit part has been
disconnected from energized parts, locked/tagged in accordance with established standards, tested to
ensure the absence of voltage and grounded (if grounding is deemed necessary).

**Electrical Work (on energized electrical conductors or circuit parts) - for the purpose of diagnostic
testing, or maintenance, repair or replacement, intentionally coming in contact with energized electrical
conductors or circuit parts with the hands, feet, or other body parts, with tools, probes, or with test
equipment, regardless of the personal protective equipment (PPE) a person is wearing. Diagnostic
(testing) is taking readings or measurements of electrical equipment with approved test equipment that
does not require making any physical change to the equipment; maintenance, repair and/or replacement
is a physical alteration of electrical equipment (such as making or tightening connections, removing or
replacing components, etc.).

Energized – Electrically connected to, or is, a source of voltage.

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**Energy Reducing Maintenance Switch - Allows a worker to set a circuit breaker trip unit to “no
intentional delay” to reduce the clearing time while the worker is working within an arc-flash boundary
as defined in NFPA 70e.

Exposed (as applied to energized electrical conductors or circuit parts) – Capable of being inadvertently
touched or approached nearer than a safe distance by a person. It is applied to electrical conductors or
circuit parts that are not suitably guarded, isolated, or insulated.

**Flashover - an abnormal electrical discharge (as through the air to the ground from a high potential
source or between two conducting portions of a structure).

**Hazard – A source of possible injury or damage to health.

**Hazardous Duty Potential Test (HDPT) – A test that determines the potential of high voltage (above
1000 V) equipment with respect to ground or any other point of reference using an approved phasing-
out testing instrument (as listed in PDI – 10.1). An HDPT must be performed before applying a ground
to high voltage equipment or is used to determine corresponding phases to two high voltage power
supplies.

Incident Energy – The amount of thermal energy impressed on a surface, at certain distance from the
source, generated during an electrical arc flash event. One of the units used to measure incident energy
is calories per centimeter squared (cal/cm2).

**Incident Energy Analysis – A component of an arc flash risk assessment used to predict the incident
energy of an arc flash for a specified set of conditions. (SAES-P-100 refers to Incident Energy Analysis
as Arc Flash Analysis)

**Independent Examiner - An independent examiner appointed in writing by the Department Manager


and or OJT Evaluators (T&D) who may certify eligible employees who meet specific job certification
requirements.

*Limited Area – (used in conjunction with “Limited Switching” defined below) A defined area, with
boundaries, where switching operations may be conducted only authorized employees within those
boundaries. A limited area (example – a specific plant area or substation) shall be defined and
designated by the employee’s Superintendent.

*Limited Switching – Specific switching tasks on specific pieces of equipment in Limited Areas, which
are typically done by individuals who have had sufficient awareness level training, adequate to
recognize the hazards and address the level of risk associated with the task.

**Normal Operation – normal operation of electrical equipment shall be permitted where all of the
following conditions are satisfied; the equipment is properly installed, maintained, doors are closed and
secured, covers are in place and secured, and there is no evidence of impending failure.

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Proponent – Organization responsible for the operations of, or owner of a facility. Normally this will
be an Administrative Area.

Proponent’s Electrical Support Organization – a department that operates and/or maintains electrical
equipment for a proponent (e.g., Power Operations Department, Utilities & Technical Support
Department).

*Qualified Person – One who has the demonstrated skills, knowledge and certification required relating
to the construction and operation of electrical equipment and installations and has received safety
training to identify and avoid the hazards involved.

**Risk – A combination of the likelihood of occurrence of injury or damage to health and the severity of
injury or damage to health that results from a hazard

**Substation - An enclosed assemblage of equipment (e.g., switches, interrupting devices, circuit


breakers, buses, and transformers) through which electric energy is passed for the purpose of
distribution, switching, or modifying its characteristics.

**Switchgear, Arc-Resistant – Equipment designed to withstand the effects of an internal arcing fault
and that directs the internally released energy away from the employee.

**Switchgear, Metal-Clad – A switchgear assembly completely enclosed on all sides and top with sheet
metal, having draw-out switching and interrupting devices, and all live parts enclosed within grounded
metal compartments

**Switchgear, Metal-Enclosed – A switchgear assembly completely enclosed on all sides and top with
sheet metal (except for ventilating openings and inspection windows), containing primary power circuit
switching, interrupting devices, or both, with buses and connections. This assembly may include control
and auxiliary devices. Access to the interior of the enclosure is provided by doors, removable covers,
or both. Metal-enclosed switchgear is available in non-arc-resistant or arc-resistant constructions.

Switching – The operation of switches, circuit breakers, fuses, or any other method of making or
breaking a circuit. Switching includes racking-in/racking-out circuit breakers and opening/closing
grounding devices.

