Arc Flash Resource Guide-Whitepaper

8/10/2019 Arc Flash Resource Guide-Whitepaper

1/19

Lewellyn TechnologyArc Flash Resource Guide200 8

ARC FLASH ANALYSIS AND TRAINING

Lewellyn Technology has one objective -- the SAFETY of your employees.

Don't waste time or money on a "Partial Study" that stops at the bus.

We offer a "Complete Study!

Click Here to receive an Arc Flash quote.

Contact us: www.lewellyn.com or 800.242.6673
http://www.lewellynsitespecific.com/Arc_Flash%20Form.htmlhttp://localhost/var/www/apps/pdf/os_pdf/www.lewellyn.comhttp://localhost/var/www/apps/pdf/os_pdf/www.lewellyn.comhttp://localhost/var/www/apps/pdf/os_pdf/www.lewellyn.comhttp://www.lewellynsitespecific.com/Arc_Flash%20Form.html


2/19

An Arc Flash is an explosive release of energy caused by an electrical arc due to either aphase to ground or phase to phase fault. This fault can be caused by many different thingsincluding: accidental contact with electrical systems, build up of conductive dust, corrosion,dropped tools, and improper work procedures.

OSHA 29CFR 1910.335 (a) (1)(i) which requires the use of protective equipment when workingwhere a potential electrical hazard exists and 29CFR 1910.132(d)(1) which requires the employ-er assess the workplace for hazards and the need for personal protective equipment. NFPA70E is the standard that assists with conducting this analysis to determine the protection needed. Can you be cited for not complying with NFPA

70E?.........YES!

Are you confused about Arc Flash and NFPA 70E? Are you in compliance? As a leader in NFPA 70E Arc Flash Hazard training and consulting, we can provide you with a customized compliancesolution for your facility through the following process:

PHASE I - Site Assessment and Electrical System Data Gathering

PHASE II - Short-Circuit and Protective Device Coordination Studies andArc Flash Analysis

PHASE III - Electrical Safe Work Practices Program Planning and Labelingof Electrical Panels, MCC s, and Switchgear

PHASE IV - Electrical Safe Work PracticesTraining

Arc Flash/NFPA 70E What is Arc Flash/NFPA 70E?

What we can do to help YOUR facilitLewellyn

Technology

We Also OfferOn-Site Training and PublicSeminar Training on topicssuch as:

Electrical70E Safety

AutomationMechanicalHVAC

CONTACT US FOR A QUOTE:www.lewellyn.com(800) 242-6673

A Few of our ClientsBall Corporation Pfizer, IncBemis Company, Inc. Philip Morris USA Cargill Meat Solutions Pratt & Whitney Rocketdyne

ConAgra Foods Roanoke SteelDial Corporation Rockwell AutomationLafarge North America, Inc. Schindler Elevator CorpLockheed Martin Siemens MedicalNestle Waters of NA SynthesOccidental Petroleum Corp Tyco HealthcareOwens-Illinois Wyeth Pharmaceutical


3/19

TechnicalArticles

Contact Us:

www.lewellyn.com or 800.242.6673


4/19

Arc Flash Myths and Misconceptions

n this article I want to explore and debunk some of the myths andmisconceptions about Arc Flash that we hear as we travel theountry performing Arc Flash Analysis and giving presentations on0E. These myths, which are numerous, sometimes originate inhe minds of technical people who try to apply their past experi-nce and education to the behavior of an Arc Flash. This doesn'tlways work. Many times we have experienced an engineer,ometimes our own, say: Wow, I didn't expect that. A good por-ion of the myths come from misinformation given out daily by peo-le selling products such as fuses, circuit breakers, infrared cam-ras, fire resistant clothing, and other equipment

will debunk the myths, regardless of the source, based on our xperience performing hundreds of Arc Flash Analyses in hun-reds of location all across the US, Canada, and the Caribbean.

