Arc Flash &

Electrical Safety
SPR IN G ED I TI ON
Contents
3 — When and how to mitigate arc flash hazards in medium-
voltage electrical systems
16 — NFPA 70B - From Recommendation to Standard Article
by Leviton
17 — Everything you need to know about the NFPA 70B: The
Standard for Electrical Equipment Maintenance
21 — Enhancing electrical safety in water, wastewater industry
24 — MELTRIC® Switch-Rated Devices are Safe, Economical,
and Convenient
25 — Prioritize Arc Flash Hazard Removal in Industrial
Environments, Why Elimination is Always Best
36 — How state-of-the-art predictive maintenance best practices
can achieve electrical safety
45 — How electrical, power system trends are affecting and
impacting safety standards
51 — How to choose the right arc flash PPE

2
When and how to mitigate arc
flash hazards in medium-voltage  Back to TOC

electrical systems
Mitigating arc flash hazards in medium-voltage systems could be performed
in synergy to achieve optimal system reliability and safety

P rotective relays are the brain and intelligence behind a medium-voltage protective
device. They are critical infrastructure for proper medium-voltage system operation
and protection and increase system reliability.

With electromechanical and solid-state protective relays being obsolete and nearing
their end of life, upgrading them with their microprocessor counterparts is paramount
for reliability of power systems. Microprocessor relays provide advanced communica-
tion, monitoring and automation capabilities along with all basic protection and con-
trol platforms.

The advancement in technology in the power industry, coupled with increase in aware-
ness about arc flash hazards, has brought a wave of arc flash hazard mitigation pro-
cesses and procedures. If the protective relay upgrade project is planned, the arc flash
hazard mitigation could become an amazing complementary result along with the relay
upgrade. The key to this process is: adequate planning and selecting appropriate re-
lays to achieve both goals.

Introduction
Protective relays are an integral part of the medium-voltage power system because
they ensure protection for equipment during fault and abnormal operating conditions. 3
When and how to mitigate arc flash hazards in medium-voltage electrical

If these protective devices are installed,  Back to TOC

engineered, programmed and maintained
properly, they keep the power system safe
and reliable.

It is critical to upgrade them to the current

technology and standards. Many electrome-
chanical and solid-state relays are becoming
obsolete, which means upgrading them is in-
evitable — either through unplanned failures
or during planned outages. As older protec-
tive relays near their end life, they cannot be
relied on for the equipment protection they
provide. Instead of providing system protec-
tion and reliability, these relays now become
a safety hazard and liability.

Figure 1: This image includes the

One of the critical factors affecting arc flash hazard is medium-voltage circuit breaker with
the protective device fault clearing time. The faster the a protective relay. Courtesy: National
fault is cleared, the lesser the incident energy resulting Field Services

in lower arc flash hazards. One of the best methods of

mitigating arc flash hazard is reducing the fault clearing time and this is where the ad-
vanced microprocessor relays come into the picture.

Most advanced relays have capabilities of detecting the fault faster and interrupting
them a lot quicker than their electromechanical counterparts. Another feature that
4
When and how to mitigate arc flash hazards in medium-voltage electrical

microprocessor relays provide is their advanced communication and automation abili-  Back to TOC
ties. This means the overcurrent device could be operated from a safe distance, which
increases the working distance and reduces the arc flash hazard.

A well-planned relay upgrade project could easily be complemented with the arc flash
hazard mitigation one. Upgrading protective relays and mitigating arc flash hazard
have a common goal of maintaining power system reliability and promoting worker
and equipment safety. With meticulous planning, well-thought equipment (protective
relay) selection along with smart engineering practices can help achieve both process-
es and their common goal (see Figure 1).

Typical protective relay upgrade process aligning with arc

flash hazard mitigation
Project planning and raising user awareness: The initial and the most important
step in upgrading relays has been planning the entire project with keeping arc flash
mitigation as one of the goals or end result. This includes understanding custom-
er’s expectations and goals and providing consultation and coaching. Many cus-
tomers are not aware that upgrading relays could aid them in mitigating arc flash
hazards and in some cases may not be aware of the arc flash hazards at all. It is vital
to educate the user about potential arc flash hazards and how upgrading the relays
could help mitigating them.

Gathering data and procuring protective relays: The next step in this process is collect-
ing accurate data such as existing device settings, drawings, short circuit, coordination
and arc flash studies, operating sequence and other original equipment manufacturer
documents. Having well-established and updated documentation helps in maintaining
5
When and how to mitigate arc flash hazards in medium-voltage electrical

existing equipment  Back to TOC

operation procedure
and provides room to
improve functionality
on existing system.

Procuring relays fol-

lows the data gather-
ing process. The key
here is being judicial
while selecting the
proposed relay. For
instance, selecting an
overcurrent relay with capabilities of having arc flash sen- Figure 2: These images are the
sor would be an excellent choice for both upgrading the before (left) and after pictures of
the medium-voltage switchgear
relay and mitigating the arc flash hazard. This selection of after relay upgrade work has been
relay aligns with the common goal of this paper and could performed. Courtesy: National
Field Services
be a cost-effective solution for arc flash hazard mitigation.
Procuring relays as soon as project scope has been out-
lined helps in reducing the original equipment manufacturer lead times as well.

Performing engineering studies, creating relay setting and updating existing draw-
ings: Performing accurate and up-to-date engineering studies consisting of at least
short circuit, coordination and arc flash analysis, with minimal assumptions, is anoth-
er critical step of the relay upgrade process. It is not recommended to convert the
existing settings into the upgraded relays. Electromechanical and solid-state relays
6
When and how to mitigate arc flash hazards in medium-voltage electrical

have very limited functionality and capabilities, whereas microprocessor relays have  Back to TOC
elaborate functions.

For instance, an overcurrent (ANSI device 50/51) electromechanical relay only has time
overcurrent and instantaneous overcurrent settings, whereas a feeder protection mi-
croprocessor relay has both of these functions with multiple group settings, directional
element, reverse power and so on.

Updating existing drawings to replace existing equipment is good and highly recom-
mended practice while upgrading relays. This process helps in the field wiring of new
relays and provides customers with updated protection schemes and documents that
could be used for troubleshooting in future. Updating existing drawings also provides
design engineers with an opportunity of incorporating remote operation of overcurrent
devices. Remote close and trip of circuit breakers could easily be incorporated in the
upgraded system. This is one of the vital components of engineering controls for arc
flash hazard mitigation.

Off-site wiring, uploading settings and testing relays: It is recommended wiring relays
and their associated test switches to the relay doors or insert panels off-site. Another
good practice is to upload relay settings, test relay elements and logic off-site. This re-
duces the outage duration in the field and helps accomplish milestones in the upgrade
process.

Reducing outages is one of the important factors in the relay upgrade process. Not
being able to schedule an outage is one of the hindering factors on relay upgrade
projects. Relays are a huge part of the power system automation and protection. Thus,
7
When and how to mitigate arc flash hazards in medium-voltage electrical

any facility can only afford to have minimal downtime involving them.  Back to TOC

Medium-voltage systems will be without any protection and automation features if

relays are safely taken out of the service. This could compromise the reliability and
safety of the power system. Many relay upgrade projects are postponed or suspended
because of the lack of switchgear shutdown or inability of any facility to schedule the
outage.