Voltage Testing – Test conducted to determine if voltage is present or not in a conductor or item of
electrical equipment. Also called potential testing.

5.0 REFERENCES

**ANSI Z87.1 American National Standard for Occupational & Educational Personal Eye & Face
Protection Devices

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ASTM F 1959 Standard Test Method for Determining the Arc Thermal Rating of Materials for
Clothing
ASTM F 2178 Standard Test Method for Determining the Arc Rating and Standard Specification for
Face Protective Products
GI 2.100 Work Permit System
GI 6.001 Notification Requirements for Incidents (Including Fires)
GI 6.003 Incident Investigation
GI 6.004 Near Miss Reporting Process
GI 6.005 Reporting, Investigation and Recording of Injuries/Occupational Illnesses
GI 6.007 Reporting of Contractor On-Job Injuries/Occupational Illnesses
GI 6.012 Isolation, Lockout and Use of Hold Tags
GI 1809.001 Industrial and Administrative Workforce Job Certification
IEC 61010 –1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use - Part 1: General Requirements
*IEEE 1584 (2011) Guide for Performing Arc-Flash Hazard Calculations
*NFPA 70E Standard for Electrical Safety in the Workplace (2015 Edition)
Power Distribution Instruction (PDI) 10.1 – Potential Testing Certification
**SABP–P–051 Arc Flash Hazard Analysis Procedure Using ETAP Software
SAEP–378 Electrical Inspection Requirements
SAES–B–019 Portable, Mobile and Special Fixed Firefighting Equipment
**SAES–P–100 Basic Power Systems Design Criteria
Saudi Aramco Construction Safety Manual (CSM)
*Saudi Aramco Safety Management System (SMS) Manual
*Saudi Aramco Safety Management Guide 02-001-2009 – Risk Assessment and Management Guide
for Managers
*Saudi Aramco Safety Management Guide 02-002-2010 – Qualitative Risk Assessment
Saudi Aramco Safety Management Guide 05-001-2006, Management of Change (MOC)
*Saudi Aramco Safety Management Guide 08-001-2008 – Emergency Preparedness
Saudi Aramco Safety Management Guide 08-001-2008, Emergency Preparedness
Saudi Aramco Loss Prevention Department’s Emergency Management Guide
**16–SAMSS–504 Indoor Metal Clad Switchgear: 1 to 38kV
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**16–SAMSS–522 Retrofit Replacement Vacuum Circuit Breaker Applied in Indoor Metal Clad
Switchgear 1 to 38kV

6.0 GENERAL REQUIREMENTS

*6.1 In accordance with the Saudi Aramco Safety Management System (SMS) Manual – Element 6
Safe Operations, exposures to arc flash hazards shall be mitigated or controlled using the
hierarchy of Controls listed below. These control strategies are listed by effectiveness, most to
least effective. Elimination (completely isolating the equipment from the source of energy) will
be the preferred control method of Arc Flash Hazard Mitigation. In the event that elimination of
hazard through isolation is not feasible, Engineering and Administrative controls will be the next
preferred methods considered.

If it has been determined by the proponent, that Engineering and Administrative controls are not
feasible or practical, then PPE, meeting all criteria listed in Section 8 and Supplements 2.721-2,
and 2.721-3, will be used to supplement arc flash hazard exposure mitigation. SAES-P-100, 16-
SAMSS-504, and 16-SAMSS-522 will guide proponents to making hazard control decisions.

1. *Elimination – removing the hazard by placing the equipment in an “Electrically Safe Work
Condition” see definition.

2. *Engineering Controls – Controls that minimize or eliminate arc flash exposures through
design, equipment, and/or operating procedure changes. Saudi Aramco Engineering
Standards (SAESs) establish minimum standards for controlling hazards through engineering
designs. Examples of engineering controls include Remote Racking Devices, and Remote
Switching capability. (Specific examples can be found in Supplement 2.721-1).

3. *Administrative Controls – (also known as work practice controls, are changes in work
procedures such as written safety policies, rules, supervision, schedules, and training with the
goal of reducing the duration, frequency, and severity of exposure to arc flash hazards.
Examples of administrative controls include Operations and Maintenance Procedures, as well
as Arc Flash labelling.

4. *Personal Protective Equipment (PPE) Equipment worn by personnel with the intent to
minimize exposure to arc flash hazards, especially where the above-listed controls have not
yet been implemented or have been implemented and found to be inadequate to completely
control the risk of exposure to arc flash hazards. This is the least preferred method of arc
flash exposure control.

