Prevent Dangerous Shocks with an Assured Equipment Grounding Conductor Program
- Brian Hall
- Nov 27, 2024
- 3 min read
Introduction: The Cost of Overlooking the Basics
Temporary power cables are extensively used during construction or other temporary projects where it is not feasible to implement ground fault circuit interruptors (“GFCI”). Improper assembly or testing, however, can lead to tragic consequences.
I was working as a maintenance electrician for a large metal forming company in Northeast Ohio. I recall being briefed about an accident in which a die setter had been electrocuted because someone had wired a 480-volt extension cable incorrectly. He had placed one of the phase conductors on the ground terminal during assembly. This simple mistake ultimately resulted in a tragic accident.
Both NFPA 70E and OSHA recognize the dangers associated with these extension cables. This is why employers, who use extension cables energized above 120 volts, are required to institute something called an Assured Equipment Grounding Conductor program (AEGC) or use a GFCI. The program is designed to prevent accidents just like the one I described. An AEGCP is a safety procedure that prevents electrical shock by ensuring temporary electrical cords, non-permanent receptacles, and connected equipment have properly functioning grounding conductors and connectors, and have been recently tested.
Despite its importance, as I travel the country conducting electrical safety training, I rarely see compliance with this standard. So, let’s demystify the Assured Equipment Grounding Conductor program (AEGC) and help you get started.
What Is an Assured Equipment Grounding Conductor Program?
An AEGC program is a safety protocol required by OSHA and recognized by NFPA 70E. It ensures that temporary power cords—like extension cables used for tools or machinery—are properly grounded to protect workers from electrical shocks and electrocutions.
By regularly testing the continuity of ground conductors and verifying their correct connection, an AEGC program minimizes risks associated with temporary power systems. This is especially important in scenarios involving higher voltages, where ground fault circuit interrupters (GFCIs) may not be practical.
Why an AEGC Program Matters
Practical Applications
AEGC programs are essential in environments where temporary power is used, such as:
Industrial Outages: Plants often rely on temporary power systems during maintenance shutdowns or outages.
Welding Operations: High-voltage cables are commonly used to power portable welding equipment.
Construction Sites: While many construction sites use GFCIs for lower voltages, higher-voltage systems often require an AEGC program for compliance and safety.
In these applications, the alternative to an AEGC program—a 480-volt GFCI—can be impractical or unavailable, making this program a necessity.
A Program Designed to Save Lives
Mistakes, such as wiring a phase conductor to the ground terminal, may seem minor but can have catastrophic outcomes. An AEGC program establishes clear testing and inspection protocols to prevent such errors, ensuring that ground conductors are continuous, properly connected, and safe for use.
How to get started with an AEGC Program
1. Written Description
Regulatory Requirement:OSHA 1910.304(b)(3)(ii)(C) and NFPA 70E mandate a documented and accessible program.
What You Need to Do:
Create a formal AEGC program.
Integrate it into your broader electrical safety plan.
Ensure employees can access it.
2. Competent Personnel
Regulatory Requirement:Qualified individuals must oversee the program to ensure compliance.
What You Need to Do:
Identify a person with the authority and knowledge to manage and enforce the program. Make sure they are properly trained
3. Testing and Inspections
Regulatory Requirement:
Test grounding conductor continuity and terminal attachment.
Inspect equipment before first use, after repairs, after incidents, and every three months.
Perform daily visual inspections for defects.
What You Need to Do:
Develop and follow a testing protocol, covering:
Continuity and terminal attachment of grounding conductors.
Schedule regular inspections:
Before use.
After repairs or damage-causing incidents.
At three-month intervals.
Train employees to conduct daily visual inspections before equipment use.
4. Record-Keeping
Regulatory Requirement:
Maintain documented results of testing and inspections.
What You Need to Do:
Record all testing and inspection data.
Use a color-coded tagging system to mark tested equipment. For example:
Winter: White tape
Spring: Green tape
Summer: Red tape
Fall: Orange tape
Addressing Common Misconceptions
When Is an AEGC Program Required?
An AEGC program or GFCI is required for temporary power cables operating above 120 volts. For higher voltages, such as 480-volt systems, an AEGC program ensures compliance and worker safety.
Does This Apply to All Extension Cords?
Although employers can choose to use the AEGC for lower-voltage applications, such as 120-volts, GFCIs are the generally preferred method to ensure safety. Many employers choose to use battery operated power tools in which case extension cords are not needed.
Conclusion: Proactive Safety Saves Lives
An Assured Equipment Grounding Conductor program is more than a compliance requirement—it’s a lifesaving tool. By implementing this program, you protect your workers from preventable electrical hazards and ensure a safer workplace. An AEGC program provides a structured, reliable approach to electrical safety. Don’t wait for an incident to occur—take action today to safeguard your team.