On-site demo, install, test and commission: The final and most important step in relay
upgrade project is bringing everything together in the form of a field installation. It
is always recommended documenting all existing wires and maintaining integrity and
aesthetic property of wires in compartment while wiring.

Another important final step is commissioning the entire system. This includes at min-
imum verifying polarities, current transformer (CT) ratios, phase rotation and direct
current trip checks to list a few. The goal is to improve the system reliability and safety
without any nuisance power interruptions. Those calculations should be redone and
documented at this time. It is imperative to have detailed plans and procedures for ex-
isting system uninstallation, new relay installation, testing and commissioning, contin-
gency plans for unexpected surprises during this entire upgrade process (see Figure 2).

Arc flash hazard mitigation methods

Arc flash hazards can be calculated by calculating the incident energy. This can be
accomplished by using any commercial software. The main components of incident
energy calculations are the amount of available fault current, the overcurrent protective
device fault clearing time and working distance. This article dives into the second two
8
When and how to mitigate arc flash hazards in medium-voltage electrical

components: fault clearing time and working distance. The methods and goals of relay  Back to TOC
upgrade aligns with NFPA 70E: Standard for Electrical Safety in the Workplace hier-
archy of controls for hazard mitigation. Some of the arc flash mitigation engineering
methods are listed below:

Eliminating the hazard is at the top of the hierarchy. This is the most effective method
of arc flash hazard mitigation because this method eliminates the hazard. The follow-
ing engineering methods are useful in eliminating the arc flash hazard from the medi-
um-voltage systems. These methods are based on reducing the fault clearing time.

Method 1: Using reduced instantaneous setting with alternate

group/maintenance mode setting
This is one of the simplest and most effective methods of reducing incident energy
and arc flash hazards. Most microprocessor relays have provision for multiple group
settings. The groups could be transferred over automatically using relay programming
logic or manually using the selector switches that could be mounted anywhere in the
switchgear.

For instance, Group 1 would have the normal system protection settings. Short circuit,
coordination and arc flash study needs to be performed to design the reduced instan-
taneous settings. This reduced instantaneous value would then be programmed into
Group 2 settings.

The reason for creating separate groups is to maintain the system reliability and func-
tionality. The user would have to switch settings into Group 2 before performing any
switching or interacting with the medium-voltage equipment. Once this electrical
9
When and how to mitigate arc flash hazards in medium-voltage electrical

work has been performed,  Back to TOC

it is imperative to return the
maintenance switch back to its
original position or change the
relay logic back to enabling
Group 1 protective device
settings.

Figure 3 shows the time cur-

rent curve (TCC) created using
SKM Systems Analysis Inc.
along with the calculated fault
current on how this reduced
instantaneous setting could
be calculated. If this reduced
instantaneous setting values
is set below the fault current
line (dotted line), the reduced
instantaneous setting could be calculated. Figure 3: SKM Systems Analysis
Inc. software time current
curve displaying the reduced
Method 2: Using concept virtual main instantaneous settings (blue curve)
This method involves installing additional hardware and versus normal instantaneous
settings (red curve). Courtesy:
relays in the existing system. However, this is an effective
National Field Services
method in reducing arc flash hazards in existing systems.
Most power systems in the past were designed without a
physical main overcurrent protective device such as a circuit breaker or fused discon-
10
When and how to mitigate arc flash hazards in medium-voltage electrical

nect. Thus, whenever there is a medium-voltage switchgear powering up a medium- to  Back to TOC
low-voltage transformer, the incident energy is high on the secondary side of the trans-
formers. Without an actual main interrupting device, there are not a lot of options of
reducing the incident energy.

This concept of virtual main fills the void on the switchgear that is not designed to have
an actual main circuit breaker. In this method, CTs are installed on the secondary side of
the transformers and/or the switchgear. Two sets are typically included in this scheme.
Then, instantaneous overcurrent devices located upstream of this transformer are de-
signed to operate if there were any fault current events on this downstream switchgear.

Substitution in medium-voltage systems

Ideally, eliminating the hazard is the best way to reduce arc flash hazards. However,
this might not be feasible in all practical applications. If the hazard could not be elim-
inated, then the next method on hierarchy of risk control is substitution. This method
involves designing engineering processes to substitute the hazard.

The following two methods are innovative on substituting arc flash hazards in the medi-
um-voltage system. These methods are based on increasing the working distance.

Method 1: Designing relay logic for remote switchgear

operations
This method is simple to implement and effective in most power systems equipped
with automation. Most modern medium-voltage systems are equipped with remote
operation. The design engineer could simply incorporate remote bits in their circuit
breaker operation logic to achieve this. Because the protective relays would open or
11
When and how to mitigate arc flash hazards in medium-voltage electrical

close the circuit breaker, the operator does  Back to TOC

not have to be present physically in front of
the switchgear during the switching process.

This method increases the working distance

from a few inches to several feet, thus aids in
keeping system operators out of the harm’s
way. The only caveat for this method is that
the switchgear must have automated switch-
ing capabilities, which could be an issue for
older switchgear.

Method 2: Engineering controls

This method is simple and effective in both
older and newer switchgear systems. The
switchgear does not have to be automated,
Figure 4: Microprocessor relay
unlike the previous substitution method. This method could
with pushbuttons. Courtesy:
be attained by programming logic in the relay for circuit National Field Services
breaker open and close operation and performing minimal
changes in wiring during the upgrade process.

Typically, the microprocessor relays have push-button in their front panel. Incorporating
a small delay of 10 or 20 seconds provides ample time for an operator to push a button
and safely move out of the switchgear room. For the relays that do not have the push
buttons, the control switch that operates the circuit breaker could be programmed in
similar fashion. This process is cost effective and could be achieved with simple engi-
neering design modifications. 12
When and how to mitigate arc flash hazards in medium-voltage electrical

Medium-voltage electri-  Back to TOC

cal system safety
Protective relays are the back-
bone of the protection, automa-
tion and control for medium-volt-
age systems. They are critical to
power system performance and
reliability; thus, utmost impor-
tance should be given to the
maintenance and upgrade of
these relays.

Arc flash hazard mitigation is a

critical part of electrical safety.
This helps to protect lives and
maintain the efficiency and reli- Figure 5: Single line diagram
ability of the power system. All the arc flash reduction modeled in SKM Systems Analysis
Inc. engineering software. Courtesy:
methods in this paper could be carried out with the re-
National Field Services
lay upgrade process as a comprehensive project. Using
engineering brainpower and harnessing the advance-
ment in technology, we can keep our electrical system safe and reliable.

Case study: Reducing incident energy

SKM Systems Analysis Inc. software was used to prepare and analyze this typical en-
gineering project that incorporates several methods of reducing arc flash hazards.
The protective relay was programmed with the reduced instantaneous settings, which
13
When and how to mitigate arc flash hazards in medium-voltage electrical

reduced the incident energy on medium-voltage switchgear bus from 22.8 cal/cm2 to  Back to TOC
1.14 cal/cm2. This protective relay pushbuttons were programmed with the delay of 20
seconds for additional arc flash hazard mitigation.

