Arc Flash

SimonAugustine/Electrical/arcflash2019
Electrical Safety Hazards
When electrical systems break down, the consequences to personnel are:
Primary Hazards are;

•Electric shock
•Exposure to Arc-Flash
•Exposure to Arc-Blast
•Exposure to excessive light and sound energies
Secondary Hazards:
• May include burns, the release of toxic gases, molten metal, airborne debris and
shrapnel.
• Unexpected events can cause startled workers to lose their balance and fall from
ladders or jerk their muscles possibly causing whiplash or other injuries.
SimonAugustine/Electrical/arcflas
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Electric Shock:
•When personnel come in contact with energized conductors, they receive a shock with
current flowing through their skin, muscles and vital organs.
•The severity of the shock depends on the current’s path through the body, the current
intensity, and the duration of the contact.
•They may only experience a mild tingling sensation or it could result in serious injury or
death.
•As voltage levels increase, the effects of electric shock escalate.
•Current may also cause an erratic heartbeat known as ventricular fibrillation.
•If fibrillation occurs even briefly and goes untreated, the effects are usually fatal.
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Arc-Flash and Arc Blasts
•An Arc-Flash is an unexpected sudden release of heat and light energy produced by electricity
traveling through air, usually caused by accidental contact between live conductors.
•Temperatures at the arc terminals can reach or exceed 35,000 degrees Fahrenheit (F), or four
times the temperature of the sun’s surface. (= 19426.667 degrees Centigrade (C).
•The air and gases surrounding the arc are instantly heated and the conductors are vaporized
causing a pressure wave called an Arc Blast.
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Personnel directly exposed to an Arc-Flash and Arc-Blast events are subject to;
•third degree burns,
•possible blindness,
•shock,
•blast effects and
•hearing loss.
Even relatively small arcs can cause severe injury.
The secondary effect of arcs includes;

•toxic gases,
•airborne debris,
•and potential damage to electrical equipment, enclosures and raceways.
The high temperatures of the arc and the molten and vaporized metals quickly ignite any
flammable materials.
While these fires may cause extensive property damage and loss of production, the hazards
to personnel are even greater.
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Arc-Flash Metrics:
In order to determine the potential effects of an Arc-Flash, we need to understand

some basic terms.
•An Arc-Flash produces intense heat at the point of the arc.
•Heat energy is measured in units such as BTU’s, joules, and calories.
The following data provides a basis for measuring heat energy:
Since energy equals power multiplied by time, and power (wattage) is volts X
amps, we can see that calories are directly related to amperes, voltage, and
time.
The higher the current, voltage and time, the more calories produced.
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A Calorie is the amount of heat energy needed to raise the
temperature of one gram of water by one degree Celsius.
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• To define the magnitude of an Arc-Flash and the associated hazards, some
basic terms have been established:
• The amount of instantaneous heat energy released by an Arc-Flash is

generally called incident energy.
• It is usually expressed in calories per square centimeter (cal/cm2) and

defined as the heat energy impressed on an area measuring one square
centimeter (cm2).
• However, some calculation methods express the heat energy in Joules/cm2

• and can be converted to calories/cm2 by dividing by 4.1868.
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Use Personal Protective Equipment (PPE):
The proper selection and use of Personal Protective Equipment will significantly reduce the
risk of Arc-Flash and other electrical hazards to personnel working on energized equipment.
OSHA Part 1910.335 (a) states:
“…Employees working in areas where there are potential electrical hazards

shall be provided with, and shall use, electrical protective equipment that is appropriate for
the specific parts of the body to be protected and for the work to be performed.”
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Common Personal Protective - Equipment Terms and Definitions
Arc Thermal Performance Exposure Value (ATPV)
•The incident energy level (in cal/cm²) that can cause the onset of a second-degree burn as defined in
ASTM F 1959 Standard Test Method for Determining the Arc Thermal Performance Value of Materials
for Clothing.
•Personal Protective Equipment will be labeled with a calorie rating (Example: 11 cal/cm²).
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Electrical Safety
What is the best way to prevent the hazards of electricity?
• Work with valid Permit.
•Stop - Before Action
• Think - Risks/Hazards
• Options - LOTO
• Protection - Proper PPE
Avoiding energized circuits is the safest way!
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Why Electrical Safety Practices and Procedures?
1. An estimated 30,000 non-fatal electrical shock accidents occur each year

