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

2. 2 Arc-Flash Hazard Study Thermal Burn Thermal Burn Voltage Range Voltage Range Subjective Analysis Subjective Analysis –Limited knowledge of hazard –Too much or too little hazard control Quantitative Analysis Quantitative Analysis –Hazard energy incident levels –Establishes boundaries at onset of 2 nd degree burn

3. 3 Energy for 2 nd Degree Burn Incident energy = 1.2 cal/cm 2 at boundary Incident energy = 1.2 cal/cm 2 at boundary 1.2 cal/cm 2 is energy level for onset of second degree burn 1.2 cal/cm 2 is energy level for onset of second degree burn

4. 4 Arc-Flash Injury Reduction Program Eliminate Hazard Eliminate Hazard –De-energize live parts before working –Lower incident energy to safe level Provide Protective Measures Provide Protective Measures –Prohibit clothing that melts –Wear FR clothing –Use Personal Protective Equipment (PPE) Measures will not eliminate all possible injuries Measures will not eliminate all possible injuries

5. 5 Program Elements Arc-Flash Hazard Analyses Arc-Flash Hazard Analyses Engineering Processes Engineering Processes Combination Daily-Wear and Checkout FR Clothing Program Combination Daily-Wear and Checkout FR Clothing Program Arc-Flash PPE Arc-Flash PPE Post Warning Signs Post Warning Signs Arc-Flash Injury Reduction Employee Training Arc-Flash Injury Reduction Employee Training

6. 6 Program Case Study Assumptions Arc-Flash Hazard Analysis Complete Arc-Flash Hazard Analysis Complete –Incident energies known –Arc-flash protection boundaries known FR clothing policy adopted FR clothing policy adopted Electrical Equipment Performs as Designed, i.e. overcurrent devices operate at specified points Electrical Equipment Performs as Designed, i.e. overcurrent devices operate at specified points

7. 7 Engineering Processes Configuration Control of electrical components impacting arc-flash hazards Configuration Control of electrical components impacting arc-flash hazards Breaker Maintenance Program Breaker Maintenance Program Updates of Arc-Flash Hazard Analyses Updates of Arc-Flash Hazard Analyses

8. 8 Arc-Flash Hazard Training Employees who may be in arc-flash hazardous areas Employees who may be in arc-flash hazardous areas Employees participating in Daily-Wear Program Employees participating in Daily-Wear Program Managers/Supervisors of the above employees Managers/Supervisors of the above employees

9. 9 Arc-Flash Hazard Training (continued) Course Content Course Content –The arc-flash hazard –Configuration control on electrical components –Breaker maintenance –FR clothing and PPE requirements –FR clothing care instructions

10. 10 Arc-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

11. 11 Sample Warning Label

12. 12 FR Clothing Programs Daily-Wear FR Clothing Program Daily-Wear FR Clothing Program –Advantages Eliminates lost productivity-change time Eliminates lost productivity-change time Eliminates flammable clothing on employees Eliminates flammable clothing on employees –Routinely be exposed to arc-flash hazards –Respond immediately conditions in arc-flash hazardous areas FR clothing does not increase extent of injuries if an arc-flash occurs FR clothing does not increase extent of injuries if an arc-flash occurs FR clothing is designed to limit the severity of burns from an arc-flash FR clothing is designed to limit the severity of burns from an arc-flash

13. 13 FR Clothing Programs (continued) Daily-Wear FR Clothing Program (continued) Daily-Wear FR Clothing Program (continued) –Disadvantages FR clothing initial and maintenance costs FR clothing initial and maintenance costs Program administrative costs Program administrative costs Lack of employee acceptance Lack of employee acceptance Heat stress concerns Heat stress concerns

14. 14 FR Clothing Programs (continued) Checkout FR Clothing Program Checkout FR Clothing Program –Advantages Lower costs for clothing and administration Lower costs for clothing and administration Fewer heat stress complaints Fewer heat stress complaints FR clothing does not increase extent of injuries if an arc-flash occurs FR clothing does not increase extent of injuries if an arc-flash occurs FR clothing is designed to limit the severity of burns from an arc-flash FR clothing is designed to limit the severity of burns from an arc-flash –Disadvantages FR Clothing not readily available for emergency work FR Clothing not readily available for emergency work Lost Productivity during checkout/dressing Lost Productivity during checkout/dressing The “5-minute” job without FR clothing The “5-minute” job without FR clothing

15. 15 FR Clothing Programs (continued) Combination Daily-Wear and Checkout FR Clothing Program Combination Daily-Wear and Checkout FR Clothing Program –Daily-Wear: routinely exposed –Checkout: intermittently exposed