The concept of virtual main was implemented in order to reduce the incident energy
on low-voltage switchgear bus. Current transformers (CTs) were installed on the sec-
ondary of the 2,000 kilovolt amperes (kVA) transformer. These CTs were connected to
the existing protective relay. Short circuit, coordination and arc flash engineering study
was performed on this new system. Instantaneous settings were designed for this virtu-
al main and programmed into the protective relay.

The incident energy on the low-voltage switchgear bus was reduced to 6.85 cal/cm2
from 137 cal/cm2. This is a significant decrease in incident energy.

Bibek Karki
Bibek Karki, PE, is Engineering Manager at National Field Services, An IPS Company.

14
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NFPA 70B - From Recommendation to Standard Article by Leviton

 Back to TOC


NFPA 70B - From Recommendation to
Standard Article by Leviton
Have you heard of NFPA 70B, the Standard for Electrical
Equipment Maintenance? It became way more relevant in 2023
- learn more about the mandatory standard and how you can
remain compliant.

16
 Everything The NFPA 70B just received a major update in
2023. Not sure if you’re in compliance? Looking
for guidance? We’ve got you covered…
you need to What is the NFPA 70B?
know about The NFPA 70B, known as the Standard for Electrical Equip-
ment Maintenance, details preventive maintenance for

the NFPA 70B: electrical, electronic, and communication systems and

equipment. And while it’s been around since 1975, it’s
become way more relevant in 2023. That’s because histor-

The Standard ically, the NFPA 70B has always been written as a recom-
mended practice, including non-mandatory suggestions

for Electrical and using language like “should” or “should not.” Howev-
er, the 2023 edition has been completely revamped and is

Equipment
now written as a Standard, now including mandatory lan-
guage like “shall” or “shall not.”

Maintenance Now that it’s a standard, what’s important

to know?
A critical portion of the NFPA 70B to be aware of is Chap-
ter 9, which covers required maintenance intervals of
equipment. Article 9.2.2 features a Table that identifies
the required maintenance intervals for specific equipment
categories, including battery ESSs, electric vehicle power
transfer systems, electronic equipment, fuses, switchgear,
wiring devices, and more. The required maintenance
Everything you need to know about the NFPA 70B

interval can range anywhere from required inspection before each use to a required  Back to TOC
inspection once every 60 months. The range is dependent upon the equipment’s physi-
cal condition, but in general, the better the condition of the equipment, the longer the
time in between each required maintenance interval. Article 9.3.1 identifies the defini-
tion of different equipment physical conditions, including Equipment Physical Condi-
tion 1 (“like-new” conditions), 2 (maintenance results deviated from previous results,
or minor issues have been identified), and 3 (maintenance has been missed the past 2
cycles, or issues or urgent actions have been identified).

What is the importance of identifying required maintenance

intervals?
Staying up to date on required maintenance intervals is critical for several reasons. At
a high-level, it helps ensure all equipment is unbroken and operating properly, improv-
ing overall equipment effectiveness. By confirming this, it will trickle down into other
benefits, including preventing safety hazards and increasing productivity.

NFPA 70, 70B, and 70E – What is the difference?

While they all sound similar, they are different standards that are all dependent on one
another to ensure an electrical “Cycle of Safety.”

• NFPA 70® - National Electric Code (NEC®) – adopted in all 50 states, the NEC is
the benchmark for safe electrical wiring and equipment, created to safeguard peo-
ple and property from hazards arising from electricity use.

• NFPA 70B® - Standard for Electrical Equipment Maintenance - covers the pre-
ventive maintenance of electrical, electronic, and communications systems and
18
Everything you need to know about the NFPA 70B

equipment to provide for the practical safeguarding of persons, property, and pro-  Back to TOC
cesses from the risks associated with failure, breakdown, or malfunction of electri-
cal equipment.

• NFPA 70E® - Electrical Safety in the Workplace - provides practices necessary

for creating a safe working area for employees relative to the hazards arising from
electricity use.

NFPA 70, 70B, and 70E – How are they related?

Using all three simultaneously and correctly provides a complete electrical safety cycle.
If one or more pieces are missing, it leaves the door open for a catastrophic accident.
A good example of their interconnectedness is the electrical maintenance program
(EMP). NFPA 70E requires an EMP, but the NFPA 70B Article 4.2 tells you how to build
one. Together, these documents are more enforceable and strengthen the electrical
safety cycle as prescribed by the NFPA.

Understanding the NFPA 70B as a professional

The NFPA 70B is critical to understand as a professional as it serves as a foundation for
providing a service to customers, unlike NFPA 70E.

• The Role of the Electrical Contractor

o The Electrical Contractor plays a critical role in ensuring effective electrical
safety cycles. Their unique position gives them visibility on both the practical-
ity and necessity in implementing electrical safety cycles, making them a val-
ued information source and advisor to facility management and construction
teams. As a contractor, you can offer electrical maintenance as a part of your
19
Everything you need to know about the NFPA 70B

service offering and provide customers with guidance in the development of  Back to TOC
preventative maintenance plans.

• The Role of the Consulting Electrical Engineer

o The Consulting Electrical Engineer has a unique challenge – they must balance
the complexity of system design and the constructability of a facility’s electrical
systems with the need for NFPA 70B maintenance actions. The intimate under-
standing of NFPA 70B will allow the Engineer to be an effective advocate and
innovation provider, tailoring the electrical system to meet operational needs
while minimizing the time and financial impacts on both capital and operation-
al expenses.

20
Enhancing electrical safety in
water, wastewater industry  Back to TOC

With population growth and limited resources for potable water, ensuring
continuous uptime is crucial.

W ith population growth and limited resources for potable water, ensuring contin-
uous uptime is crucial. However, maintenance and downtime pose risks, making
safety and efficiency paramount.

Minimizing downtime risks

In the water treatment industry, the significance of minimizing downtime risks cannot
be overstated, particularly when the interruption of service can leave an entire pop-
ulation without water. With reactive maintenance scenarios being a leading cause of
injuries, it becomes imperative to prioritize safe and efficient maintenance practices.
Minimizing downtime risks and exploring solutions will ensure continuous uptime while
safeguarding the water supply for communities.

• Downtime in water treatment plants can lead to the loss of water for an entire
population.

• Reactive maintenance scenarios contribute to 70% of injuries, emphasizing the

need for safe and efficient maintenance practices.

Lockout/tagout (LOTO) challenges

The implementation of LOTO procedures is crucial for ensuring electrical safety in
treatment plants. However, challenges often arise, leading to missteps and potential
21
 Enhancing electrical safety in water, wastewater industry

OSHA violations. Moreover, the  Back to TOC

traditional approach to LOTO pro-
The Ultimate Tool cedures in treatment plants can
for Safety and be time-consuming and requires

Downtime Free Operation

the involvement of two personnel.
Innovative solutions to streamline
MELTRIC® Switch-Rated Plugs and Receptacles
and enhance the effectiveness of
these procedures will ensure the
highest level of safety while mini-
mizing disruptions in water treat-
ment operations.