2. Over 600 people die from electrocution each year
3. Electrocution remains the fourth (4th) highest cause of industrial fatalities
4. Approximately 3000 flash burn incidents reported annually along with
approximately 350 deaths
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Work Requirements
Employer must develop and enforce safety-related work practices to prevent

electric shock or other injuries resulting from either direct or indirect electrical
contacts.
These safety related work practices could include:
• Energized Electrical Work Permit

• Pre-work Job Briefing
• Personal Protective Equipment
• Insulated Tools
• Written Safety Program
• Qualified Person Training
• Flash Hazard Labeling
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• Insulated tools are hand tools used by electricians, designed to protect
them against injury if they encounter an energized source.
• The use and application of insulated tools and PPE by electricians are
required by the OSHA (Occupational Safety and Health Administration).
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Why Use Insulated Tools
Insulated tools are important when conducting any electrical work that needs to be
carried out “hot” or on live circuits.
By using insulated tools, you will have significant protection in situations where it may
not be possible to disconnect the circuit e.g.:
•Working on a railway track that needs to remain active.

-Insulated tools are also very important in circumstances where you are
unaware that you are working on a live circuit.
-Without these insulated tools or even insulated gloves to hand, you could
be at risk of a serious incident.
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How to tell if hand tools are insulated
Every insulated tool must be marked with the year it was insulated and an official 1,000-volt
rating symbol, which ensures protection for live use up to this voltage.
Most hand tools come with a rubber coating over the handle.
It is essential to know that this material is primarily designed for comfort and grip, and is not
principally there for protection from electricity; the rubber is too thin on these tools to be
preventing you from an incident.
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Insulated hand tools provide two types of protection for workers around live electrical
equipment.
First, they help protect individuals against electrical shock and arcing.
Second, they help protect the equipment being inspected or repaired.
This is important because even if electricians or technicians are working on a deenergized

piece of equipment they are still likely near other energized equipment.
If they are using hand tools that aren’t insulated and they happen to accidentally contact an
energized component it could send live voltage through the tool directly to the user.
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• The thing to understand is that insulated tools aren’t just regular tools with some extra
rubber on the handles or generic coating on the tool end.
• They are designed end to end to protect workers from electrical shock up to 1000 V ac
and 1500 V dc.
• They provide this protection in several ways.
• All parts of the tool, including the insulation, must be flame resistant and must function
from -20° C (-4°F) to 70°C (158°F).
• Tools such as pliers and cutters should have a guard rail to protect a user’s hand from
slipping down to the exposed metal part of the tool.
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Electrical Hazards
• Shock
• Arc Flash & Arc Blast
•Fire Ignition
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The Effects of Shock:
Immediate: Long Term:

- Muscle contraction - Memory Loss
- Vital organs (heart, lungs, etc.) - Nervous disorders
- Tingling - Chemical imbalances
- Pain - Damage to vital organs
- Breathingg - Sometimes fatal
- Disorientation
- Dizziness
-- Death Death
• According to findings outlined in the OSHA Standards, deaths from electrical shock are the
fourth leading cause of death at a construction site.
• Contact with a mere 1 to 3 milliamperes is enough to affect a worker`s perception and

cause a painful shock. In fact, 9 to 35 mA can cause great muscular contractions, the
inability to let go, and respiratory paralysis.
• Between 50 and 250 mA, the effects are usually fatal heart failure and tissue burning.
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Two Types of Burns from Shock:
Surface Burns:
• Caused by entrance and exit of electrical currents through the body
• Can be caused by a very small amount of current of the body
• 1st degree to 3rd degree
Internal Tissue Burns:

