Electric Arc-Flash Injury Reduction Program Herman O. Kemp Electrical Safety Consultant Safety Program Consultants, LLC.

Electric Arc-Flash Electric Arc-Flash Injury Reduction Injury Reduction

ProgramProgram

Herman O. KempHerman O. KempElectrical Safety ConsultantElectrical Safety Consultant

Safety Program Consultants, LLCSafety Program Consultants, LLC

22

Arc-Flash Hazard Arc-Flash Hazard StudyStudy Thermal BurnThermal Burn Voltage RangeVoltage Range Subjective AnalysisSubjective Analysis

– Limited knowledge of hazardLimited knowledge of hazard– Too much or too little hazard controlToo much or too little hazard control

Quantitative AnalysisQuantitative Analysis– Hazard energy incident levelsHazard energy incident levels– Establishes boundaries at onset of 2Establishes boundaries at onset of 2ndnd

degree burndegree burn

33

Energy for 2Energy for 2ndnd Degree Degree BurnBurn

Incident energy = 1.2 cal/cmIncident energy = 1.2 cal/cm22 at at boundaryboundary

1.2 cal/cm1.2 cal/cm22 is energy level for onset is energy level for onset of second degree burnof second degree burn

44

Arc-Flash Injury Arc-Flash Injury Reduction ProgramReduction Program

Eliminate HazardEliminate Hazard– De-energize live parts before workingDe-energize live parts before working– Lower incident energy to safe levelLower incident energy to safe level

Provide Protective MeasuresProvide Protective Measures– Prohibit clothing that meltsProhibit clothing that melts– Wear FR clothingWear FR clothing– Use Personal Protective Equipment Use Personal Protective Equipment

(PPE)(PPE) Measures will not eliminate all Measures will not eliminate all

possible injuriespossible injuries

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Program ElementsProgram Elements

Arc-Flash Hazard AnalysesArc-Flash Hazard Analyses Engineering ProcessesEngineering Processes Combination Daily-Wear and Combination Daily-Wear and

Checkout FR Clothing ProgramCheckout FR Clothing Program Arc-Flash PPEArc-Flash PPE Post Warning SignsPost Warning Signs Arc-Flash Injury Reduction Arc-Flash Injury Reduction

Employee TrainingEmployee Training

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Program Case Study Program Case Study AssumptionsAssumptions Arc-Flash Hazard Analysis Arc-Flash Hazard Analysis

CompleteComplete– Incident energies knownIncident energies known– Arc-flash protection boundaries knownArc-flash protection boundaries known

FR clothing policy adoptedFR clothing policy adopted Electrical Equipment Performs as Electrical Equipment Performs as

Designed, i.e. overcurrent devices Designed, i.e. overcurrent devices operate at specified pointsoperate at specified points

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Engineering ProcessesEngineering Processes

Configuration Control of electrical Configuration Control of electrical components impacting arc-flash components impacting arc-flash hazardshazards

Breaker Maintenance ProgramBreaker Maintenance Program Updates of Arc-Flash Hazard Updates of Arc-Flash Hazard

AnalysesAnalyses

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Arc-Flash Hazard Arc-Flash Hazard TrainingTraining Employees who may be in arc-Employees who may be in arc-

flash hazardous areasflash hazardous areas Employees participating in Daily-Employees participating in Daily-

Wear ProgramWear Program Managers/Supervisors of the Managers/Supervisors of the

above employeesabove employees

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Arc-Flash Hazard Arc-Flash Hazard Training Training (continued)(continued)

Course ContentCourse Content– The arc-flash hazardThe arc-flash hazard– Configuration control on electrical Configuration control on electrical

componentscomponents– Breaker maintenanceBreaker maintenance– FR clothing and PPE requirementsFR clothing and PPE requirements– FR clothing care instructionsFR clothing care instructions

1010

Arc-Flash WarningArc-Flash Warning

National Electric Code– Switchboards, panelboards, industrial

control panels, and motor control centers

No guidance on end device terminations

Alternative Forms of Communication– Substations– Transmission and Distribution

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Sample Warning LabelSample Warning Label

WARNING !Arc Flash and Shock HazardAppropriate PPE Required

24 inch Flash Hazard Boundary3 cal/cm2 Flash Hazard at 18 inchesII PPE Level

480 VAC Shock Hazard when Cover is removed

12 inch Minimum Approach - 500 V Class 00 Gloves

Equipment Name: Slurry Pump Starter

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FR Clothing ProgramsFR Clothing Programs

Daily-Wear FR Clothing ProgramDaily-Wear FR Clothing Program– AdvantagesAdvantages