**6.2 The proponent is responsible for conducting an Arc Flash Analysis (Incident Energy Analysis)
as defined in SAES-P-100 on all existing electrical distribution equipment (rated up to 38kV),
using a qualified vendor. Consulting Services Department (CSD) and Power Systems
Engineering Department (PSED) will provide any needed support in reviewing the analysis
and or vendor qualifications. The Incident Energy and Arc Flash Boundary Calculation
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Methods outlined in IEEE 1584 – Guide for Performing Arc Flash Hazard Calculations will be
considered by this G.I. to be the only method acceptable to determine Incident Energy Level
for electrical equipment rated 15kV and below. For electrical equipment rated 15kV and
higher, Incident Energy Analysis will be based on the Ralph Lee Calculation Method outlined
in NFPA 70E (2015). For DC equipment, the Incident Energy Analysis shall be based on
NFPA 70E (2015). Users are encouraged to consult the latest version of the document to
understand basis, limitations, rationale and other pertinent information necessary for proper
application of the standard.

**6.3 Arc Flash Incident Energy shall be categorized as follows:

Calculated Incident Energy Range (cal/cm2) Level


0.0 1.2 A
1.2 12 B
12 40 C
40 40+ DANGER

**6.4 If the arc flash incident energy exceeds 40 cal/cm2, the equipment must be put in an electrically
safe work condition or recommended arc flash mitigation control strategies shall be put into
effect as listed in Supplement 2.721-1 – Specific Examples of Arc Flash Hazard Mitigation
Controls shall be used to lower incident energy to 40 cal/cm2 or less. When conducting
electrical work on energized equipment, the PPE Arc Thermal Protective Value (ATPV)
must exceed the arc flash incident energy determined by the Arc Flash Analysis.

*6.5 Proponents shall install Arc Flash and Shock Hazard Warning Labels on equipment listed
below:

 Panel boards, switchboards, and switch racks (240V & ≤600V)


 All metal clad switchgear (38kV)
 Low and high voltage motor control gear (38kV)
 Automatic Transfer Switches, Variable Frequency Drive and Control Cabinets
 Pad Mounted SF6 Switchgear
 DC Systems (UPS, DC Switchboards, Battery Systems and DC supply sources – as per
Table 130.7 (C)(15)(b) of NFPA 70 E - 2012)

Labels shall be (8.89 cm x 12.7 cm) or (3.5 inch x 5 inch), thermal transfer type label of high
adhesion polyester for each location analyzed and shall be machine printed, with no field
markings. Labels shall meet the requirements of SAES-B-067 Paragraph 4.1.7. Refer to
standard label layout below.

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**6.6 An Arc Flash Analysis according to SAES-P-100 shall be conducted during new and expansion
projects to include all new electrical equipment. Existing electrical equipment shall be included
in the Arc Flash Analysis when the expansion entails a major system modification such as
adding co-generation unit, changing system configuration, changing equipment ratings, or
changing protective device settings. In case of conflict, CSD shall be consulted to determine
the extent of the Arc Flash Analysis to be conducted. The installation of new equipment should
include engineering controls that would alleviate and/or reduce the need for using PPE as a
method of exposure control to arc flash.

**6.7 Project Management Team (PMT) shall be responsible to have Arc Flash Analyses conducted
for new projects as well as expansion projects including existing equipment provided that a
previous Analysis has been completed. Arc Flash Mitigation to meet the criteria outlined in
SAES-P-100 shall also be handled by PMT for both new and existing systems as applicable. If
the project is not being handled by the PMT, the proponent/end user shall be responsible to
provide Incident Energy analysis results and mitigation as applicable.

*6.8 Only qualified persons shall conduct electrical work on electrical equipment operated at higher
than 240 volts. They shall wear the proper PPE in accordance with Section 8.0 and Supplement
2.721-3, be trained and certified in accordance with Section 10.0, and be familiar with the
specific work procedures and/or tests required. Unqualified persons shall not be permitted to
enter spaces that are only allowed to be accessible to qualified persons (e.g., the unqualified
person must not cross the restricted approach boundary under any circumstances).

6.9 All arc flash incidents shall be reported as per GI 6.001, GI 6.004, GI 6.005 and/or GI 6.007.
Incident investigations, when required, shall be conducted in accordance with GI 6.003.

*6.10 Proponents shall identify credible scenarios of Arc Flash incidents and incorporate the
corresponding prevention and mitigation measures into their emergency response plan (ERP).
Refer to the Saudi Aramco Safety Management Guide 08-001-2008 and the Emergency
Management Guide for guidance.

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7.0 SAFE OPERATING AND MAINTENANCE PROCEDURES

*7.1 Proponents shall implement uniform electrical system operation procedures (including
switching/isolation and clearance/outage request procedures) that are aligned with the company’s
uniform electrical system operating procedures.