• Caused by current flowing through organs and through the body
• Caused by currents in excess of 1.5 amps
• 4th degree
• Internal organs
• Typically fatal
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One Type of Burn from Arc Flash
Surface Burns:
• Caused by exposure to the arc flash
• Can cause more surface burns if the initial arc flash ignites other material
such as clothing
• 1st degree to 3rd degree
• It has and may cause death!
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Arc Flash Defined
•The energy released during an arcing fault
•Occurs when current flows through a medium that is not intended to conduct electrical
current (e.g. air).
• OSHA says “An arc flash is a phenomenon where a flashover of electric current leaves
its intended path and travels through the air from one conductor to another, or to ground.
•The results are often violent and when a human is in close proximity to the arc flash,
serious injury and even death can occur.”
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.....Arc Flash Defined
“Arc Flash:
an electrical discharge that uses the air as a conductor, exploding from a high
voltage source to another conductor
or
ground nearby release can be 5,000oF or hotter, melting nearby metals and
damaging the electric circuits involved.
The brightness, heat and force of the arc flash can cause damage to the human
body.”
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Arc Flash Injuries
•Burns
•Respiratory System Damage
•Vision Damage
•Hearing Damage
•Skin Penetration from Flying Debris
Injuries will occur based on the intensity of the heat generated by an

electrical arc incident.
The level of damage is dependent upon:
•Power of the Arc (Incident Energy)
•Distance of the Worker from the Arc
•Time Duration of the Arc Exposure
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Electric Shock & Burn:
-Over 4,000 nonfatal electrical shock accidents occur each year.

-Cost of treatment can exceed $1,000,000/case.
-Does not include litigation fees or process loss.
-Treatment can require years of rehabilitation.
-Victim may never return to work or retain quality of life.
National Safety Council:

• 300 fatalities each year due to electrocution.
• Many of those while servicing equipment 600V or under.
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A number of “approach boundaries” exist and both qualified and non-qualified
persons must understand these definitions.
Flash Protection Boundary (outer boundary): The flash boundary is the farthest established
boundary from the energy source. If an arc flash occurred, this boundary is where an
employee would be exposed to a curable second-degree burn (1.2 calories/cm2)
Limited Approach: An approach limit at a distance from an exposed live part where a
shock hazard exists.
Restricted Approach: An approach limit at a distance from an exposed live part

which there is an increased risk of shock.
Prohibited Approach (inner boundary): A distance from an exposed part which is considered
the same as making contact with the live part.
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Approach Boundaries
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Causes of Arc Flash
• Overloading/overheating of circuits
• Damaged circuit breakers
• Over-fusing
• Wiring in a non workman

-like manner
• Faulty electrical panels
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Causes of Arc Flash
• System overload
• Incorrect wire gauge for system requirements
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• Faulty panels or overloading panels
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Arc Blast
• Accompanies the flash
• Intense radiant heat released
• Nearby surfaces (persons and objects) absorb and are

instantly heated to vaporizing temperatures
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Arc Blast Hazards
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Possible “Traps”
Beware of a “profusion of electrical confusion”
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Aids to Safe Operations
• NFPA 70E-2004
Standard for Electrical Safety Requirements for
Employee Workplaces
• IEEE 1584
Guide for Arc Flash Hazard Calculations
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Types of Damage
• Fully understand the hazards

related to these activities
• If possible, review case

histories of your industry to
devise safe operations
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Caution!!
Abide by distances determined by

NFPA or IEEE
NO SHORT CUTS!!!
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Signage
Ensure signage fits hazard and

conforms to regulatory
requirements
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Hazard Pre-plan
• Use checklists to preplan

equipment needs when
performing service or
maintenance
• Label systems for future

maintenance and arc flash
studies
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PPE
Tests for arc rating of PPE

Found in ASTM F1506
“Standard Performance
Specifications for Flame
Resistant Textile
Materials for Wearing
Apparel for Use by
Electrical Workers
Exposed to Momentary
Electric Arc and Related
Thermal Hazards”
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Level 1 PPE
PPE must provide protection to 5 calories/cm2 from potential Arc Flash

Thermal Energy.
Total clothing weight usually is 4.5 oz/yd2 to 8 oz/yd2 and may consist of:
• FR long sleeve shirt and FR long pants, FR Coveralls or 50” FR smock;
• Safety glasses with side shields and electrically non-conductive frames;
• Polycarbonate or propionate goggles, if goggles are required;
• Electrically-rated safety shoes;
• Electrically non-conductive hardhat; and
• Arc Flash Hazard rated gloves shall be worn to protect against the Arc Flash
Hazard energy for this level of PPE.
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Level 2 PPE
• PPE must provide protection to 8 calories/cm2 from potential Arc Thermal