Eliminates lost productivity-change timeEliminates lost productivity-change time Eliminates flammable clothing on Eliminates flammable clothing on

employeesemployees– Routinely be exposed to arc-flash hazardsRoutinely be exposed to arc-flash hazards– Respond immediately conditions in arc-flash Respond immediately conditions in arc-flash

hazardous areashazardous areas FR clothing does not increase extent of FR clothing does not increase extent of

injuries if an arc-flash occursinjuries if an arc-flash occurs FR clothing is designed to limit the FR clothing is designed to limit the

severity of burns from an arc-flashseverity of burns from an arc-flash

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FR Clothing Programs FR Clothing Programs (continued)(continued)

Daily-Wear FR Clothing Program Daily-Wear FR Clothing Program (continued)(continued)

– DisadvantagesDisadvantages FR clothing initial and maintenance FR clothing initial and maintenance

costscosts Program administrative costsProgram administrative costs Lack of employee acceptanceLack of employee acceptance Heat stress concernsHeat stress concerns

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FR Clothing Programs FR Clothing Programs (continued)(continued)

Checkout FR Clothing ProgramCheckout FR Clothing Program– AdvantagesAdvantages

Lower costs for clothing and administrationLower costs for clothing and administration Fewer heat stress complaintsFewer heat stress complaints FR clothing does not increase extent of injuries FR clothing does not increase extent of injuries

if an arc-flash occursif an arc-flash occurs FR clothing is designed to limit the severity of FR clothing is designed to limit the severity of

burns from an arc-flashburns from an arc-flash

– DisadvantagesDisadvantages FR Clothing not readily available for emergency FR Clothing not readily available for emergency

workwork Lost Productivity during checkout/dressingLost Productivity during checkout/dressing The “5-minute” job without FR clothingThe “5-minute” job without FR clothing

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FR Clothing Programs FR Clothing Programs (continued)(continued)

Combination Daily-Wear and Combination Daily-Wear and Checkout FR Clothing ProgramCheckout FR Clothing Program– Daily-Wear: routinely exposedDaily-Wear: routinely exposed– Checkout: intermittently exposed Checkout: intermittently exposed

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Combination FR Clothing Combination FR Clothing ProgramProgram

FR GarmentsFR Garments– ASTM StandardsASTM Standards– Arc Thermal Performance Value Arc Thermal Performance Value

(ATPV)(ATPV)– Number of Garments per employeeNumber of Garments per employee– FR Tee ShirtsFR Tee Shirts– Inclement Weather GarmentsInclement Weather Garments

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Direct Purchase of FR ClothingDirect Purchase of FR Clothing– Contract with clothing manufacturerContract with clothing manufacturer– Sizing garments to individualsSizing garments to individuals– Care of garmentsCare of garments– Replacement of garmentsReplacement of garments

Combination FR Clothing Combination FR Clothing Program Program (continued)(continued)

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Combination FR Clothing Combination FR Clothing Program Program (continued)(continued)

Leasing of FR ClothingLeasing of FR Clothing– Vendor owns garmentsVendor owns garments– Vendor sizes garments to individualsVendor sizes garments to individuals– Vendor provides laundry serviceVendor provides laundry service– Vendor provides for garment repairVendor provides for garment repair– Vendor replaces garment as neededVendor replaces garment as needed

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Daily-Wear FR Clothing Daily-Wear FR Clothing ProgramProgram

Program ParticipantsProgram Participants– IndividualsIndividuals

Electricians/electrical techniciansElectricians/electrical technicians Linemen/line techniciansLinemen/line technicians Instrument mechanicsInstrument mechanics Electrical engineersElectrical engineers Substation/plant operatorsSubstation/plant operators ManagersManagers Others qualified to perform electrical work Others qualified to perform electrical work

routinelyroutinely

2020

Must Wear Daily-Wear FR ClothingMust Wear Daily-Wear FR Clothing– Reporting to workReporting to work– Receiving daily work assignmentReceiving daily work assignment– After callout for emergencyAfter callout for emergency

Daily-Wear FR Clothing Not Required Daily-Wear FR Clothing Not Required When Assigned To Non-Exposure Work When Assigned To Non-Exposure Work LocationsLocations

Long Sleeved Shirt-Sleeves down and Long Sleeved Shirt-Sleeves down and Buttoned at CuffButtoned at Cuff

Daily-Wear FR Clothing Daily-Wear FR Clothing Program Program (continued)(continued)