Myth #1 - A Current Limiting Fuse Will Always Reduce TheArc Flash Hazard:This is simply not true. We have met people that have been toldhat if they replaced all of their fuses with the current limiting typehey would not need to purchase fire resistant PPE nor do an Arc

Flash Analysis because the fuses would remove the Arc Flashazards. This could not be more false. In determining the extent of burn injury, the duration is as important as the temperature of

he Arc Flash and the distance from it. The way a current limitinguse operates is when the fault current reaches what is known ashe current limiting range the fuse then becomes an extremely fastcting fuse. Clearing the fault rapidly. These current limiting fusesould even have time delay characteristics, but when the currentimiting range is reached they trip very quickly. A current limitinguse is a quality fuse and we highly recommend their use whenev-r possible; however, they are certainly not a cure-all for Arc Flashazards. A current limiting fuse will mitigate an Arc Flash hazardnly if the fault current is high enough. In their defense, fuse com-anies, in their technical documentation, do not try to hide thisact. In our experience looking at hundreds of facilities, the serious

Arc Flash exposures are created when the fault current is low andoes not reach that current limiting range of the fuse. When thisccurs, the fuse does not clear the fault quickly, which results inengthening the duration of the Arc Flash. Therefore, that particular

use characteristic, and the money you spent to buy it, are wastednd do nothing to remove Arc Flash hazards.

Myth #2 The Arc Flash Hazard Downstream Will Always BeLess Than Upstream:

ometimes the higher Arc Flash hazard will be downstream inour electrical system. Some facilities ask us to come in and do atudy down to the point where the hazard level is a 1 or 2 andhen stop. We refuse to do that because that is not a completetudy and there could certainly be higher than a category 2 expo-ure on down in the system. An example of such an exposureccurred in a factory of a defense contractor where there was a08/120 volt panel serving single phase loads in an office area. It

was fed from a 300kva transformer next to it with no disconnect

etween transformer secondary and the panel. The panel, with

dead-front removed, was a category 4. That requires a full flashsuit, which is commonly referred to as a space suit among electri-cians. The panel that fed this category 4 location was a category2. This panel was installed per the National Electrical Code andviolated no local codes. The combination of no secondary protec-tion, and the clearing time of the over-current protective devicefeeding the transformer, created a tremendous downstream ArcFlash exposure.

Myth #3 An Arc Flash Analysis Is All About Labeling Panels: An Arc Flash Analysis is more than an engineering study that willresult in the labeling of panels. It is a safety survey where you are

identifying hazards in your facility. Some companies speak of an Arc Flash study in terms such as these: We'll come in and doyour study, label your equipment and then you'll know whatPersonal Protective Equipment to wear and that's it. What awaste of money. To reduce the hazards in your facility the studyshould be much more than that. Whoever does your analysis mustnot only identify the hazards; they should also make recommenda-tions on how to mitigate these hazards. You want to engineer these hazards out of your plant, not just identify them so you'llknow what clothes to wear.

Myth #4 We Don't Have To Do An Arc Flash AnalysisBecause We Do Regular Infrared Scans Of Our Equipment:I'm not even sure where to start with this one. We hear this myth

occasionally due to our contact with so many facility safety andmaintenance people.

Arc Flash can be caused by equipment failure such as loose con-nections. An IR scan for hot spots could certainly find this and youcould avoid an arc flash. However, a large number of Arc Flashinjuries are caused by human error. I do not believe data exists onthis, but by speaking to thousands of people across the countryduring presentations of Arc Flash and 70E training, I always askfor personal experiences with Arc Flash. Most of the injuries inthese impromptu case studies are caused by human error. An IRscan you had performed a month ago is not going to protect anelectrician in any way if he accidentally drops his screw driver intoa live panel. We strongly recommend regular IR scans of your

equipment, but they will not remove the need for an Arc Flash Analysis.

Myth #5 NFPA 70E Is Mostly About Arc Flash:If I had to summarize what the latest edition of 70E is trying toaccomplish, I would have to say: to reduce the amount of livework that is being done. I would not say: Arc Flash. Eventhough there are some huge changes in the standard for mostfacilities concerning Arc Flash and the proper Personal ProtectiveEquipment (PPE), it is really about trying to get people to de-ener-gize the circuit first. Putting the circuit in an electrically safe condi-tion is the first line of defense. The PPE, in the words of the IEEEis the last line of defense.

Article by:Daryn LewellynPresident/Founder Lewellyn Technology, [email protected]

CONTACT US:

www.Lewellyn.com or (800) 242-6673
mailto:[email protected]:[email protected]


5/19

70E "What is all the fuss about?"