Energy,
• Total clothing weight of all layers usually is 9 oz/yd2 to 12 oz/yd2 and may
consist of as per table below:
9-12oz = 0.25 – 0.34kg SimonAugustine/Electrical/arcflas

1yard=0.91meter
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Level 3 PPE
• PPE must provide protection to 25 calories/cm2 from potential Arc Thermal Energy.
• Total clothing weight of all layers usually is 16 oz/yd2 to 20 oz/yd2 and may
consist of as per table below:
16-20 -oz = 0.45 – 0.56kg SimonAugustine/Electrical/arcflas

1yard=0.91meter
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Level 4 PPE
• PPE must provide protection to 40 calories/cm2 from potential Arc Thermal Energy,
Level 4
• Total clothing weight of all layers usually is 24 oz/yd2 to 30 oz/yd2 and may consist of
as per table below.
24-30 -oz = 0.68 – 0.85kg SimonAugustine/Electrical/arcflas

1yard=0.91meter
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Match PPE to Task
Level 2
• Protective Coverall
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Match PPE to Task
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Match PPE to Task
Prepare for the possible!
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• Support equipment
rated for the task
• Tools properly
insulated
• Correct support
equipment for the
job
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Safety
Robotic removal or disengagement

devices can do much to maximize
personnel safety
Also:
✓ Draw-out circuit
breakers on a life bus
✓ Remote racking
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Lock-out/Tag-out:
• Make sure you’re wearing the proper PPE for this job also
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Avoiding Arc Flash
Assign qualified person

• Conduct system analysis to
determine arc flash hazard
• When working, secure all

power and enact Lock- out/Tag-out
• Proper tools and PPE rated

for the job
• Assign electrical safety

program manager familiar
with codes
• Properly maintain system

and components
• Apply warning labels
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Protective Measures
Power lines:
• Always assume energized unless proven otherwise
• Keep equipment at least 20 feet away
• Follow lockout/tagout procedures
• Determine location before performing work
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Protective Measures
Use proper warning labels:
• Equipment operating at 50 volts or more and not put into a de-energized

state must be evaluated for arc flash and shock protection
• Evaluation determines
– Actual boundaries
– PPE
• After evaluation, Arc Flash Hazard warning label must be

affixed to equipment and readily accessible
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Protective Measures
• De-energize the circuit before starting work

– Identify all power sources
– Interrupt load and disconnect power
– Visually verify that a disconnect has opened the circuit
– Lock out/tag out the circuit
– Test for voltage
– Ground all power conductors
• Use guarding procedures

• Set up barricades
• Utilize ground fault circuit interrupters (GFCI)
• Use grounding as secondary protection
Note:
The most effective and fool-proof way to eliminate the risk of electrical shock
or arc flash is to de-energize the equipment.
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Protective Measures
If you are required to work “hot,” your employer must develop and enforce
safety-related work practices which include:
• Energized electrical work permits
• Personal protective equipment
• Insulated tools
• Written safety programs
• Job briefings
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Protective Measures
PPE for shock and arc flash protection

includes :
• Safety glasses
• Voltage-rated gloves
• Fire-resistant or flame retardant work clothes
• Arc-rated face shields
• Flash suits with hoods
• Hearing protection
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Employee Responsibilities
Employees must:
• Report hazards to life or property as soon as possible

• Make preliminary inspections
• Conduct appropriate tests to determine conditions before starting work on

electrical equipment or lines
• Use appropriate electrical tools and equipment in wet areas
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Employee Responsibilities
Employees must:
• Maintain a clear 3 foot area surrounding all electrical equipment to

permit ready and safe operations and maintenance
• Not work alone on energized lines or equipment over 600 volts