*7.2 Proponents shall implement uniform preventive maintenance (PM) procedures for similar
electrical equipment operated at higher than 240 volts that are aligned with the company’s
uniform PM procedures.
*7.3 Proponents, electrical support organizations, contractors, and relevant third parties shall develop
and implement written, clear, and consistent delineation of operation and maintenance interfacing
and responsibilities.

**7.4 Electrical conductors shall be considered energized until proven otherwise (e.g., by voltage
testing). Electrical equipment shall be properly de-energized, voltage tested, grounded, locked-
out and tagged out in accordance with GI 6.012 and local operating instructions prior to
conducting electrical work on them, whenever possible. It is recognized that there are times where
troubleshooting, monitoring and/or diagnostic testing needs to take place on equipment in a
energized state. In these instances, the Arc Flash Analysis must have been completed, the incident
energy levels determined, and the appropriate engineering, administrative and PPE controls must
be in place to reduce arc flash hazard exposure.

Modifications and/or connection of new electrical loads are sometimes carried out on energized
equipment due to operational requirements. This particular work is outside the scope of
“energized work” and requires the following three components to be completed before work takes
place; 1) Written Work Instruction, 2) Risk Assessment and JSA, and 3) Saudi Aramco Hot Work
Permit.

*7.5 Personnel shall not wear meltable (plastic) or conductive (metal) glasses, jewelry, rings, watches,
belt buckles, etc., within the limited approach boundary of energized electrical equipment.

*7.6 Remote racking and remote switching should be considered and used on all equipment that is
capable of accommodating this type of device. The remote racking devices (RRD) and remote
switching equipment are to be supplied by the proponent. When racking and switching is not
being performed remotely, proper personal protective equipment (PPE) as per section 8.0 shall
be worn for all tasks and bodily exposure to potential arc flash minimized (e.g., by standing as
far away from the equipment as possible).

*7.7 No modification, renovation, or change in relay protection settings shall take place unless MOC
procedures, in accordance with Saudi Aramco Safety Management Guide 05-001-2006 –
Management of Change which include review and update of the Incident Energy Analysis, are
completed.

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*7.8 Proponents, in coordination with the area Loss Prevention Division as needed, shall perform site
inspections and audits, at least annually, to ensure personnel conducting electrical work on
electrical equipment operated at higher than 240 volts are properly certified, properly following
procedures, proper engineering and administrative arc flash hazard exposure controls using the
required personal protective equipment (PPE), etc. Inspections and audits will be used as a
proactive means of identifying program gaps or hazards.

8.0 PERSONAL PROTECTIVE EQUIPMENT (PPE)

** 8.1 Arc-rated clothing meeting requirements of Supplement 2.721-2 shall be worn by anyone
entering substations.

**8.2 Everyday work clothing for Saudi Aramco and contractors who conduct electrical work on
electrical equipment operated at higher than 240 volts (e.g., Electrical System Operators,
Electricians, Power Operations and Utilities Department Technicians) shall be arc-rated
clothing that conforms to Supplement 2.721-3 Tables 1 and 2. In order to ensure adequate
ATPV protection for both Level A (0-1.2 cal/cm2) and Level B (greater than 1.2 – 12 cal/cm2),
the minimum ATPV value is 12 cal/cm2. The second level in the two-category system is
minimum 40 cal/cm2 Arc Flash Suit with associated protection as outlined in Supplement 2.721-
3 (Tables 1 and 2).

A phase-in period will allow proponents to budget for and procure new Arc-rated clothing to
meet the requirements of the revised G.I. One calendar year after the signature date of this GI,
PPE must meet the requirements of Supplement 2.721-3 Tables 1 and 2 All proponents will
need to adhere to the new PPE requirements by this deadline. PPE requirements listed in
Supplement 2.721-3 of this GI shall align with the CSM Part 1 - General Safety, Section 3.0 -
PPE Requirement.

*8.3 Saudi Aramco proponents, electrical support organizations, and contractor companies shall
provide a sufficient supply of arc-rated pants/shirts or three arc-rated coveralls. Proponents shall
determine what is sufficient for their workforce. Garments shall be replaced when visual
inspection shows irreparable damage or excessive wear and tear and replacement will be at the
discretion of the supervisor.

*8.4 An arc rated face shield shall be worn by anyone conducting electrical work on electrical
equipment operated at higher than 240 volts as per Supplement 2.721-2. Face shields without
an arc rating shall not be used when an arc flash hazard exists. The arc rating for face shields
shall be as per ASTM F 2178.