The National Fire Protection Association's70E Standard for Electrical Safety in theWorkplace is causing quite a storm in indus-ry. From the same people that bring you a

new version of the National Electrical Codeevery three years, 70E has a lot of peopleasking questions like: "What is it?", "Does itapply to us?", "Does OSHA require it?", "Canwe be fined for not doing it?". Some of thesequestions are easily answered-- others aremore difficult.

The national discourse on 70E is pushed intoa gray area by comments made by OSHAeadership. From comments like "OSHA does-

n't require NFPA 70E per se," to an OSHAdirector going as far as saying if he were anemployer and wanted to protect his employ-ees from electrical hazards, he would certain-y "turn to NFPA 70E." However, if you read

between the lines it appears more black andwhite.

Years ago, OSHA realized that national con-sensus standards producing organizations likeNFPA were quite good at the process of

developing standards for specific hazards andt was unwise for OSHA to reinvent the wheel.Why not rely on these existing organizationso develop the standards and OSHA will usehem where applicable. In the mid seventies,

OSHA approached NFPA and asked them tocreate a standard to protect workers fromelectrical hazards in the workplace. Thus theNFPA 70E was born; OSHA used it to createmuch of its 1910 Subpart S and 1926 Subpart

K standards. Through this collaboration, elec-

trical safety in the workplace was improved;many lives were saved and many accidentswere averted.

Although it has been a while since OSHAadopted all of the changes in the newer edi-tions, there have been several updates sinceNFPA 70E was first created. The latest edi-

tion, 70E 2004, has in it many requirementsthat, quite frankly, only a small percentage of facilities in this country have put into practice.

The dilemma is centered on the vagueness of OSHA standards involving electrical safety.OSHA says an employer must protect work-ers from electrical hazards and that employ-ees must wear personal protective equipment(PPE) to protect themselves. This can be

quite complicated; they do not tell you howthis should be done. 70E explains for youhow to accomplish both of these OSHArequirements. I believe the combination of OSHA's intentional vagueness and their reliance on other organizations for detailmakes the process effective. Although, in situ-ations like we find ourselves today, where theNFPA standard has been updated but not fullywritten into the OSHA code, it can become aconfusing environment for the employer toprovide a safe and OSHA compliant work-place.

I travel the country speaking to upper man-agement and electrical personnel of large andsmall organizations regarding the implementa-tion of 70E. Some of the requirements of 70Ethat are causing the most angst in industryamong those companies implementing thestandard are: energized work permits, puttingpanels in an electrically safe condition, writtenelectrical safety programs, Arc Flash, PPErequirements, training requirements, outsidecontractors, and approach boundaries. If these terms sound foreign, it is time youlearned more about 70E.

CONTACT US:



6/19

Of these concerns, none cause more confu-sion than Arc Flash. In some organizations its believed that 70E associates itself with Arc

Flash and nothing more. This assumption iswrong. Arc Flash hazards, which are a smallpart of the standard, are hazards createdwhen electrical energy is release in the formof heat and pressure. It can be caused by a

myriad of problems, some as simple as thedropping of a wrench into a live panel. Otherscan have causes such as an internal failure ina fuse or circuit breaker. The energy releasedcan cause a small spark or a potentially fatalexplosion created by massive amounts of electrical current flowing through superheatedair. As I speak to groups, I always ask who inhe room has witnessed or been a victim of

an Arc Flash. In every group a large number

of students raise their hands; when they areasked to tell their stories, it is obvious thathey have become believers in the power of

Arc Flash and its ability to cause injury. Inevery case, it was an eye opening experiencehat gave birth to a new respect for electricity-an awareness of the fact that the electricity

can not only shock you, but it can also causea potentially fatal injury due to exposure to theheat and explosive properties of an Arc Flash.Fortunately, we do not have to rely on our workers experiencing a near miss or witness-ng an Arc Flash accident to make them

aware of this hazard. We can rely on 70E todo it for us.

An electrical engineering study done of your acility called an Arc Flash Hazard Analysis isequired to protect your employees from Arc

Flash. This study will determine the hazardsof each point in your facility where live electri-cal conductors might become exposed by theopening of electrical enclosures. Simply put,he engineers will calculate the temperature of he energy release and how long it will last.

