Arc flash and electrical safety hazards can cause severe injury or death. Proper safety procedures and personal protective equipment are necessary when working with energized equipment. An arc flash incident captured on video shows three workers engulfed in flames after an arc flash from a 13,200V switchgear, resulting in severe burns over 60% of their bodies. Employers, employees, and owners all share responsibility for electrical safety programs, policies, training, and coordinating hazards.

1. ARC FLASH / BLAST SAFETY

2. What is the best way to prevent the hazards of electricity? S top - Before Action T hink - Risks/Hazards O ptions - LOTO-Tagout- Tryout P rotection - Proper PPE Avoiding energized circuits is the Safest Way!

3. ELECTRICAL SAFETY Why Electrical Safety Practices and Procedures? An estimated 30,000 non-fatal electrical shock accidents occur each year. Over 600 people die from electrocution each year. Electrocution remains the fourth (4th) highest cause of industrial fatalities. Approximately 3000 reported flash burn incidents reported annually along with approximately 350 deaths.

4. ELECTRICAL SAFETY NFPA 70E – Standard for Electrical Safety in the Workplace Formally “Standard for Electrical Safety Requirements for Employee Workplaces” Begin 1976 by NFPA to assist OSHA

5. ELECTRICAL HAZARDS Shock Arc Flash & Arc Blast Fire Ignition

6. Some arc flash injury statistics: Five to ten arc flash explosions occur in electrical equipment every day in the United States, according to statistics compiled by Cap-Schell, Inc., a Chicago-based research and consulting firm that specializes in preventing workplace injuries and deaths. Injuries from arc flash events range from minor injuries to third degree burns and potential death due to the energy released. Other injuries include blindness, hearing loss, nerve damage, and cardiac arrest. The average cost of medical treatment for survivors of arc flash incidents is $ 1,500,000 Total costs including litigation can be $8M - $10M

7. The Effects of Shock - Immediate Immediate Muscle contraction Vital organs (heart, lungs, etc) Tingling Pain Breathing Disorientation Dizziness

8. The Effects of Shock – Long Term Long Term Memory Loss Nervous Disorders Chemical Imbalances Damage to Vital Organs Sometimes Fatal

9. Injury Facts Numerous workers are injured or killed each year while working on energized equipment. Defining incident energy hazards raises awareness of the harm to humans that can result from an electric arc. Injuries often include: Severe skin burns Hearing damage Face and eye injuries Blast pressure injuries

10. Effects of AC Current More than 3mA - Painful shocks which can cause indirect accidents More than 10mA - Muscle contraction, “not able to let go” More than 30mA - Lung paralysis, usually temporary

11. Effects of AC Current More than 50mA - Possible ventricular fibrillation 100mA to 4amp - Certain fatal ventricular fibrillation Over 4 amps - Severe burns, heart paralysis

12. Resistance and the Body The body has a natural defense system (Skin) Why 50 volts? How can you raise body resistance? The key to survival is decrease our exposure. Ohm’s Law for Electric current (amps), voltage and Body Resistance The typical body has a contact resistance of 500 ohms at the point of contact with the electrical source. The body has an internal resistance of approximately 100 ohms. There is another point of contact to ground of maybe 5000 ohms. 120v / (500: + 100: + 5000:) = 21mA 50v / (500: + 100: + 5000:) = 8.9 mA It is around 10 mA that the “cannot let go” level is reached. Once lock up occurs, exposure time is increased and the possibility of electrocution may occur.

14. 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 1st degree to 3 rd degree

15. Two types of burns from Shock Internal Tissue Burns Caused by current flowing through organs of the body Caused by currents in excess of 1.5 amps 3rd degree Internal organs Typically fatal

17. 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 3 rd degree It has and may cause death!!!!!!