• LOTO, a vital procedure,

often encounters missteps,
resulting in OSHA violations.

• Traditional LOTO procedures

Arc Flash Protections without PPE in treatment plants can be
time-consuming, involving
• DECONTACTOR™ Technology
two personnel.
• Enclosed Arc Chambers
• Dead-Front Safety Shutter
• NEC and NFPA 70E Compliant
The role of a permanent
• Type 4X/IP69/IP69K Watertightness
Try a Product,
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electrical safety device
(PESD)
#safetyfirst
When it comes to electrical safe-

22
#plugintosafety
ty, compliance with regulations is
Enhancing electrical safety in water, wastewater industry

crucial. However, forward-think-  Back to TOC

ing companies understand that
going beyond mere compliance
can significantly enhance both
safety and productivity. The PESD
offers innovative solutions to
improve LOTO procedures. By
installing this onto enclosures,
companies can reduce LOTO procedure times, enable safer Courtesy: Grace Technologies

absence of voltage tests and mitigate hazardous electrical

exposure risks. A PESD revolutionizes LOTO procedures, creating a safer and more
efficient work environment.

• Installing PESD onto enclosures reduces LOTO procedure times by 35-40 minutes.

• ChekVolt allows a qualified electrician to perform absence of voltage tests safely

and efficiently from the outside.

• Hazardous electrical exposure risks are mitigated, enabling a single electrician to

complete the procedure in less than 5 minutes.

Nick Schiltz
Nick Schiltz is a copywriter for Grace Technologies located in Davenport, Iowa. The
company specializes in electrical safety products and predictive maintenance solutions.
During his five years at Grace, Schiltz has published more than 250 blog posts rang-
ing in topics from electrical safety best practices to the future impact of the industrial
Internet of Things (IIoT) in the industrial space. 23
MELTRIC® Switch-Rated Devices are Safe, Economical, and Convenient

 Back to TOC


MELTRIC® Switch-Rated Devices are Safe,
Economical, and Convenient
MELTRIC DS and DSN Series Switch-Rated plugs and receptacles
combine the safety of a switch with the convenience of a plug
and receptacle in one reliable, cost-effective device. Their
DECONTACTOR™ technology, with spring-loaded silver-nickel
butt contacts, push button disconnection, enclosed arc chambers
and dead-front construction with safety shutter provides users with
safety, code compliance and operating cost benefits that are not
possible with other devices.
24
 Prioritize Arc
Flash Hazard
Removal in
Industrial
Environments,
Electrical Hazards are Real
Why Elimination In industrial settings, the presence of electrical hazards
is a constant reality. From power distribution systems to

is Always Best equipment operation, the risk

of arc flash and arc blast looms.
According to the National Safety
Council, 30,000 non-fatal electrical
shock accidents occur each year,
with 1,000 yearly fatalities directly
caused by electrocution.

Arc Flash and Arc Blasts Incidents Happen

Arc flash events occur when electrical current deviates
from its intended path, creating a luminous discharge
accompanied by extreme heat, light, and pressure. Simi-
Prioritize Arc Flash Hazard Removal in Industrial Environments

larly, arc blasts result from the explosive re-  Back to TOC
lease of energy, causing severe injuries and
equipment damage in their wake. The Na-
tional Institute for Occupational Safety and
Health indicates that five to ten arc flash
explosions occur in electrical equipment
every day in the United States. According
to the National Fire Protection Association
(NFPA), arc flash accidents send more than
2,000 workers to burn centers with severe
injuries each year.

Safety is Your Responsibility

and it’s the Law
As an official act of Congress, the Occupa-
tional Safety and Health Act (OSHA) of 1970
was signed into law. With a stroke of a pen, the U.S. ensured the safety of personnel
in the workplace, not just a moral imperative, but also a legal obligation. Regulatory
standards such as NFPA 70E ® mandate compliance with stringent safety protocols to
mitigate electrical hazards and protect
workers from harm. If an employer is
negligent and does not take appropri-
ate precautions, they may be subject
to substantial fines, and management
personnel may be held criminally liable.

26
Prioritize Arc Flash Hazard Removal in Industrial Environments

Costs of Electrical Accidents can be Enormous  Back to TOC

The repercussions of electrical accidents extend far beyond the immediate after-
math. From medical expenses and lost productivity to legal liabilities and reputa-
tional damage, the costs of electrical incidents can be astronomical. On average,
OSHA issues 40,000 safety citations per year. When serious electrical accidents
occur, the cost to a business often exceeds $1 million and the cost to the injured
person is immeasurable.

NFPA 70E®
The NFPA 70E® standard serves as a guiding
framework for electrical safety in the work-
place, providing guidelines and best practic-
es for hazard identification, risk assessment,
and mitigation strategies. Compliance with
NFPA 70E ® standards is essential for safe-
guarding personnel and maintaining regula-
tory compliance.

Electrical Safety Programs

Establishing robust electrical safety programs are crucial for mitigating arc flash haz-
ards and fostering a culture of safety within the organization. These programs en-
compass training, hazard analysis, equipment maintenance, and emergency response
protocols to minimize risks and ensure preparedness.

27
Prioritize Arc Flash Hazard Removal in Industrial Environments

Hierarchy of Risk Control Methods  Back to TOC

“If a hazard can be eliminated, it should be eliminated; there is

no risk of injury if hazards do not exist.”

The hierarchy of risk control methods prioritizes

hazard elimination over mitigation measures, em-
phasizing the importance of addressing root caus-
es to prevent incidents from occurring in the first
place. By eliminating hazards at the source, orga-
nizations can effectively reduce risks and enhance
workplace safety.

Establishing an Electrically Safe Work Condition

Creating an electrically safe work condition involves
de-energizing electrical systems and implementing
lockout/tagout procedures to prevent inadvertent
energization during maintenance activities. This
ensures the safety of personnel working on or near
electrical equipment.

Limits of Approach
Establishing safe working distances, known as
limits of approach, helps mitigate the risk of
accidental contact with live electrical parts.
By maintaining appropriate clearance distanc-
28
Prioritize Arc Flash Hazard Removal in Industrial Environments

es, workers can avoid exposure to elec-  Back to TOC

trical hazards and minimize the risk of
arc flash incidents.

Engineering a Plant to
Prevent Arc Flash without
Compromising Functionality
Designing industrial plants with arc flash
prevention in mind requires a compre-
hensive approach that balances safety
requirements with operational functionality. Incorporating engineered solutions
such as arc-resistant equipment and protective barriers minimizes the likelihood of
arc flash events while preserving operational efficiency. One such piece of equip-
ment are the plugs and receptacles offered by MELTRIC ®, a manufacturer of indus-
trial electrical solutions.