*8.5 Saudi Aramco and contractor personnel shall wear the proper arc rated clothing (e.g., arc flash
suit) and use the PPE listed in Supplement 2.721-2 when performing any task where there is a
possibility that an arc flash may occur or when working within the Arc Flash Boundary of
energized electrical equipment operated at higher than 240 volts (e.g., as noted on any posted
arc flash hazard warning sign).

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*8.6 Saudi Aramco proponents are responsible for procuring and installing at a minimum, one Arc
Flash Suit (as per Table 2) in each substation or electrical room where tasks are performed on
equipment with an Incident Energy Level higher than 12 cal/cm2.

*8.7 The capital project scope for new electrical equipment facilities (e.g., substation, electrical room)
shall include, at least one Arc Flash suit as described in 8.6 above.

*8.8 The user shall inspect all personal protective equipment (PPE), including arc-rated clothing,
before each use. Inspect for the presence of damage, tears, excess moisture, dirt, or hydrocarbon
buildup. Moisture and contaminants negatively affect arc rated performance.

*8.9 Polyester, polyester-cotton blends, nylon, nylon-cotton blends, rayon or other meltable
(thermoplastic) synthetic fabric shall not be worn under arc-rated clothing, due to the possibility
that melting clothing will increase the severity of a burn injury. However, an incidental amount
of elastic used on non-melting fabric underwear or socks is permitted. Non-Arc rated clothing
shall not be worn as an outer layer over arc rated clothing.

8.10 Arc-rated garments shall cover potentially exposed areas as completely as possible. Shirt sleeves
shall be fastened at the wrists, and shirts and coveralls shall be closed at the neck. Tight-fitting
arc-rated garments shall be avoided. Belts shall not contain any conductive materials.

8.11 PPE and arc-rated garments shall be stored in a manner that prevents physical damage and
damage or contamination from moisture, deteriorating agents, flammable materials, etc.

*8.12 Those altering or repairing arc-rated clothing must follow manufacturer’s instructions which
stipulate laundering and garment repair.

9.0 OTHER PROTECTIVE EQUIPMENT

*9.1 Personnel shall use insulated/insulating protective equipment and hand tools when conducting
electrical work on exposed electrical conductors or circuit parts, or when working within the
restricted approach boundary. Insulated tools shall be protected to avoid damage to the insulating
material.

9.2 Electrical insulated/insulating protective equipment and hand tools, such as the following, shall
be maintained in a safe working condition and stored in a manner to prevent damage:

 grounding equipment and test devices,


 hot sticks,
 rubber gloves, sleeves, and leather protectors,
 voltage test indicators,
 blanket and similar insulating equipment,

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 insulating mats and similar insulating equipment,


 protective barriers,
 external circuit breaker rack-out devices,
 safety grounding equipment,
 bypass jumpers, and
 insulated and insulating hand tools.

9.3 Only electrical testing equipment (e.g., digital multimeters and digital clamp meters) that have
been certified by a recognized third-party organization (e.g., Underwriters Laboratories [UL],
Council of Europe [CE]) in accordance with IEC 61010-1 shall be purchased and used.

9.4 Proponents shall develop and implement procedures to ensure that insulated/insulating protective
equipment, electrical testing equipment, and hand tools are periodically tested and/or
calibrated/labeled by a testing laboratory in accordance with the manufacturer’s
recommendations and/or internationally accepted standards.

9.5 The user shall visually inspect insulated/insulating protective equipment and hand tools before
each day’s use and immediately following any incident that could have caused damage. Any
electrical testing equipment that is damaged, malfunctioning, or has a calibration sticker that is
out-of-date, missing or not legible shall be removed from service and repaired/re-calibrated.
Insulating gloves shall be given an air test, along with the visual inspection.

10.0 TRAINING AND CERTIFICATION

*10.1 Personnel with potential exposure to Arc Flash hazards shall be trained and certified in accordance
with the requirements of the Saudi Aramco Safe Electrical System Operations Program, and shall
be familiar with the specific work procedures, and/or tests required. Unqualified persons shall not
be exposed to arc flash hazards. The Certification/Re-certification shall be conducted following
the intent of the Corporate “Certification/Re-Certification” guidelines as outlined in GI-1809.001.

*10.2 Saudi Aramco and Contractor employees who conduct electrical work/perform switching on
electrical equipment operated at higher than 240 volts, must possess a valid Saudi Aramco
Electrical Hazards Recognition (EHR) Certificate, resulting from the successful completion of BET
# 40057766 and BET # 40084962 (recertification).