The three determining factors of the extent of an Arc Flash injury are temperature, distance,and time. Using the results of the study it canbe determined what type of PPE is required

at the location and at what distance to the

exposed live parts must it be worn. The studywill identify those areas of greatest hazard,and make recommendations to reduce thosehazards through modifications in your over-current protective equipment, current limitingfuses, adjustable breakers, etc.

As a former electrician in industry, I under-

stand the changes that 70E will bring to theway electrical personnel do their job. Oneexample of such a change is the push to elim-inate working on exposed energized equip-ment. This is strongly discouraged, unless de-energizing the equipment introduces addition-al hazards or is infeasible.

If you are unable to put the equipment in anelectrically safe condition due to the excep-

tions allowed, then you must obtain an ener-gized work permit, perform a shock hazardanalysis of the equipment, determine appro-priate PPE and insulated tools that arerequired for shock protection, determine theshock protection boundaries, perform an arcflash hazard analysis, determine appropriatePPE required for arc flash protection, deter-mine flash protection boundaries, and notifyanyone in the area of your work. These taskshave been simplified, but represent some of the changes in behavior that are required.

These new requirements will be quite foreignto some electrical personnel, and it is thesepeople that will undergo the greatest changein their behavior. 70E should be looked at as

just that, a behavior change. It must start atthe top of your organization, because every-one needs to realize it is no longer businessas usual.


CONTACT US:



7/19

California and NFPA 70E

n 2004 The National Fire Protection Associationeleased the latest edition of their NFPA 70E Standardor Electrical Safety in the Workplace. This new electri-

cal safety standard has revolutionized electrical safetyor employees and employers throughout the United

States. Everywhere except California, some wouldead you to believe. However, under further examina-ion, employers in California do need to implement

70E as much as the rest of the country.

Myself, and two representatives from Cal/OSHA wereamong the speakers at a recent Arc Flash/70E confer-nce held in Oakland. Being from Indiana I found it

necessary to conduct some research prior to thepeaking engagement on Cal/OSHA's position on 70E

and Arc Flash. I spoke to some of our clients inCalifornia as well as Cal/OSHA officials and what Iheard, over and over, was Oh, it's different out here,or we follow Cal/OSHA not federal OSHA, or aCal/OSHA representative saying. We have not adopt-

d nor do we enforce 70E.

All of those statements are true. Like federal OSHA,Cal/OSHA has not adopted NFPA 70E.

Cal/OSHA's title 8 low voltage regs state:Each employee who is exposed to the hazards of lames or electric arcs wears apparel that, whenxposed to flames or electric arcs, does not increasehe extent of injury that would be sustained by themployee. This subsection prohibits clothing maderom the following types of fabrics, either alone or in

blends, unless the employee can demonstrate that theabric has been treated with flame retardant: acetate,

nylon, polyester, and rayon.

This regulation is good as far as it goes, but it is veryvague and does not tell us how to accomplish it'sequirement. The limited restriction against wearingome synthetic fabrics certainly is not all there is to

protecting an employee from an arc flash incident. It isidiculous to believe that simply wearing a cotton shirtnstead of Rayon will protect anyone from a Category

4 Arc Flash incident. It is impossible to cover all situa-

tions concerning suitable arc flash clothing in the smallparagraph that Cal/OSHA has set aside for this. That'swhere NFPA 70E comes in. Cal/OSHA, just like feder-al OSHA, is relying on 70E as a How To Complyguide. During the presentations in Oakland theCal/OSHA officials stated that 70E would be used assupporting documentation for citations involving elec-trical accidents. And when the Cal/OSHA officials dis-played a slide that said Suitable arc flash clothingwas required by electricians when working on live cir-cuits, I asked, How do you determine what is suit-able arc flash clothing? The Cal/OSHA official repliedNFPA 70E

In summary the position of Cal/OSHA towards 70E isthe same as Federal OSHA. They are not officiallyadopting it, or making it part of the code. But, they willcertainly be using it to determine if you are protectingyour employees.

Article by:Daryn LewellynPresident/Founder Lewellyn Technology, Inc.

[email protected]

CONTACT US:



8/19

Prepare Your Plant for an Arc Flash Hazard Study

An Arc Flash Hazard Study is a complicated engineer-ng survey and analysis; however, preparing for thetudy in advance can make the process much easier

and more accurate, thereby providing your personnela higher level of safety. While an AF study can bedemanding on your time, a correctly executed studycan help improve plant safety by identifying wherehazards are located and whether they can be correct-

d.