Electrical Connections with Built-In Safety

Investing in electrical connections equipped with built-in safety features simplifies
arc flash mitigation and enhances worker protection. Innovative devices, from MEL-
TRIC, incorporate arc flash resistant designs that isolate load making and breaking in
enclosed arc chambers, along with a safety shutter mechanism to prevent unintend-
ed exposure to live parts.

The advanced design of MELTRIC devices also combine the safety and functionality of
a disconnect switch with the convenience of a plug and receptacle. Using DECONTAC-
TOR™ technology, MELTRIC devices provide consistently reliable connections that re-
29
Prioritize Arc Flash Hazard Removal in Industrial Environments

sist wear, withstand arcing and corrosion,  Back to TOC

and maintain superior electrical perfor-
mance through thousands of cycles.

Prevent Unintended Exposure to

Live Parts and Arcing
By implementing advanced safety designs
to include MELTRIC devices from the
very first engineering stages, organiza-
tions can prevent unintended exposure to live electrical parts and mitigate the risk of
arc flash incidents. From arc-resistant enclosures to line-of-sight disconnects, these
measures minimize hazards
and promote a safer work
environment.

Simplify NFPA 70E

Compliance
Adopting electrical con-
nections with built-in safety
features streamlines NFPA 70E compliance efforts by reducing the need for personal pro-
tective equipment (PPE) and engineering controls. Eliminating the need for PPE not only
enhances worker comfort but also reduces administrative burdens and associated costs.

Elimination means no PPE

The ultimate goal of arc flash hazard removal is elimination, where the risk of incidents
is eradicated altogether. By prioritizing elimination strategies over remediation efforts, 30
Prioritize Arc Flash Hazard Removal in Industrial Environments

organizations can minimize reliance on PPE and create a safer, more sustainable work  Back to TOC
environment for all personnel.

“MELTRIC Switch-Rated plugs and receptacles meet NFPA 70E’s ‘Normal Operation’
definition, so there is no special personal protective equipment required.”

MELTRIC Switch-Rated
plugs and receptacles
simplify compliance
with NFPA 70E by elim-
inating the possibility
of exposure to ener-
gized parts and arc-
ing when making and
breaking the electrical
connections required
to changeout motors and other equipment. This avoids the need to take many of the
special precautions required to ensure that workers are aware of and protected from
the electrical shock and arc flash hazards that exist whenever work is performed on or
around energized circuit components.

Choosing MELTRIC Devices to Eliminate Arc Hazards

Arc flash incidents pose significant risks to personnel, equipment, and business
continuity in industrial settings. Effective arc flash mitigation strategies are es-
sential to safeguarding lives and assets while ensuring regulatory compliance and
operational efficiency.
31
Prioritize Arc Flash Hazard Removal in Industrial Environments

MELTRIC Represents Safety and Efficiency  Back to TOC

MELTRIC devices represent a commitment to safety and efficiency in electrical connec-
tivity, offering unparalleled arc flash mitigation capabilities and quick changeout func-
tionality. By incorporating innovative features such as
DECONTACTOR™ technology and integral arc-flash
mitigation, MELTRIC devices empower organizations to
mitigate risks, enhance productivity, and maintain a safe
working environment.

MELTRIC is Dedicated to Innovation,

Quality, & Safety
MELTRIC’s dedication to innovation, quality, and safety
has earned the trust of industry professionals world-
wide. With a comprehensive portfolio of plugs and receptacles catering to diverse
industrial applications, MELTRIC continues to set the standard for safety excellence in
electrical connectivity.

Whether it’s in manufacturing facilities, petro-

chemical plants, food processing, or renewable
energy installations, MELTRIC devices deliver
unparalleled performance and peace of mind.
By investing in MELTRIC plugs and receptacles,
organizations can optimize their operations, min-
imize downtime, and most importantly, protect
their most valuable assets—their people.

32
Prioritize Arc Flash Hazard Removal in Industrial Environments

MELTRIC Switch-Rated Plugs and Receptacles  Back to TOC

Enhancing operational efficiency and safety within industrial settings is always a task
that hinges on the necessary step of updating electrical infrastructure. However, the
prospect of disrupting plant uptime and facing substantial costs can create a challenge
for an organization looking to make changes. Thankfully, MELTRIC presents a solution
that seamlessly integrates ease of installation, minimal downtime, and cost-effective-
ness with the series of DSN and DS plugs and receptacles. Not only are DSN and DS
plugs and receptacles an easy upgrade, but they also offer advantages over traditional
pin and sleeve connectors, throughout their lifetime.


MELTRIC Series of DSN and DS Plugs and Receptacles:
MELTRIC’s Series of DSN and DS plugs and receptacles are specifically designed for
customization and to streamline the process of updating electrical infrastructure with-
out compromising performance or safety. These innovative devices offer a range of
benefits that make them ideal for a variety of industrial applications. With a versatile
33
Prioritize Arc Flash Hazard Removal in Industrial Environments

 Back to TOC

design, both devices accommodate various mounting options, providing installation

flexibility. Both devices incorporate self-cleaning contacts, integral arc-flash mitigation,
and DECONTACTOR™ technology, providing safe and reliable operation in critical
electrical systems.

DSN Devices
The DSN series boasts a robust design capable of handling currents ranging from 20 A
to 150 A, catering to a wide spectrum of electrical requirements. With its rugged con-
struction and high-quality materials, the DSN series excels in applications where device
size and washdown ratings are paramount. 34
Prioritize Arc Flash Hazard Removal in Industrial Environments

DS Devices  Back to TOC

The DS series offers a compact and versatile solution for lower current applications,
ranging from 20 A to 200 A. With a quality material build, meant to hold up in extreme
environmental pressures, the DS series provides a different set of benefits such as a
larger wiring capacity and zinc alloy casings.

MELTRIC is the Answer

In today’s dynamic industrial landscape, investing in MELTRIC devices is not just a
choice; it’s a commitment to safety, reliability, and performance excellence. With un-
matched reliability, durability, and ease of installation, MELTRIC devices empower
organizations to enhance safety, efficiency, and cost-effectiveness while minimizing
downtime and operational disruptions. Join the ranks of industry leaders who trust
MELTRIC for their electrical connectivity needs and experience the difference of ad-
vanced safety firsthand.

Make the Switch to MELTRIC

MELTRIC provides the opportunity to try before you buy. Please
contact us to request a free product sample of a standard DSN20
or DSN30 sample, free of charge, for potential new customers
with appropriate application and volume opportunities.

35
How state-of-the-art predictive
maintenance best practices can  Back to TOC

achieve electrical safety

Predictive maintenance can ensure electrical systems are designed correctly
and operated safely

M anaging maintenance and operating electrical systems in facilities without prop-

er controls can lead to safety and financial risks, including unplanned outages
that can cause harm to on-site personnel and equipment damage. Such outages can
also cause excessive financial losses to businesses. Uptime Institute research data
found that around a third of all reported outages cost more than $250,000, with many
exceeding $1 million. Data center outages are some of the costliest, with a quarter of
respondents in a survey indicating that their most recent outage cost more than $1
million in direct and indirect costs.