18. ELECTRICAL SAFETY How to prevent Shock? 1. Place Circuits in an Electrically Safe Working Conditions by Locking out and tagging out all sources Chapter 1, Section 120.2(D) of NFPA 70E- 2004 2. Verifying that no electrical energy is present Chapter 1, Section 120.2(D) of NFPA 70E- 2004

19. AF Incident 480 Volt System 22,6000 Amp Symmetrical Fault Motor Controller Enclosure 6-Cycle Arcing Fault (0.1 sec)

20. Exposure to Danger The National Electric Code protects individuals from shock hazards under normal conditions. It is not designed to protect us from abnormal conditions. We need additional policies to protect from abnormal conditions.

21. Conditions Normal Conditions Panel Covers In Place. Equipment plugged in normally. Normal, designed protection in place.

22. Conditions Abnormal Conditions Panel covers removed. Equipment temporarily wired. Normal designed protection such as guards, limits switches, etc., not in place.

23. Protection from Abnormal Conditions The Company NFPA 70 E OSHA Electrical Safety Procedures Manual Electrical Safety Training

24. Protection from Abnormal Conditions You The first line of defense Only you can truly keep you safe Implement Safety Procedures Outlined in Safety Manual Only you can ensure that you go home at night

25. Old School Electricians have always recognized the shock hazards of electricity. They are taught: To consider circuits to be energized To insulate and protect our selves Stand to one side if you suspect an arc flash/blast

26. New School Arc Flash and Blast hazards were not formally studied until 1993 (IEEE 1584 began study) Electricians have not experienced arc flash and blasts to the same frequency as electrical shock. We have not been trained how to avoid and minimize arc flash and blasts in the past. The Electrical Energized Work Practices outlined in NFPA 70E incorporates measures to help avoid or minimize damage from arc flash.

27. What is an Arc Flash? NFPA 70E says an arc flash hazard is: A dangerous condition associated with the release of energy caused by an electric arc A hazard beyond shock and electrocution

28. Bolted and Arcing Fault Characteristics Arcing fault incident energy released is: Greater at higher bolted fault current levels Reduced by dynamic impedance (air) And increased by the time duration of the arc The most controllable factor in reducing the incident energy is time Current flow in a 480V arcing fault is approximately half that of the bolted fault current (impedance of air) Fuses or circuit breakers are the first line of defense in reducing arcing fault incident energy Calculating arc fault incident energy is a very complex engineering task

29. Causes of Bolted and Arcing Faults What causes these types of faults? Bolted faults (low impedance and high current) Commonly caused by Improper connections after maintenance Installation errors Arcing faults (high impedance, lower current) Commonly caused by Careless cover or device removal Foreign object (tool) dropped into equipment Misalignment of moving contacts (parts failure) Dirt contamination or dielectric breakdown Entry of foreign body (rodent, snake, squirrel, human)

30. Insulation Failures Loose Connections Animals Poorly maintained equipment Equipment failures Inadvertent contact

31. Two Types of Major Electrical Faults Can Occur Bolted faults Low impedance and high current Energy is contained by the conductor (bus or cable) Cleared quickly by circuit breakers or fuses Arcing is confined within the circuit breaker or fuse Usually no damage to equipment Relatively low safety risk to personnel Arcing faults High impedance (air) results in lower current Persist longer and propagate High release of heat and blast energy Are very destructive and dangerous to personnel

32. Electric Arcs Produce: The intense heat from arc causes the sudden expansion of air that results in a blast with very strong air pressure (Lightning is a natural arc).

34. Electric Arcs Produce: Electric arcs produce the highest temperatures on earth –up to 35,000 degrees Fahrenheit (4 x temp of the sun)!

35. AF Incident

36. AF Incident

37. AF Incident

38. AF Incident

39. AF Incident

40. Developments Leading to NFPA 70E-2004 Large Hydro in Pacific NW 6.9 kV Swgr Racking in Breaker AF occurred One worker injured 5+ years $10+ million

41. Electric Arcs Effects: All known materials are vaporized at this temperature. (Copper expands 67,000 times, Water 1670 times).

42. Developments Leading to NFPA 70E-2004

43. Electric Arcs Effects: Arcs in enclosures, such as a Motor Control Centers (MCCs) or switchgear, magnify blast and energy transmitted as the blast is forced to the open side of the enclosure.

