An arc flash is a powerful and dangerous electrical explosion that can cause severe injuries and costly equipment repairs. According to the Occupational Safety and Health Administration (OSHA), arc flashes are responsible for the majority of electrical injuries each year in industrial and manufacturing facilities. Yet, many industrial workplaces operate under a “safe enough” mindset, putting workers at unnecessary risk.
Understanding what an arc flash is and how to prevent one with regular arc flash analysis assessments is the best way to protect your employees and facilities.
What Is an Arc Flash?
An arc flash is a sudden release of electrical energy caused by an electrical fault, which produces an explosion of intense light and heat. Key features of an arc flash include:
- Extreme Heat: Temperatures can reach up to 35,000°F (19,426°C), hotter than the surface of the sun, which can lead to severe and even life-threatening burns.
- Pressure Wave: The rapid expansion of heated air creates a pressure wave that can cause severe injuries and damage equipment.
- Light and Noise: Blinding light and deafening noise can lead to sensory damage, such as hearing loss.
- Molten Metal: Vaporized metal droplets and flying debris can cause burns and start fires.
In addition to the potential risk to employees, arc flashes can result in costly repairs, unplanned downtime, and production disruptions, all of which can lead to significant financial losses.
What Causes an Arc Flash?
Arc flashes result from a combination of equipment issues and human factors. Outdated equipment and equipment with a lot of wear and tear can compromise insulation or connections, increasing the likelihood of an arc flash. Faulty or outdated electrical equipment can be minimized or avoided with electrical preventive and predictive maintenance.
It's unfortunately all too common for employees to ignore safe work procedures or use tools improperly. This can cause accidental contact with energized parts and devastating arc flash accidents. Additionally, improper installation, such as incorrect configurations or setups, can create vulnerabilities that heighten the risk of an arc flash.
How to Prevent an Arc Flash
Arch flashes can be prevented with diligence, regular equipment inspections and preventive electrical maintenance that specifically includes Arc Flash Analysis. This allows you to address potential hazards before they escalate into serious incidents and helps protect both workers and equipment.
A comprehensive arc flash prevention plan should include the following steps:
- Commit to Routine Maintenance: Schedule regular inspections and servicing to identify and resolve potential issues early. Consistent upkeep helps maintain system integrity and safety.
- Train Employees Thoroughly: Provide proper and frequent training on equipment operation, safety protocols, and emergency procedures to ensure employees are prepared to handle potential risks.
- Require Personal Protective Equipment (PPE): Equip workers with appropriate arc-rated clothing, gloves, face shields, and hearing protection to reduce the risk of injury.
- Label Equipment Clearly: Mark arc flash hazard boundaries and provide equipment-specific energy level information to ensure workers are aware of potential dangers.
- De-energize Before Working: Whenever possible, work only on de-energized equipment to reduce or eliminate the risk of an arc flash.
- Follow Established Safety Standards: Train and adhere to specific guidelines such as NFPA 70E (Standard for Electrical Safety in the Workplace) to maintain compliance and implement best practices.
Preventive maintenance is the best way to improve workplace electrical safety and prevent injuries. Check out our complete preventive maintenance guide to learn more!
Importance of an Arc Flash Analysis
Industrial facilities should also conduct regular arc flash analysis assessments to significantly reduce the risk of an arc flash. These assessments closely examine the electrical systems and equipment components like switches, panels, and breakers. An arc flash analysis helps uncover risks, identify problem areas, and ensure everything operates safely and efficiently.
A thorough Arc Flash risk assessment includes:
- System Evaluation: Review electrical equipment to identify potential failure points.
- Data Collection: Gather system specifications, diagrams, and maintenance history.
- Energy Calculations: Determine incident energy levels and safe working distances.
- Hazard Identification: Pinpoint high-risk areas and assess the likelihood of incidents.
- Risk Mitigation: Recommend system upgrades, operational changes, and appropriate PPE.
- Labeling and Documentation: Provide hazard labels and detailed assessment reports.
- Compliance Verification: Ensure systems meet NFPA 70E and OSHA standards.
- Employee Training: Educate workers on safe practices and proper use of PPE.
An arch flash analysis not only protects workers but also helps facilities avoid expensive repairs and comply with safety regulations from organizations like OSHA and NFPA.
Who Can Perform an Arc Flash Analysis?
Only qualified engineers and trained individuals with expertise in electrical design and electrical distribution systems should conduct an arc flash analysis. These professionals use advanced technology to model simulated arc flash events on the equipment. This ensures accurate hazard identification and tailored recommendations.
How Often Should Arc Flash Analysis Be Conducted?
Industry standards recommend conducting an arc flash analysis every five years or whenever there are significant changes to an electrical system, such as new equipment installations, system upgrades, and adjustments to breaker settings and load configurations.
Lemberg is proud to offer Milwaukee-area businesses a full range of expert commercial and industrial electrical services for buildings of any size or complexity. Contact us today!
Choosing the Right Electrical Contractor to Perform an Arc Flash Analysis
Selecting the right partner for an arc flash analysis ensures accuracy, compliance, and safety. Look for an electrical contractor with in-depth knowledge of workplace electrical safety, NFPA 70E standards, and proven expertise working with complex industrial and manufacturing heavy equipment. Certifications, positive customer reviews, and a strong commitment to safety are also important indicators of a reliable and trustworthy industrial electrical contractor.
Developing a relationship with a trusted contractor who can assist you in creating a preventive maintenance calendar will help protect your employees, your business and your budget.
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Why Choose Lemberg?
Lemberg is the trusted electrical contractor for industrial facilities in the Milwaukee area. With decades of experience and a focus on safety, our expert team recognizes the distinct needs and challenges of industrial environments.
Our team is fully equipped to work on heavy machinery for manufacturing processes and provide comprehensive industrial electrical services, including tailored arc flash analysis assessments. We are also happy to provide a quote for arc flash training for our customers and their maintenance staff.
Contact us today to schedule an arc flash analysis and ensure a safer, more efficient workplace.