Power systems engineers working in plants often rely on static paper or PDF-based
electrical single-line diagrams to prevent these outages and maintain their facilities.
This introduces limitations that increase operational risks and create challenges in
maintaining and updating the documentation for electrical systems. Adopting predic-
tive maintenance best practices to mitigate these risks, such as digital twins, safety au-
dits, smart sensors and arc flash solutions, can help ensure electrical safety and reduce
unplanned downtime.

Tapping into the power of digital twins

Digital twins are virtual replicas of physical objects, processes or systems that are cre-
36
How state-of-the-art predictive maintenance best practices can achieve

ated using real-time data and simulations. These digital representations can help im-  Back to TOC
prove complex systems’ understanding, design and operation by providing insights
into their behavior, performance and potential problems.

For example, a digital twin of a power distribution system could monitor the flow of
electricity through various components, identify potential areas of overload or over-
voltage and predict the likelihood of equipment failure.

Digital twin technology can be employed during the design phase of an electrical sys-
tem and the life cycle’s operations and maintenance phases to increase safety signifi-
cantly. Intelligent single-line diagrams using digital twin technology can create active
blueprints of single- and three-phase power systems. These tools facilitate seamless
collaboration and the application of real-time insights, which can streamline diagnos-
tics and troubleshooting.

Operators and engineers can improve their understanding of existing electrical sys-
tems by using digital twins as a comprehensive digital learning environment. New-gen-
eration predictive tools use real-time and archived data as a simulation platform that
enables power systems engineers to run “what if” scenarios. This online predictive
simulation is a potent analytical tool that allows engineers to anticipate the system’s
response to operator actions.

Such an approach offers several advantages, including the ability to experience emer-
gencies and precarious situations without actual danger, resulting in fewer safety ex-
posures. Additionally, precise “what if” scenarios can illustrate how to improve opera-
tional efficiency and enhance decision-making. The practical post-mortem analysis and
37
How state-of-the-art predictive maintenance best practices can achieve

event playback capabilities facilitate  Back to TOC

faster incident response times.

Using audits to improve

safety and electrical system
performance
Audits can be another valuable tool
for promoting safety and enhancing
the performance of electrical sys-
tems. Having the capability to identify
technical deficiencies and anticipate
potential failure risks in a facility’s
electrical system is vital. By conduct-
ing audits, organizations can identify
potential hazards and areas for improvement, allowing Figure 1: ETAP is an analytical
engineering solution company
them to implement corrective actions before accidents
specializing in the simulation,
or failures occur. Audits can also help ensure that elec- design, monitoring, control, operator
trical systems are operating efficiently, identify areas of training, optimizing and automating
of power systems. ETAP’s integrated
noncompliance and verify that maintenance programs
digital twin platform offers the best
are being executed effectively. This proactive approach comprehensive suite of enterprise
can improve safety, reduce downtime, extend equip- solutions. Courtesy: Schneider Electric

ment life span and save costs.

However, detecting these shortcomings can be daunting, particularly when faced with
limited resources. Collaborating with expert consultants and the operations team can
help identify critical areas for improvement. Using nonintrusive state-of-the-art technol-
38
How state-of-the-art predictive maintenance best practices can achieve

ogy, an on-site audit assesses the electrical installation. It builds a single-line diagram  Back to TOC
of the devices, quickly identifying potential weak points that could compromise system
safety and performance. This process helps uncover potential vulnerability hazards and
recommends optimal performance and safety improvements.

Experts with specialized software provide a comprehensive modernization plan, includ-

ing 10-year maintenance, monitoring and management plans, spare parts and techni-
cal documentation management. Following the audit, debrief sessions with all stake-
holders highlight observations, risks and recommended next steps. Comprehensive
reports relay vital, actionable insights and standardized deliverables across locations,
segments or countries to ensure multisite or country consistency and develop ongoing
monitoring and management strategies for maintenance plans.

Reducing the hazards of electrical system arc flash threats

Arc flash is one of the most potentially destructive and hazardous forces in electrical in-
stallation, operations and maintenance. It is highly complex, dangerous and difficult to
avoid and contain. An uncontrolled arc has the potential to generate extreme heat ex-
ceeding 35,000°F and a blast force with pressure waves up to 1,000 pounds per square
foot. The resulting noise can reach 160 decibels and high-velocity projectiles from
the arc can travel up to 700 mph. The toxic gases produced can expand by a factor of
67,000, posing a significant risk to workers, equipment and facilities.

Arc flash mitigation and arc flash hazard analyses have been complex until recently.
Although many empirical formulas and significant testing have been developed, the
algorithms and formulas available are still challenging for engineers to solve without a
computing tool and nearly impossible for people in the field to apply.
39
How state-of-the-art predictive maintenance best practices can achieve

However, with an in-  Back to TOC

creased industry focus
on electrical safety,
arc flash hazards are
now more broadly
recognized.

Mitigating the risk of

arc flash is complex
and typically requires
collaboration be-
tween multiple par-
ties, including facility
owners, electrical
system designers and
equipment manu-
facturers. However,
obtaining accurate
information can be
challenging, espe-
cially in traditional design-and-build project environments. Figure 2: Screen captures of
ETAP Predictive Stimulation
Information exchange may be limited, such as the system
Analysis information shows
short circuit level, the composition of electrodes, enclosure sequences of operations and
sizes or standard operating procedures. Failure to consider time current curves, among
other things. Courtesy:
these factors can undermine even the most well-conceived Schneider Electric
mitigation solutions.
40
How state-of-the-art predictive maintenance best practices can achieve

Compliance with Title 29 of the Code of Federal Regulations Part 1910 is required to  Back to TOC
reduce the risk and severity of arc flash incidents and ensure worker safety. A proac-
tive approach to electrical system design can eliminate the risk of arc flash hazards.
Engineered solutions can reduce the likelihood of accidental contact with energized
components using a safety-by-design methodology during a new system’s design and
specification stage.

Understanding the arcing current’s magnitude, path and duration is necessary for
effective mitigation. The incident energy level is a parameter used to quantify the arc
flash hazard. Eliminating the risk or reducing the arc flash incident energy is possible
through de-energized work, arc-resistant switchgear or removing personnel outside of
the arc flash boundary.

However, these solutions only sometimes prevent equipment damage. Alternatively,

arc fault detection solutions can clear arc faults by upstream overcurrent protection de-
vices. However, these solutions can be risky and require auxiliary power, system design
or operator intervention, which introduces the possibility of human error. Additionally,
these solutions are one-time use and require inspection or replacement of failed com-
ponents.

A straightforward and reliable solution for controlling arc flash hazards can be achieved
with a passive, repeatable, always-on system that does not require complex engineer-
ing. An always-on arc flash prevention and containment system works to minimize the
chances of an arc occurring. If a sustained arcing current does occur, the system will
extinguish it within one cycle or less, which is faster than any other active or reactionary
protection system.
41
How state-of-the-art predictive maintenance best practices can achieve

This approach eliminates the need for operator intervention, does not rely on auxiliary  Back to TOC
power and significantly reduces the risk of harm to people and electrical equipment.
With the implementation of a passive arc flash protection system, managing arc flash
hazards becomes more straightforward and mitigation strategies become more acces-
sible. Unlike many active solutions, an always-on arc flash prevention and containment
system does not cause tripping, leading to zero downtime or disruption of upstream
devices while still containing the arc fault.