*10.3 Electrical System Operators and Contractor (ESO’s) who operate switches, circuit breakers, fuses,
or any other method of making or breaking a circuit including racking-in/racking-out circuit
breakers and opening/closing grounding devices rated 400 volts and above are required to
successfully complete the Corporate Electrical System Operator Certification/Re-certification
(CESOR) test BET# 40033611. In addition, a successful completion of the field assessment test is
required in order to issue the CESOR certificate.

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*10.4 Nominated Electrical Technicians, Power Technicians and Contractors (Electrical Technicians) who
operate switches, circuit breakers, fuses, or any other method of making or breaking a circuit
including racking-in/racking-out circuit breakers and opening/closing grounding devices rated 400
volts and above for limited area are required to successfully complete the Corporate Electrical
System Operator Certification/Re-certification (CESOR) test BET# 40033611. In addition, a
successful completion of the field assessment test is required in order to issue the CESOR (limited)
certificate.

*10.5 Saudi Aramco and Contractor Nominated Electrical Technicians / Power Technicians who receive
or release clearances, test for potentials and, or apply/remove grounds on electrical equipment rated
at 1000 volts and above, must hold a valid Aramco Hazardous Duty Potential Testing
Certificate/Re-certification – BET # 40033612. In addition, a successful completion of the field
assessment test is required in order to issue the HDPT certificate.

**10.6 EHR Certified Field Operators are limited to only turning 480V breakers on and off, either at local
control panel or at the MCC. Operators must ensure that doors on breakers are closed and secured
prior to operating. These operators are strictly prohibited from racking-in/racking-out any MCC
Breaker(s). Electrical Hazard Recognition (e-learning) BET # 40059229 is required to ensure
adequate hazard awareness to conduct this task. Individual departments may develop additional
practices or procedures to cover their own specific requirements, but the minimums listed above
must be met. Division Heads shall issue operator certificates upon successful completion of EHR
course and associated exam. Certifications will only be issued once operator is deemed competent
and qualified to perform these limited electrical tasks, and is aware, through the training, of all
electrical hazards associated with these tasks, including working on and around energized high
voltage electrical equipment and fully understanding Arc Flash and Shock Boundaries and safe
working requirements. A sample Certificate is attached in Supplement 2.721-5 – Field Operator –
EHR Certificate.

**10.7 Electrical System Operators who may be required to issue work permits;
Effective January 1, 2016, In addition to the minimum requirements for Work Permit Issuers
described in G.I. 2.100 – Work Permit System; Electrical System Operators (Issuers) must
possess the following certifications before being allowed to issue work permits to receivers:
1. Electrical Hazard Recognition
2. Corporate ESO – Certification Test (CESOR)
Only ESO’s with valid certifications of EHR, CESOR, and SA Work Permit Issuer are allowed to
issue work permits.
*10.8 Electrical Technicians, Power Technicians, and Contractors (Electrical Technicians) who receive
work permits;

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Effective January 1, 2016, In addition to the minimum requirements for Work Permit
Receivers described in G.I. 2.100 – Work Permit System; Electrical Technicians, Power
Technicians, and Contractors (Electrical Technicians) who:

 receive or release clearances,


 test for potentials, and, or
 apply/remove grounds on electrical equipment rated at 1000 volts and above,
must possess the following certifications before being allowed to accept a permit:
1. Electrical Hazard Recognition
2. Hazardous Duty Potential Test (HDPT)

*10.9 All organizations must maintain records of their EHR, CESOR, CESOR (Limited) and HDPT
certified personnel. All certifications expire three years after the date of passing above tests.
Accordingly, participants must be recertified every three years.

All proponent departments must appoint a qualified Independent Examiner(s) for field testing. The
Independent Examiner must be a senior experienced and certified ESO/Operation Engineer and must
be a Certified Evaluator/Trainer (See BET #’s below). On the basis of Field Assessment results, the
proponent department Division Head/Superintendent may issue the CESOR, CESOR (Limited) and
HDPT certificate to the respective employee(s).

BET # 40011221 – Evaluator Certification


BET # 40006396 – Trainer Certification

For more details please refer to Safe Electrical System Operations Program on the following link:

http://tdonline.aramco.com.sa/Catalog/TrainingPath/TPathTemplate.aspx?TPath=688&page=250&str=105

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RECOMMENDED: ___________________________________ DATE: ______________


Vice President, Power Systems

CONCUR: _______________________________________ DATE: ______________


Manager, Loss Prevention Department

CONCUR: _______________________________________ DATE: ______________


General Manager, Training and Career Development

APPROVED : _______________________________________ DATE: ______________


Senior Vice President, Upstream

APPROVED : _______________________________________ DATE: ______________


Senior Vice President, Downstream

APPROVED : _______________________________________ DATE: ______________


Service Line Head, Technical Services

APPROVED: _______________________________________ DATE: ______________


Service Line Head, Operations & Business Services

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**SUPPLEMENT 2.721-1 – SPECIFIC EXAMPLES OF ARC FLASH MITIGATION CONTROLS