16. 16 Combination FR Clothing Program FR Garments FR Garments –ASTM Standards –Arc Thermal Performance Value (ATPV) –Number of Garments per employee –FR Tee Shirts –Inclement Weather Garments

17. 17 Direct Purchase of FR Clothing Direct Purchase of FR Clothing –Contract with clothing manufacturer –Sizing garments to individuals –Care of garments –Replacement of garments Combination FR Clothing Program (continued)

18. 18 Combination FR Clothing Program (continued) Leasing of FR Clothing Leasing of FR Clothing –Vendor owns garments –Vendor sizes garments to individuals –Vendor provides laundry service –Vendor provides for garment repair –Vendor replaces garment as needed

19. 19 Daily-Wear FR Clothing Program Program Participants Program Participants –Individuals Electricians/electrical technicians Electricians/electrical technicians Linemen/line technicians Linemen/line technicians Instrument mechanics Instrument mechanics Electrical engineers Electrical engineers Substation/plant operators Substation/plant operators Managers Managers Others qualified to perform electrical work routinely Others qualified to perform electrical work routinely

20. 20 Must Wear Daily-Wear FR Clothing Must Wear Daily-Wear FR Clothing –Reporting to work –Receiving daily work assignment –After callout for emergency Daily-Wear FR Clothing Not Required When Assigned To Non-Exposure Work Locations Daily-Wear FR Clothing Not Required When Assigned To Non-Exposure Work Locations Long Sleeved Shirt-Sleeves down and Buttoned at Cuff Long Sleeved Shirt-Sleeves down and Buttoned at Cuff Daily-Wear FR Clothing Program (continued)

21. 21 Removal of Long sleeved FR Shirt Removal of Long sleeved FR Shirt –Wear FR tee shirt –Working outside of arc flash boundaries –Working on de-energized parts (electrically safe condition established) –Implement LOTO –Verify part to be work is within LOTO boundary –Test for the absence of nominal voltage –Install temporary protective grounds as required –Install barricade to other energized exposed parts –Verify area is not within another arc-flash boundary –Test for absence of voltage upon returning to vacated area Daily-Wear FR Clothing Program (continued)

22. 22 Checkout FR Clothing Program Program Participants Program Participants –Construction –Contractors –Vendors –Other employees who intermittently have exposure to arc-flash hazards

23. 23 Arc-Flash Hazard PPE Establish Arc-Flash Protection Boundary Establish Arc-Flash Protection Boundary –Working on or near exposed energized parts –Tasks listed in Table 130.7(C)(9)(a), “Hazard Risk Category Classifications,” National Fire Protection Association 70E, “Standard for Electrical Safety in the Workplace” Designate Boundary Designate Boundary –Distance where calculated incident energy is 1.2 cal/cm 2 (onset of 2 nd degree burn) –Mark boundary to prohibit entry of unauthorized employees Conduct Pre-Job Safety Briefing Conduct Pre-Job Safety Briefing

24. 24 Arc-Flash Hazard PPE (continued) Required PPE based on level of incident energy at the work location (18 inches) Required PPE based on level of incident energy at the work location (18 inches) Common Arc-Flash PPE Common Arc-Flash PPE –Hard hat –Safety glasses with side shields –Hearing protection –Gloves: leather, FR, rubber voltage rated with protectors –Industrial grade work shoes –Arc-flash rated face shield –Arc-flash suit with hood

25. 25 Arc-Flash Hazard PPE (continued) Electrically Safe Condition Established Electrically Safe Condition Established –May remove arc-flash PPE –Continued use of PPE for any other hazards –Daily-Wear FR clothing required –Checkout FR clothing may be removed

26. 26 Arc-Flash Injury Reduction Program Issues Heat Stress Heat Stress –Daily-wear FR clothing program –Arc-flash suit and hood Visibility Visibility –Arc-flash face shield –Arc-flash suit hood Cold Weather Cold Weather –Thermal underwear –Non-FR garments worn over FR clothing –FR garments within arc-flash boundaries

27. 27 Arc-Flash Injury Reduction Program Issues (continued) Garments Worn Under FR Clothing Garments Worn Under FR Clothing –Underwear (tee shirts, shorts, panties, bras, and thermals) Natural Fiber (wool, cotton, and silk) Natural Fiber (wool, cotton, and silk) FR Materials FR Materials –Non-FR work clothes, i.e., shirt/pant, coveralls –FR tee shirt

28. 28 Arc-Flash Injury Reduction Program Calculate the Hazards Calculate the Hazards Eliminate the Hazards Eliminate the Hazards Provide Protective Measures Provide Protective Measures Measures may not eliminate all possible injuries Measures may not eliminate all possible injuries The author of this presentation does not warrant the accuracy or content of this work. The work is supplied only “as is.”