The initial cost of implementing a passive, repeatable, always-on arc flash control solu-
tion may be approximately 15% more than standard equipment. However, the return
on investment over the equipment life cycle is significant. The benefits of this system
include a reduction in additional arc flash engineering controls, lower installation, com-
missioning and ongoing maintenance costs, decreased need for personal protective
equipment and associated costs. Furthermore, businesses can avoid direct and indirect
arc flash-related expenses, such as medical and legal costs, fines, increased insurance
premiums and business continuity interruptions.

Using smart sensors for greater operational capabilities

Smart sensors, breakers and electrical panels with shared visibility benefit various
stakeholders along the risk-management value chain. Smart sensors can be used to
monitor plant conditions and alert engineers to potential safety hazards by monitoring
air quality, temperature, humidity and other environmental conditions in the plant. If
levels exceed safe limits, alerts can be sent to engineers or safety personnel, allowing
them to take appropriate action. Smart sensors can also detect the presence of gases
that can be hazardous to human health or safety and detect the presence of smoke or
fire in the plant.
42
How state-of-the-art predictive maintenance best practices can achieve

 Back to TOC
When circuit breakers and electrical panels are equipped with built-in smart sensor
monitoring capabilities, they can provide operational data right from the moment they
are installed. These novel capabilities have numerous advantages, such as reducing
risk for insurers and supporting testing, inspection and certification providers to offer
value-added services to their clients throughout the year, not just during annual in-
spections.

Smart sensors can be used to monitor critical plant equipment and processes in re-
al-time, allowing engineers to quickly detect any anomalies or potential problems and
take corrective action before they escalate into more serious issues. By analyzing data
from smart sensors, engineers can predict when maintenance is required for plant
equipment. This allows maintenance to be scheduled in advance, minimizing down-
time and reducing costs. These capabilities are continually evolving and hold the po-
tential to provide even more comprehensive insights into electrical operations in the
future.

Predictive maintenance as a best practice for proactive safety

measures
Ultimately, state-of-the-art predictive maintenance best practices are all about accom-
plishing the four broad dimensions of safety: reduction, avoidance, prevention and
containment. Ensuring safety and reducing unplanned downtime in electrical systems
is essential to minimize financial risks and safeguard personnel and equipment. Adopt-
ing predictive maintenance best practices such as digital twins, safety audits and arc
flash solutions can significantly enhance safety and reduce unplanned downtime.

43
How state-of-the-art predictive maintenance best practices can achieve

Digital twin technology can be employed during the design, operations and main-  Back to TOC
tenance phases to streamline diagnostics and troubleshooting. Audits can identify
potential hazards and areas for improvement, allowing organizations to implement
corrective actions before accidents or failures occur. Mitigating the risk of arc flash
is necessary to reduce the risk and severity of arc flash incidents and ensure work-
er safety. Adopting these proactive measures to ensure electrical safety and prevent
unplanned downtime can lead to financial benefits, increase safety and extend equip-
ment life span.

Carsten Baumann
Carsten Baumann is Director Strategic Initiatives and Solution Architect at Schneider
Electric.

44
How electrical, power system
trends are affecting and  Back to TOC

impacting safety standards

Electrical and power system trends are often impacted and affected by
evolving safety standards, which are critical for workers.

Left to right: Ken Crawford, senior director of automation, Weidmuller USA; Scott
Dowell, senior vice president and general manager, Wesco; Zack Mitchell, assistant
corporate safety manager, Stellar; Marc Elliott, marketing director, Eaton. Courtesy:

45
Weidmuller, Wesco, Stellar, Eaton
How electrical, power system trends are affecting and impacting safety

Question: What are the key components of an effective electrical safety  Back to TOC
program in an industrial setting?

Scott Dowell: A comprehensive safety program is key to providing the safest possible
work environment on the plant floor. In a manufacturing facility, equipment is always being
moved around, and new pieces added. Powering those machines requires electricity and
while it is a ubiquitous necessity, it is also one of the most significant safety risk factors. We
often help implement plant floor checks which are visual plant walkthroughs with trained
professionals designed to identify electrical hazards before they become a problem. The
mission is to pinpoint where all the danger points are and how they may be exacerbated
as operations ebb and flow. It’s a simple but underutilized safety strategy.

Taking advantage of new technologies is also key to reducing electrical safety risks.
Going beyond OSHA’s 70B requirement, manufacturers can deploy monitoring tech-
nologies that alert to an instance of misused or unused PPE. For example, cameras
monitoring the plant floor can alert if an employee isn’t using glasses to perform a task
or is in an area where hard hats are required. These cameras function as sensors and
can alert your team to potential hazards, mitigating the situation before it causes dam-
age to employees. Robots are also increasingly used on the factory floor. Instead of us-
ing your key personnel to rack things in and out or encounter a situation that requires
additional layers of protection, robots can go into the dangerous area instead to do
the dirty work so to speak.

However, no program or technology is useful without proper training. Training may be

the single most important factor in providing an effective electrical safety program.
Ensuring employees know how to properly use equipment can mitigate much of the
46
How electrical, power system trends are affecting and impacting safety

potential risk. In our experience, you can never communicate too much about electrical  Back to TOC
safety protocols.

Marc Elliott: Advancing safety requires education, training and controls to eliminate
or reduce hazards. The hierarchy of controls (source: The National Institute for Occupa-
tional Safety and Health) provides guidance in preferred order. Fundamentally, safety
programs must seek to eliminate hazards and keep people out harm’s way. Industrial
digitalization efforts are supporting safer conditions through remote monitoring, con-
trol and operations.

Amid big changes to energy systems, education and training are vital to reduce risk.

Digital tools are providing novel ability to help. At Eaton, we provide expansive elec-
trical training programs. Our programs include interactive, virtual simulation providing
immediate feedback in a safe environment.

Justin Mitchell: A clearly communicated purpose for the program, proper assignment
of responsibilities, ensuring all components comply with current industry standards and
OSHA standards, and ensuring that all of these components are communicated and
followed company wide.

Question: How frequently do you train staff on electrical and power safe-
ty, and what have been some of your most successful training programs?

Justin Mitchell: Training on electrical safety is performed on an annual basis at the

very least. Stellar’s safety department conducts in-house training that covers safety
training topics in compliance with industry standards, including electrical safety. 47
How electrical, power system trends are affecting and impacting safety

Question: How do you address arc flash hazards, and what measures can  Back to TOC
be taken to minimize their risks?

Scott Dowell: First and foremost, there must be a mandated arc flash program in
place. An arc flash incident can be especially devastating as the release of the electri-
cal energy can be hotter than the surface of the sun and produce a powerful explosion
equal to that of eight sticks of dynamite. Given the chaos this can cause, arc flashes
threaten personnel safety, widespread equipment damage, and downtime with lost
production.