44. Electric Arcs Effects: Arcs spray droplets of molten metal at high-speed pressure. Blast shrapnel can penetrate the body.

45. AF Incident

46. Electric Arcs Effects: Blast pressure waves have thrown workers across rooms and knocked them off ladders. Pressure on the chest can be higher than 2000 lbs/ sq. ft.

47. Electric Arcs Effects: Clothing can be ignited several feet away. Clothed areas can be burned more severely than exposed skin.

48. Electric Arcs Effects: Hearing loss from sound blast. The sound can have a magnitude as high as 140 dB at a distance of 2 feet from the arc.

49. Electric Arcs Effects: Energy released is a function of: system voltage fault current magnitude fault duration

50. Results of an Arc Flash Other non-human consequences Downtime Lost revenue Loss of product Equipment damage Regulatory impact OSHA citation and fines

51. How to protect against Shock and Arc Flash/Blast? Chapter 1, Section 130 of NFPA-70E2004 Justification for Live Work Work Permits Secured if Applicable Approach Boundaries Established Shock Protection Limited Boundary Restricted Boundary Prohibited Boundary Flash Protection –– ONE BOUNDARY

52. Electrical Arc Facts Arc is electric current passing through air Shock potential from contact with arc Temperature of arc plasma center is greater than 5000°F (some say much higher) Radiated heat burns Pressure wave generated from arc Impact to hearing, etc Gaseous copper is 44,000 times solid Molten metal expelled from equipment at high speed Arc fault results from something wrong or out of place

53. Arcing Short Circuit

54. Flash protection boundary Limited approach boundary Limited space Restricted approach boundary Restricted space Any point on an exposed, energized electrical conductor or circuit part Prohibited space Prohibited approach boundary Flash protection boundary: An approach limit at a distance from exposed live parts within which a person could receive a second degree burn if an electric arc flash were to occur. (NFPA 70E)

55. Arc Flash Boundary

57. Approach Boundaries Limited Approach Boundary entered only by qualified persons or unqualified persons that have been advised and are escorted by a qualified person Restricted Approach Boundary entered only by qualified persons required to use shock protection techniques and PPE Prohibited Approach Boundary entered only by qualified persons requiring same protection as if direct contact with live part Flash Protection Boundary linear distance to prevent any more than 2nd degree burns from a potential arc-flash (Typically 4 feet)

58. Section 110.16 of the 2002 NEC® Requires Arc Flash Hazard Labels

59. Arc Flash Labeling Required by NEC 110.16 Flash Protection. Switchboards, panelboards, industrial control panels, and motor control centers in other than dwelling occupancies, that are likely to require examination, adjustment, servicing, or maintenance while energized, shall be field marked to warn qualified persons of potential electric arc flash hazards. The marking shall be located so as to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment.

60. Arc Flash Labeling Required by NEC FPN No. 1: NFPA 70E-2000, Electrical Safety Requirements for Employee Workplaces, provides assistance in determining severity of potential exposure, planning safe work practices, and selecting personal protective equipment. FPN No. 2: ANSI Z535.4-1998, Product Safety Signs and Labels, provides guidelines for the design of safety signs and labels for application to products. Reprinted from NEC® 2002

62. Arc Flash and Shock Hazard Appropriate PPE Required

65. 48 inch Flash Hazard Boundary 7.4 cal/cm 2 Flash Hazard at 18 inches HRC 2 PPE Level, FR Clothes, Shield, Hard Hat, Leather Gloves, Leather Shoes, Hearing Protection 480 VAC Shock Hazard when Cover is removed 42 inch Limited Approach 12 inch Restricted Approach - 500 V Class 00 Gloves 1 inch Prohibited Approach - 500 V Class 00 Gloves Courtesy E.I. du Pont de Nemours & Co. Arc Flash and Shock Hazard Appropriate PPE Required

66. Minimize Risk with Good Safety Practices

67. Arc Flash and Shock Hazard Appropriate PPE Required 24 inch Flash Hazard Boundary 3 cal/cm 2 Flash Hazard at 18 inches HRC 1 PPE Level, FR Pants & Shirt – 4 cal/cm 2 480 VAC Shock Hazard when Cover is removed 42 inch Limited Approach 12 inch Restricted Approach - 500 V Class 00 Gloves 1 inch Prohibited Approach - 500 V Class 00 Gloves Courtesy E.I. du Pont de Nemours & Co.