The Arc Flash Hazard Study will involve four phases:

1) Data Gathering2) Engineering Analysis of the Data3) Report Presentation, PPE Procurement, and

Labeling4) Training

Of these four phases, only the engineering analysis isdone off site; the remainder of the process occurs

within your plant.

Prepare Yourself n addition to preparing the plant for the study, facili-ies management personnel also need to preparehemselves for the process. As a facilities manager, its important to remember that you are not conducting

an Arc Flash Hazard Study to identify places whereyour electrical personnel will have to wear specialPersonal Protective Equipment (PPE), as the wearingof PPE is a last resort.

Whenever possible, circuits should be put in an elec-rically safe condition before work begins; however,

circuits can't always be rendered safe, and it is for thateason that an Arc Flash Hazard Study is necessary.

The study will identify the hazards so that you canemove as many of them as possible. When hazards

cannot be removed and where circuits cannot be shutdown, your personnel will have to wear special PPEwhile working on exposed live parts of the circuit.They will also be required to wear PPE when they areverifying that a circuit is safe during lockout/tag out

procedures.

Utilizing Your PersonnelThe demands on plant personnel are greatest inphase one. In this phase, outside field technicians willcome to your facility and collect data on your electricaldistribution system, and you and your personnel willneed to assist them. Field technicians will begin atyour connection point(s) to your electric utility, record-ing transformer KVA, wire size, wire length, etc. Fromthere, they will observe your main switchgear, wherethey will collect fuse and/or circuit breaker informationand wire size and length, recording the information onthe panels and equipment fed from the switchgear.They will then move to those loads and panels,repeating the process until they have gathered dataon your entire system.

If your plant has a complete set of accurate one linedrawings of your electrical distribution system, phaseone could be eliminated, but very few plants retainaccurate and updated drawings. Some facilitieschose to do the data collection themselves, but allow-

ing personnel who have not been trained in recogniz-ing exposures to exposed conductors to do so pres-ents significant safety risks. Allowing only trained pro-fessionals to collect data ensures that proper labelsare created and appropriate safety procedures are fol-lowed.

Depending on the size of your facility, the data collec-tion phase could take anywhere from half a day toseveral months, and someone from your plant shouldbe available to assist the field personnel when need-ed. Consider the following example of how your per-

sonnel could provide the field technicians with valu-able and time-saving information: A circuit breaker ina panel is labeled Press #16. The field person needsto know the location of Press #16 so conductor lengths can be recorded and the piece of equipmentevaluated. Generally, the field technician will not befamiliar with your plant and will have no idea wherethat machine is or how to find it. Your personnel willknow where the machine is located, and whether youeven still own it. Oftentimes, the assisting plant per-sonnel will remember that the machine was removedtwo years ago, and that now Furnace #5 is sittingthere. At that point, it must be determined what, if anything, this breaker is actually feeding and its loca-tion in the facility; otherwise the study will have inac-curacies.

The importance of confirming proper labeling prior tothe start of the project cannot be emphasized enough.If panel labels are updated and confirmed prior to thearrival of the field technicians, the study will be muchmore accurate, and less rework will be needed.

CONTACT US:



9/19

Preparing Your PersonnelAs the field technicians arrive at your facility, your per-onnel are going to have some questions. It is best to

prepare yourself for questions in advance, as the fieldechnicians likely will be wearing PPE when they open

panels, and some of this PPE might be foreign to your taff.

One of the common questions we get in the field frommaintenance staff is, "Am I going to have to wear thatgear?"

Our general answer is that we are wearing the PPE toprotect ourselves as we identify hazards so that theydon't have to wear all of the PPE on a regular basis.Let your people know what is happening and thathere are changes coming.

PlanningWhen planning for the Arc Flash Hazard Study it ismportant to consider who at your facility will need to

be present for each phase of the study.

During the data collection phase, an experienced plantlectrician or someone with similar knowledge will

need to escort the field personnel to help them inquipment identification.

Phase three will require plant management, safetypersonnel, engineers, and select other personnel tobe present and will last only a few hours.

Phase four, the training, will involve many people.

Qualified and unqualified both need to be trained.Remember that procedures developed as a result of he study are not only a big change for your electricaltaff but also for anyone working in the vicinity.