2121

Removal of Long sleeved FR ShirtRemoval of Long sleeved FR Shirt– Wear FR tee shirtWear FR tee shirt– Working outside of arc flash boundariesWorking outside of arc flash boundaries– Working on de-energized parts (electrically Working on de-energized parts (electrically

safe condition established)safe condition established)– Implement LOTOImplement LOTO– Verify part to be work is within LOTO boundaryVerify part to be work is within LOTO boundary– Test for the absence of nominal voltageTest for the absence of nominal voltage– Install temporary protective grounds as requiredInstall temporary protective grounds as required– Install barricade to other energized exposed partsInstall barricade to other energized exposed parts– Verify area is not within another arc-flash Verify area is not within another arc-flash

boundaryboundary– Test for absence of voltage upon returning to Test for absence of voltage upon returning to

vacated areavacated area

Daily-Wear FR Clothing Daily-Wear FR Clothing Program Program (continued)(continued)

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Checkout FR Clothing Checkout FR Clothing ProgramProgram

Program ParticipantsProgram Participants– ConstructionConstruction– ContractorsContractors– VendorsVendors– Other employees who intermittently Other employees who intermittently

have exposure to arc-flash hazardshave exposure to arc-flash hazards

2323

Arc-Flash Hazard PPEArc-Flash Hazard PPE

Establish Arc-Flash Protection BoundaryEstablish Arc-Flash Protection Boundary– Working on or near exposed energized partsWorking on or near exposed energized parts– Tasks listed in Table 130.7(C)(9)(a), “Hazard Tasks listed in Table 130.7(C)(9)(a), “Hazard

Risk Category Classifications,” National Fire Risk Category Classifications,” National Fire Protection Association 70E, “Standard for Protection Association 70E, “Standard for Electrical Safety in the Workplace”Electrical Safety in the Workplace”

Designate BoundaryDesignate Boundary– Distance where calculated incident energy is Distance where calculated incident energy is

1.2 cal/cm1.2 cal/cm22 (onset of 2 (onset of 2ndnd degree burn) degree burn)– Mark boundary to prohibit entry of Mark boundary to prohibit entry of

unauthorized employeesunauthorized employees Conduct Pre-Job Safety BriefingConduct Pre-Job Safety Briefing

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Arc-Flash Hazard PPE Arc-Flash Hazard PPE (continued)(continued)

Required PPE based on level of incident Required PPE based on level of incident energy at the work location (18 inches)energy at the work location (18 inches)

Common Arc-Flash PPECommon Arc-Flash PPE– Hard hatHard hat– Safety glasses with side shieldsSafety glasses with side shields– Hearing protectionHearing protection– Gloves: leather, FR, rubber voltage rated Gloves: leather, FR, rubber voltage rated

with protectorswith protectors– Industrial grade work shoesIndustrial grade work shoes– Arc-flash rated face shieldArc-flash rated face shield– Arc-flash suit with hoodArc-flash suit with hood

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Arc-Flash Hazard PPE Arc-Flash Hazard PPE (continued)(continued)

Electrically Safe Condition Electrically Safe Condition EstablishedEstablished– May remove arc-flash PPEMay remove arc-flash PPE– Continued use of PPE for any other Continued use of PPE for any other

hazardshazards– Daily-Wear FR clothing requiredDaily-Wear FR clothing required– Checkout FR clothing may be Checkout FR clothing may be

removedremoved

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Arc-Flash Injury Reduction Arc-Flash Injury Reduction Program IssuesProgram Issues

Heat StressHeat Stress– Daily-wear FR clothing programDaily-wear FR clothing program– Arc-flash suit and hoodArc-flash suit and hood

VisibilityVisibility– Arc-flash face shieldArc-flash face shield– Arc-flash suit hoodArc-flash suit hood

Cold WeatherCold Weather– Thermal underwearThermal underwear– Non-FR garments worn over FR clothingNon-FR garments worn over FR clothing– FR garments within arc-flash boundariesFR garments within arc-flash boundaries

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Arc-Flash Injury Reduction Arc-Flash Injury Reduction Program Issues Program Issues (continued)(continued)

Garments Worn Under FR ClothingGarments Worn Under FR Clothing– Underwear (tee shirts, shorts, panties, Underwear (tee shirts, shorts, panties,

bras, and thermals)bras, and thermals) Natural Fiber (wool, cotton, and silk)Natural Fiber (wool, cotton, and silk) FR MaterialsFR Materials

– Non-FR work clothes, i.e., shirt/pant, Non-FR work clothes, i.e., shirt/pant, coverallscoveralls

– FR tee shirtFR tee shirt

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Arc-Flash Injury Arc-Flash Injury Reduction ProgramReduction Program Calculate the HazardsCalculate the Hazards Eliminate the HazardsEliminate the Hazards Provide Protective MeasuresProvide Protective Measures Measures may not eliminate all Measures may not eliminate all

possible injuriespossible injuries

The author of this presentation does not warrant theaccuracy or content of this work. The work is supplied only “as is.”