• Be instructed in CPR if they regularly work on or around energized
electrical equipment
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Electrical Safety is a Serious Issue:
• Electrical Safety in the workplace is the most important job of an electrical worker.
• No matter how much training one has received or how much employers try to
safeguard their workers, Electrical Safety is ultimately the responsibility of the
electrical worker.
• The human factor associated with electrical accidents can be immeasurable.
• No one can replace a worker or loved one that has died or suffered the irreparable
consequences of an electrical accident.
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FACTS...
• 97% of all electricians have been shocked or injured on the job.
• Approximately 30,000 workers receive electrical shocks yearly.
• Over 3600 disabling electrical contact injuries occur annually.
• Electrocutions are the 4th leading cause of traumatic occupational fatalities.
• Over 2000 workers are sent to burn centers each year with severe Arc-Flash burns.
• Estimates show that 10 Arc-Flash incidents occur every day in the US.
• 60% of workplace accident deaths are caused by burn injuries.
• Over 1000 electrical workers die each year from workplace accidents.
• Medical costs per person can exceed $4 million for severe electrical burns.
• Total costs per electrical incident can exceed $15 million.
• In the year 2002, work injuries cost Americans $14.6 billion.
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When electrical faults occur, the electrical system is subjected to both thermal and
magnetic forces.
These forces can severely damage equipment and are accompanied by fires,
explosions and severe arcing.
Such violent damage often causes death or severe injury to personnel.
Costs of repairs, equipment replacements, and medical treatment can run into millions
of dollars.
Loss of production and damaged goods are also important considerations.
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The standards give the following guidelines:
• defining a safety program with clear responsibilities;
• procedures for arc flash hazard assessment;
• defining appropriate personal protective equipment (PPE) to be provided for the

employees;
• training program for the employees regarding arc flash hazards;
• choosing suitable tools for a safe workplace;
• labeling equipment; labels shall be placed on the equipment by the plant owner and not by
the manufacturer. The labels shall indicate the minimum protective distance, the energy
level which can be released and required personal protective equipment (PPE).
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Arc Flash Flow Chart
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SimonAugustine/Electrical/arcflash2019

Electrical Safety Hazards

When electrical systems break down, the consequences to personnel are:

Primary Hazards are;

•As voltage levels increase, the effects of electric shock escalate.

•Current may also cause an erratic heartbeat known as ventricular fibrillation.

Even relatively small arcs can cause severe injury.

The secondary effect of arcs includes;

In order to determine the potential effects of an Arc-Flash, we need to understand

•An Arc-Flash produces intense heat at the point of the arc.

•Heat energy is measured in units such as BTU’s, joules, and calories.

The following data provides a basis for measuring heat energy:

• The amount of instantaneous heat energy released by an Arc-Flash is

• It is usually expressed in calories per square centimeter (cal/cm2) and

• However, some calculation methods express the heat energy in Joules/cm2

“…Employees working in areas where there are potential electrical hazards

Arc Thermal Performance Exposure Value (ATPV)

What is the best way to prevent the hazards of electricity?

• Work with valid Permit.

•Stop - Before Action

• Protection - Proper PPE

Avoiding energized circuits is the safest way!

1. An estimated 30,000 non-fatal electrical shock accidents occur each year

Employer must develop and enforce safety-related work practices to prevent

These safety related work practices could include:

• Energized Electrical Work Permit

•Working on a railway track that needs to remain active.

Second, they help protect the equipment being inspected or repaired.

This is important because even if electricians or technicians are working on a deenergized

• They provide this protection in several ways.

• Arc Flash & Arc Blast

Immediate: Long Term:

• Contact with a mere 1 to 3 milliamperes is enough to affect a worker`s perception and

• Can be caused by a very small amount of current of the body

• 1st degree to 3rd degree

Internal Tissue Burns:

• Caused by currents in excess of 1.5 amps

• 1st degree to 3rd degree

• It has and may cause death!

•The energy released during an arcing fault

•Respiratory System Damage

•Skin Penetration from Flying Debris

Injuries will occur based on the intensity of the heat generated by an

The level of damage is dependent upon:

•Power of the Arc (Incident Energy)

•Distance of the Worker from the Arc

•Time Duration of the Arc Exposure

-Over 4,000 nonfatal electrical shock accidents occur each year.

National Safety Council:

Restricted Approach: An approach limit at a distance from an exposed live part

• Damaged circuit breakers

• Wiring in a non workman

• Faulty electrical panels

• Incorrect wire gauge for system requirements

• Accompanies the flash

• Intense radiant heat released

• Nearby surfaces (persons and objects) absorb and are

Beware of a “profusion of electrical confusion”

• Fully understand the hazards

• If possible, review case

Abide by distances determined by

Ensure signage fits hazard and

• Use checklists to preplan