Removal of HazardsThe removal of unidentified hazards is the final step inhe process. Although not part of the study, this steps the most important in protecting your personnelrom an arc flash. Money and time will have to be

budgeted for these changes, which might involvechanging fuses or adjusting trip settings on breakersor relays.

After the hazard removal recommendations have beencarried out, new labels must be made, and your studyneeds to be updated.

Safety ProgramYou are required to have a written Safety Program.Make your study part of it. Also write policies requir-ng anyone making modifications to your distributionystem to record any changes they make so the study

can be updated. Ensure that this policy goes into

effect before the study begins so that your systemdoesn't change between data collection and labeling,as this would create inaccuracies. Implementing thepolicy and making it common practice before the stud-ies can help to prevent undocumented changes fromrendering your study inaccurate. Most companies aremaking annual updates a part of their policies. In your Safety Program, you must include information abouthow the modifications will be handled between thetime they are made and recorded and when the studyis updated.

Special Locations and EquipmentIf the location of any panels or equipment is going torequire special training, clearance, or equipment, it isimportant to make arrangements for field personnel tocollect or obtain the necessary data. For example:During the course of an Arc Flash Hazard Study at adefense contractor, we discovered a panel that weneeded was in a clean room that we did not havetraining or clearance to enter. Another instance

occurred at a medical equipment manufacturer, wherea rooftop panel serving air handlers for a clean roomcould not be opened without being shut down. Thefacility was unable to shut it down during our visit. Inboth cases, the plant personnel collected the datalater and forwarded it to us. Plan for these eventsbefore the study to prevent delays.

An Arc Flash Hazard Study can be made less painfulwith proper planning and by preparing your plant andpersonnel before the study begins.


CONTACT US:



10/19

Why You Can't Rely On the 70E Tables to Select PPE

Employers must protect their employees from the dangerous thermal effects of an arcing fault. Employers accomplish this bydetermining what Personal Protective Equipment (PPE) is required for a given electrical exposure. This PPE may involve fire

esistant clothing, hard hats, face shield, full body flash suit, etc. There are two methods commonly used to determine the appro-priate level of PPE required. You can use Table 130.7 (C)(9)(A) from NFPA 70E 2004, or you can perform an arc flash hazardnalysis, which includes calculating the incident energy using commercially available software based on the IEEE 1584 stan-

dard. This more in-depth arc flash hazard analysis is far superior to the tables alone. In very few cases will the table alone resultn the proper level of protection for your employees.

The tables are tasked based and divided into eight equipment and voltage specific sections. In each section several tasks areisted that might be performed on that piece of equipment. An example of this would be in the section labeled, 600V Class Motor

Control Centers (MCCs). One of the ten tasks listed for that piece of equipment is: Work on energized parts, including voltageesting - The table says when doing that task on that piece of equipment it is a Hazard Risk Category 2*. A worker could satisfyhis category by wearing a non-melting t-shirt made of untreated natural fibers, an 8 Cal/cm2 long sleeve fire resistant shirt, 8

Cal/cm2 pants, hard hat, safety glasses, face shield, hearing protection, leather gloves, and leather work shoes. The asteriskmeans the addition of a double layer switching hood is also required. Voltage rated gloves and tools must also be used.

The tables are limited to only 8 specific pieces of equipment. Although the equipment listed covers most situations it may notover yours. If your equipment, voltage, or task is not listed 70E requires an arc flash analysis. The tables most glaring short-oming is that it is based on a predetermined available short circuit current and clearing time. This current is the maximummount that would flow during a short circuit at that point. The clearing time is the length of time it would take the circuit protec-ive device to open and clear the fault. The problem with assuming a certain level of current is that your facility may have a high-r current or a lower current and both can result in an increased thermal hazard. More current can mean a higher temperaturend larger flash, a lower current can result in a smaller flash but a longer clearing time lengthening the duration of the arc flash.