Appendix “A”-, Recommended Arc Flash Mitigation Solutions

ENGINEERING CONTROLS

1. Energy Reducing Maintenance Switch (ERMS): Reduces arc flash incident energy by temporary
reducing clearing time during maintenance or live work activities. Two application examples are
provided as follows:
a. Reduce Arc Flash Incident Energy in any particular LV MCC: This could be achieved by
enabling the ERMS at the upstream low voltage feeder circuit breaker.
b. Reduce Arc Flash Incident Energy at the line side (incomer’s cubicle) of a LV Switchgear:
This could be achieved by enabling the ERMS associated with the microprocessor digital
protective relay at the upstream HV feeder circuit breaker.

ERMS must be turned off after live work has been completed to avoid possible protection miss-
coordination and subsequent loss of selectively during a fault condition. ERMS’s overcurrent
pickup setting must be set lower than the available arcing current with no intentional delay in
order to effectively reduce arc flash incident energy. ERMS shall be equipped with provisions to
apply lockout/tagout procedures.

2. Zone Selective Interlock (ZSI) for LV Switchgears: Reduces arc flash incident energy by
reducing clearing time when fault occurs at the bus side (feeder/tie cubicles) of low voltage
switchgears. This scheme utilizes commination signals between the incomer and feeder trip units
to trip the incomer breaker with no intentional delay when the fault is located on the bus side.
Most ZSI schemes are effective only for ground fault and short time functions. Therefore, an
engineering analysis must be conducted to assure that the available arcing current is greater than
the short time pick setting. In addition, ZSI does not reduce arc flash incident energy for line side
faults.

3. Remote Racking Device (RRD): Reduces level of risk exposure to the arc flash incident energy
by increasing working distance during racking operations. Various universal Remote Racking
Devices are available in the market that could be utilized to remotely rack in/out low and high
voltage circuit breakers. All qualified personnel should be trained on operating, maintaining and
calibrating RRD by the vendor.

4. Remote Switching Capability (RSC): Reduces level of risk exposure to the arc flash energy by
increasing working distance during switching operations. RSC must be installed outside the pre-
calculated arc flash boundary. Remote switches shall be hardwired to all circuit breakers and
shall be equipped with provisions to apply lockout/tagout procedures.

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a. Portable Remote Switching Control Switches that are operable outside of the Arc Flash
Boundary

5. Fast acting clearing devices, current limiting fuses, circuit breakers with adjustable trip settings,
use of digital relays vs. mechanical overcurrent relays.

6. Relay design – transformer differential protection – virtual main configuration and optical
relaying.

7. System grounding – impedance grounding vs. solidly grounded – i.e. – high resistance
grounding.

8. Arc resistant switchgear – passive and active Arc-Resistant Switchgear.

ADMINISTRATIVE CONTROLS

1. Training

2. Qualification requirements

3. Work Practices

4. Planning tools

5. Lockout/Tagout

6. Auditing Procedures

7. Maintenance and Reliability Improvement Programs

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**SUPPLEMENT 2.721-2 –ARC FLASH PPE REQUIREMENTS

Arc flash PPE (meeting requirements of Supplement 2.721-3) are as follows:

Arc Flash Incident


PPE Requirements
Level Energy

 Arc rated clothing, long sleeved shirt and pants, or


coverall (12 cal/cm2 minimum)
 Aramco approved:
Less than or
o Safety glasses
Level A equal to 1.2
o Hard hat
cal/cm2
o Safety Footwear
 Hearing protection
 Heavy-duty leather gloves
 All of the above, plus
Greater than  Arc-rated face shield that covers the face, neck, and chin
Level B 1.2 to 12 area, and an arc-rated balaclava, or an arc-rated flash suit
cal/cm2 hood
 Rubber insulating gloves with leather protectors
 Arc rated clothing, long sleeved shirt and pants, or
coverall, or arc flash suit (40 cal/cm2 minimum)
 Arc rated arc flash suit hood
 Arc rated gloves
Greater than
 Arc rated hard hat liner
Level C 12 to 40
cal/cm2  Hearing protection
 Aramco approved:
o Safety glasses
o Hard hat
o Safety Footwear

Greater DANGER, Energized Work not allowed! Equipment must


DANGER
than 40 cal/2 be placed in an electrically safe work condition.

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**SUPPLEMENT 2.721-3 – ARC-RATED CLOTHING AND PPE SPECIFICATIONS

NOTE - A phase-in period of one year from the date of signing of this GI, will allow affected parties to
budget for and procure new Arc-rated clothing to meet the requirements of the revised G.I.