Power circuit breakers are especially vulnerable as these devices have limits on their
clearing time. That often results in a limit to just how much the device can reduce
potential arc energy. Any further reduction requires factories to consider alternative
ways of capturing and containing the energy. One such advancement to address that
problem is arc quenching devices. This powerful tool can provide better protection for
employees as well as equipment and deliver a significant reduction in downtime if an
arc flash does occur.

Proactive training and ongoing testing are also major factors to reduce overall risk
from arc flash hazards. Equipment should be properly labeled, the right PPE should be
available and worn correctly, and only a “qualified person” should be engaging where
arc flash may be a risk. For those qualified persons, manufacturers should clarify with
those employees which scenarios are safe given their training and identify where fur-
ther instruction for the installation and operation of a given electrical system may be
needed before approaching.

48
How electrical, power system trends are affecting and impacting safety

Justin Mitchell: Employees who perform tasks involving potential arc flash hazards are  Back to TOC
provided arc flash kits and specific training to reduce and/or eliminate the safety risks.
Considerations include location and access to the electrical system, as well as whether
lockout/tagout (LOTO) is required.

Question: How do you manage electrical isolation and LOTO procedures

to prevent accidental energization during maintenance?

Justin Mitchell: Prior to beginning any work involving lockout/tagout, a preparatory

meeting is held with all relevant parties to ensure lines of communication remain open
and that all involved personnel understand the work procedures and duration. We en-
force a lockout-only method, where a physical lock is applied to all power sources prior
to beginning work on any equipment. Tags are used as a means of identification only.

Question: What are the safety implications of introducing renewable

energy systems into existing infrastructure, and how can these risks be
managed?

Justin Mitchell: We manage these risks by identifying the power source and equip-
ment we are tying into and ensuring it is de-energized prior to executing the proce-
dure. We also carefully coordinate with existing infrastructure so as to not interrupt
ongoing operations and productivity.

Question: How do you ensure the safety of electrical equipment during

extreme weather conditions or natural disasters?

49
How electrical, power system trends are affecting and impacting safety

Justin Mitchell: Whenever possible, all electrical equipment is required to be kept  Back to TOC
indoors to protect it from the elements. All equipment introduced into outdoor condi-
tions are grounded and properly mounted to foundations that meet wind codes.

Question: What are the best practices for grounding and bonding in
electrical systems to prevent electrical hazards?

Justin Mitchell: It’s critical to ensure everything is properly grounded per the National
Electrical Code (NEC) standards. Proper grounding techniques include drilling tap, me-
chanical means and CAD welding.

Question: What role does personal protective equipment (PPE) play in

electrical safety, and how do you ensure its proper usage?

Justin Mitchell: PPE plays a major role in electrical safety. Per Stellar policy, we inspect
all PPE prior to each use to ensure the individual will receive the most complete pro-
tection possible throughout its use.

Question: How do you conduct risk assessments and audits to continu-

ously improve electrical safety practices within an organization?

Justin Mitchell: Electrical safety is built into the daily safety audit conducted by man-
agement. Electrical work is added to our daily safe plan of action when performing this
work, including plans to mitigate hazards.

Plant Engineering
50
How to choose the right arc
flash PPE  Back to TOC

Emphasizing the critical importance of proper personal protective equipment

(PPE) in safeguarding workers from the risks of arc flash events is critical.

W hen thinking about personal protective equipment (PPE) used for arc flash pro-
tection, many would first imagine it being used in a high voltage setting such
as a substation or generation facility. The truth is given the right conditions, an arc
flash event can occur inside any business. Selecting the right arc flash PPE is critical for
keeping workers safe who are exposed to electrical hazards. Without a good process,
an arc flash event can cause serious injury or death. Therefore, taking note of a process
to get the right equipment helps ensure a safer workplace.

Understanding three important PPE factors

Arc flash PPE requirements are difficult to navigate if the information is not readily
available. To start, you can often find this information displayed in a high-voltage elec-
trical panel. The arc flash and shock hazard label outlines three important factors:

1. Working distance – Refers to the distance between the person’s head and chest
area from the potential arc source.

2. Incident energy – Measured in calories per square centimeter (Cal/Cm^2) which

is the amount of thermal energy exerted on a surface, positioned a specified dis-
tance from the source, produced during an electrical arc event.

3. Arc flash boundary – The distance at which a person without PPE may get a
51
How to choose the right arc flash PPE

second-degree burn from an  Back to TOC

arc flash occurrence.

If the above information is un-

available on the arc flash equip-
ment, it is recommended an arc
flash hazard and risk assessment
is conducted to establish the
incident energy and boundary at
a specific location. This can be
completed by consulting an elec-
Jarred Richter wearing arc flash PPE.
trical engineer to perform the analysis or using software
Courtesy: Hedgehog Technologies
tools that calculate arc flash energy and working dis-
tance.

Using standards for verification

With those three pieces of information, verify them using relevant standards such as
NFPA 70 (America), CSA Z462-21 (Canada) or IEEE 1584. These standards will support
the decision in selecting PPE based on the incident energy levels.

For example, using CSA Z462-21 incident energy analysis will provide insight into the
appropriate PPE from Table 3, 6A, and 6B. Once the PPE category is determined, refer
to Table 6C which outlines the required PPE to be used.

Prioritize buying arc flash gear that provides an acceptable fit for every team mem-
ber. It’s pivotal to invest in multiple sizes because loose or tight-fitting equipment
52
How to choose the right arc flash PPE

 Back to TOC

can become a safety risk. It is recom- Chart representing the difference between four different
mended all workers using arc flash PPE PPE categories. Courtesy: Hedgehog Technologies

should have their own pair of flame-re-

sistant coveralls, balaclava, approved
safety footwear, safety glasses and
hearing protection. Inspecting these
items should become part of the reg-
ular maintenance routine to identify
any potential risks. For example, parts
Example of an equipment testing interval
of the arc flash equipment have a shelf life which
53
with recommendations for inspection.
requires inspection. Courtesy: Hedgehog Technologies
How to choose the right arc flash PPE

Arc flash PPE best  Back to TOC

practices
It is recommended an inspec-
tion checklist is filled out before
each use of arc flash PPE and
other isolated equipment. Like
fall protection requirements, If
any damage is spotted, employ-
ees should tag it, remove the
PPE from service, and report it
to management.

Training is another crucial fac-

Jarred Richter providing training on arc
tor. Ensure the team follows a detailed and regular
flash PPE safety. Courtesy: Hedgehog
training schedule to educate on the hazards associat- Technologies
ed with arc flash and how to properly use the equip-
ment. This is a good place to revisit the equipment selection criteria, especially after
there has been any upgrades or changes to the electrical system.

Lastly, fostering a company culture towards safety can greatly improve employee safe-
ty. Each person is their own safety critic and having safe operations top of mind is
going to mitigate the risk of serious injury or death on any job site.

Jarred Richter
Jarred Richter is an electrical technologist at Hedgehog Technologies, an electro-me-
chanical engineering firm.
54
 Arc Flash &
Electrical Safety
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