Both of these scenarios increase the extent of the burn injury to the employee. The clearing times for the circuit protectivedevices that are also assumed by the tables may not be your clearing times at that current level. This will introduce huge inaccu-acies in the PPE selected. Another limitation is that it only covers situations up to category 4. Some equipment is higher thanategory 4 in what is known as the dangerous level. This level means the arc flash will be so severe you cannot work on the

panel live.

t is widely known that all accepted methods of calculating the energy released by an arc flash have inherent inaccuracies. Arc

lash is not an exact science and research continues. The use of the tables alone could cause your employees to wear a catego-y 4 flash suit in some situations where if an arc flash hazard analysis had been conducted it would show that perhaps the expo-ure is actually only a category 1 that requires very little PPE. This will make a huge difference to your electrician and his or her bility to do the work. Through years of doing hundreds of studies we have found many examples of this and of the opposite. A

panel that the table says is a category 1 but we calculate it as a dangerous level. It happens all of the time in every study we dohat the tables leave you and your employees vulnerable to exposure to hazardous levels of thermal energy.

The tables are a great tool in a limited number of situations, but if you want to more accurately protect your employees you musthave an arc flash hazard analysis performed at your facility.

Article by:Daryn LewellynPresident/Founder Lewellyn Technology, Inc

[email protected]

C o n t a c t U s : w w w . L e w e l l y n . c o m o r 8 0 0 . 2 4 2 . 6 6 7 3


11/19

Contact Us:


OSHACitations


12/19

Milwaukee Company Penalized$193,500 for Failing to Protect Workersfrom Electrical Hazards

MILWAUKEE, Wis. -- The U.S. Labor Department's Occupational Safety andHealth Administration (OSHA) has issuedcitations and proposed penalties to Pieper

Electric, Inc., of Milwaukee, Wis., for failingo protect workers from electrical hazards.

"To ensure that injury and illness ratescontinue to decline, we must make surehat employers protect employees from

workplace hazards," said U.S. Secretary of Labor Elaine L. Chao. "The significantpenalty of $193,500 in this case demon-

strates this Administration's commitment toprotecting the health and safety of American workers."

The penalty and OSHA citations are basedon an inspection initiated in September 2003 following an incident at a Racine,Wis., wastewater treatment facility wherePieper Electric was contracted to furnish

and install various electrical equipment.On September 23, three Pieper employ-ees were severely burned by an arc flashand explosion that occurred while theywere testing an electrical switchgear unit.OSHA cited the firm for a serious violationof federal training requirements and willfulviolations of lack of personal protectivegear and for failing to de-energize or effec-

ively guard exposed live equipment parts.

Pieper Electric, Inc., employs approximate-ly 430 workers nationwide and had 16workers on the Racine project at the timeof the accident. The company has beeninspected 63 times at various job sitessince 1972 and has been issued a total of 13 serious and 40 other violations.

The company has 15 working days fromreceipt of the citations to appeal before theindependent Occupational Safety andHealth Review Commission.

In fiscal year 2003, OSHA conductedalmost 40,000 inspections, an increase of more than 2000 inspections over 2002 lev-els; more than half focused on high-hazardindustries. For more information, visitwww.osha.gov. The Department of Labor'sOccupational Safety and Health

Administration is dedicated to saving lives,preventing injuries and illnesses and pro-tecting the health and safety of America'sworkers.

For more OSHA Citations visit:

www.OSHA.gov

CONTACT US:

http://localhost/var/www/apps/pdf/os_pdf/www.osha.govhttp://localhost/var/www/apps/pdf/os_pdf/www.osha.gov


13/19

OSHA Citation 306798679/01001

Section 5(a)(1) of the Occupational Safety and HealthAct of 1970: The employer did not furnish employmentand a place of employment which were free from rec-ognized hazards that were causing or likely to causedeath or serious physical harm to employees in thatmployees were exposed to electrical arc flash: a) Athe Weston WPS Power Plant #4, an arc flash hazard

analysis was not conducted. Employees, were working

within the flash boundary (that was not determinedprior to exposure) while testing on an energized 6.9KVprimary/480V secondary panel board without theappropriate personal protective clothing or equipmentand were exposed to the hazard of electrical burnsdue to arc flash. Among feasible means of abatementwould be to comply with the 2004 Edition of theNational Fire Protection Association (NFPA) 70E,Standard for Electrical Safety in the Workplace, Article130, Section 130.3 Flash Hazard analysis: to deter-mine the flash protection boundary, Article 110,Section 110.7(G) Job Briefing: covers hazards associ-

ated with the job, work procedures involved.Abatement Certification or Abatement Documentationequired.tion

Inspection: 306798679

Reporting ID: 0521100

Open Date: 02/11/2005

SIC: 1623

Establishment Name: Van Ert ElectricCompany Inc.