TABLE 1 – EVERYDAY WORK CLOTHING FOR ELECTRICAL WORKERS


*One-year phase in period from date of GI signing to meet this criteria

Garment Fabric Style and


Fabric Fabric Weight Garment ATPV
Type Weave

DuPont NOMEX® 220g/m2


Shirt Fritsche DPF Power® 12cal/cm2
ComfortTM

DuPont NOMEX® 220g/m2


Pants Fritsche DPF Power® 12cal/cm2
ComfortTM

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TABLE 2 – ARC FLASH SUIT


(For use when conducting electrical work on energized electrical equipment above 12 cal/cm2)

Fabric Style Fabric Garment


Garment Type Fabric
and Weave Weight ATPV

Salisbury by Honeywell – HRC4 Shell – Inherently FR 11.0 oz/yd2 44


ProWear Arc Flash Suit Twaron/Kynol Aramid Fabric (385 g/m2) cal/cm2
(consisting of Coat, Bib-overall,
Liner: DuPont
Hood with Task Lighting)
NOMEX IIIA –
Para Aramid Blend

OR: (both products will be carried in Saudi Aramco Purchasing System) for further procurement
information, contact Power Systems Engineering

Oberon Arc 40 Series Arc Flash


DuPont NOMEX®
Suit (consisting of Coat, Bib- Inherently FR 10.7 oz/yd2 43
100% Meta-
overall, Hood c/w Ventilation Aramid Fabric (363 g/m2) cal/cm2
Aramid)
System, and LED Task Light)

**SUPPLEMENT 2.721-4 – ARC-RATED CLOTHING - GENERAL LAUNDERING GUIDELINES

Garments constructed of NOMEX can be washed and dried by conventional home method
followed by hand ironing, if desired. No special technology is needed for home laundering.

If home laundering does not remove contaminants or contaminant build-up, garments can be
periodically dry cleaned or commercially laundered.

 Wash in temperatures between 140 degrees F (60C) – max. 165 degrees F (74C)
 Use high surfactant, low alkaline detergents (standard off-the-shelf laundry detergents
 Avoid water softeners and starch
 Thoroughly rinse all garments after washing
 No Chlorine based, or Hydrogen Peroxide-based bleaches – they will affect the rating of the
garment
 Partially tumble dry and hang to dry
 Pressing will not adversely affect garment

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DuPont, the manufacturer of the NOMEX fabric, has produced a detailed Laundering Guide covering all
aspects of laundering NOMEX Aramid Fibers. It contains detailed guidelines for:

- Commercial Laundering
- Home Laundering
- Dry Cleaning
- Removing Spots and other Non-Standard Contaminants

For full details regarding laundering of NOMEX products, see:

www2.dupont.com/Personal_Protection/en_US/assets/downloads/nomex/h71603launderingguidefornomexaramidfiber.p
df

Use, care and maintenance of all arc rated garments should follow the following standards.

ASTM F1449 — Standard Guide for Industrial Laundering of Flame, Thermal, and Arc Resistant Clothing

ASTM F2757 — Standard Guide for Home Laundering Care and Maintenance of Flame, Thermal and Arc
Resistant Clothing

NFPA 2113 — Standard on Selection, Care, Use, and Maintenance of Flame-Resistant Garments for
Protection of Industrial Personnel Against Flash Fire

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**SUPPLEMENT 2.721-5 – FIELD OPERATOR – EHR CERTIFICATE

FIELD OPERATOR
ELECTRICAL HAZARD RECOGNITION (EHR)
CERTIFICATE

The individual list below has successfully completed all of the educational and testing requirements of
the Saudi Aramco Electrical Hazard Recognition program (EHR), a component of the Saudi Aramco
Safe Electrical Systems Operation – Training and Certification Program.

The program consists of:

1) General Hazards Associated with Electrical Work


2) Arc Flash and Shock Protection and PPE Selection, and
3) Safe Electrical Work Practices

The EHR course provides consists of educational materials designed to ensure a sufficient level of
awareness level knowledge associated with the Operational task of turning on and off, 480V or less,
breakers, either at local control panels or at MCC’s in substations.

Operator has completed review required EHR Modules, and has achieved a minimum passing score of
80% on the associated exam. The re-certification frequency for this course is 3 years.

DATE OF CERTIFICATION
NAME OF OPERATOR
CERTIFICATION EXPIRES

I do hereby deem the above-mentioned operator, qualified to operate (turn-on/off) 480V or less breakers
either at the local control panel or at an MCC in a substation

DIVISION HEAD NAME/DEPT./LOCATION SIGNATURE

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