69. NFPA 70E: Safety in Workplace OSHA 1910.333 (a) (1) & NFPA 70E 130.1 Qualified electrical workers shall not be asked to work on equipment that is “hot” or “live” except for two demonstrable reasons : De-energizing introduces additional or increased hazards: a) cutting ventilation to a hazardous location b) emergency alarm systems or 2. Infeasible due to equipment design or operational limitations: a) voltage testing for diagnostics b) start up testing

70. Safety-Related Work Practices 1910-333 Selection & use of work practices General . Safety-related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contact, when work is performed near or on equipment or circuits which are or may be energized. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards

71. Safety-Related Work Practices 1910-335 Safe guards for personnel protection (a)(2)(B)(ii) Protective shields, protective barriers, or insulating materials shall be used to protect each employee from shock, burns, or other electrically related injuries while that employee is working near exposed energized parts which might be accidentally contacted or where dangerous electric heating or arcing might occur.

72. Arc Flash Incident

73. Background May 2003 Troubleshooting energized outdoor switchgear Three workers, all wearing polyester blend clothing Voltage = 13,200V A company security camera filmed the entire accident

74. AF Incident The next scene shows a ball of flame totally engulfing the three workers

75. AF Incident The worker who was standing in front of the equipment on the left hand side is engulfed in flames. The worker laying in the cell is propelled outward in a ball of flames.

76. Injuries 3 rd worker not burned but suffered neurological damage from the blast. Note: He weighed approximately 300 lbs. and was thrown almost 12 feet backwards. Currently OSHA has $148,000 in penalties pending for serious and willful violations.

77. Injuries Two workers 2 nd and 3 rd degree burns over 60% of the body. Synthetic hair nets and hardhat suspension burned into scalp. One burn victim in drug induced come for 6 weeks while burns being scrubbed.

78. AF Incident The worker who was at the bottom of the compartment is crawling away from the equipment with his clothing on fire. The worker on the right lands on his back with his feet in the air. The worker on the left is running away.

79. AF Incident State of shock. Panic after the Arc Flash and Arc Blast.

80. AF Incident The worker on fire is frantically tearing his coveralls from his body. As he is doing this, we can see the workpants he is wearing underneath his coveralls are on fire.

81. Who’s Responsible for Safety? The “Employer” is responsible for OSHA requirements Electrical Safety Program Safety Policies and Procedures Safety Training and Retraining The “Employee” is responsible for Implementing procedures [NFPA 70E-110.3(B)] The “Owner” and Contractors are both responsible To coordinate and document hazards and safety procedures Contractors on site and visa versa [NFPA 70E-110.3(B)]

82. Response to an Electrical Accident Personnel that are Trained in CPR should be identified and available when work near or on energized parts is being performed

83. Response to an Electrical Accident The first step must be to “ TURN THE POWER OFF”

84. What an Arcing Fault looks like:

85. Steps to Take if an Electrical Accident Happens Remove the Immediate Hazard: turn Off the Power Remember that Speed is Essential Extinguish flames Call for Help (911) Begin CPR & First Aid

86. Steps to Take if an Electrical Accident Happens First Aid Cool the burn with water Do not attempt to remove burned clothing Elevate burned limbs Handle the victim with care Treat for shock Maintain body temperature Do not give anything by mouth

87. CPR Personnel that work near or on energized parts should be trained in CPR.

88. What is the best way to prevent the hazards of electricity? S top - Before Action T hink - Risks/Hazards O ptions - LOTO-Tagout- Tryout P rotection - Proper PPE Avoiding energized circuits is the Safest Way!

89. The End Gillis safety services, llc © 6479 County Road 437 Cullman, Alabama 35057 Phone: (205) 913-0107 Cell: (205) 212-4087 E-Mail: [email_address]