Citation: 01001

Issuance Date: 05/09/2005

Hazard Category: Electric

For more OSHA Citations visit:

www.OSHA.gov

CONTACT US:

http://localhost/var/www/apps/pdf/os_pdf/www.osha.govhttp://localhost/var/www/apps/pdf/os_pdf/www.osha.gov


14/19

Contact Us:


CourseOutlines


15/19

This program is designed for all personnel who work on, around,or near any type of electrically energized equipment. Electrical haz-ards, proper electrical work practices and procedures, and the safe

installation of electrical equipment will be discussed. You will beintroduced to the rules and regulations as required by the OSHAElectrical Safety Related Work Practices Standard 1910.331-1910.335. You will also learn how the NFPA 70E requirementswork in conjunction with the OSHA requirements. Many industryleaders are adopting 70E as their safety standard. Designed tokeep workers safe and up-to-date, this program provides workerswith life saving information. It is perfect for those who needrefresher training, or those who have had little exposure to properwork practices.

OSHA 1910.331-.335Introduction to Electrical Safety and OSHA

Basic Electricity Hazards of Electricity Guarding Exposed/Energized Parts OSHA Standards 1910.331-.335 Accident Awareness and Prevention Proper System and Circuit Grounding Ground Fault Circuit Interrupters Basic Electrical Safety Practices Most Common Electrical Accidents Actual Case Studies

OSHA 1910.331-.335 & NFPA 70E

Note: This program contains graphic accidentmaterial.

NFPA 70E Topics of Interest Background of 70E Qualified vs. Unqualified Hazard Analysis

- Shock Hazards vs. Flash Hazards Approach Boundaries for Shock Protection

- Limited- Restricted- Prohibited

Flash Protection BoundariesPPE Fire Resistant Clothing (definitions) Fire Resistant Clothing Use Simplified PPE Matrix Hazard Risk Categories Sample Tasks with Appropriate PPE Voltage Rated Gloves Insulated Tools Conductive Articles

1910.147 Lockout/Tagout

PROGRAM DESCRIPTION : PROGRAM TOPICS :

E LECTRICAL S AFE W ORK P RACTICES E LECTRICAL S AFE W ORK P RACTICES

Call Us Today! (800) 242-6673 or Visit Us At w w w .Lew ellyn.com

Program Benefits:Increase your safety awarnessLearn how OSHA Standards can work for youBe able to spot hazards and avoid accidentsPossibly prevent the death or injury of a co-

f worker or yourself

Prerequisite: NoneStandard Class Size: Up to 20

Program Length: 1 2 hoursCEUs: 1.2

Please call one of our training specialists about tailoring thisprogram to your specific needs.

S_C112


16/19

E LECTRICAL S AFETY FOR U NQUALIFIED P ERSONNEL

This 4-hour class is designed for personnel that do not performelectrical w ork, but w ork w ith o r near those that do. It is an

excellen t short-class for m achine operators, m echanics, w elders,and non-technical supervisors and m anagers. Th is class w ill dis-cuss electrical hazards, the fourth lead ing cause o f fatalities in thew orkplace, and h ow to avoid them . A ttendees w ill learn w hat isrequired to create an "Electrically Safe W ork C ondition", w hatinform ation is included on the new A rc-Flash and Shock W arningLabels, and w hat this inform ation m eans to " qualified and u nqual-ified" em ployees. In addition, the com m on causes of electricalinjury to "unqualified" p ersonnel w ill be discussed. This class isdesigned to m eet the N FPA 70E requirem ents for training ofunqualified persons".

Note: This program contains graphic accidentmaterial.

HAZARDS ASSOCIATED WITH ELECTRICITYo SHOCKo ARC-FLASHo ARC-BLAST

FUNDAMENTALS OF ELECTRICITYo FLOWo PRESSUREo PATH

ELECTRICALLY SAFE WORK CONDITIONo DE-ENERGIZEDo LOTOo VERIFIED

BOUNDARIESo LIMITED APPROACHo RESTRICTED APPROACHo FLASH

QUALIFIED VS UNQUALIFIED

o DEFINITIONSo TRAINING & TASK TRAINING

LABELSo EXPLANATION OF INFORMATION

EQUIPMENTo CORDS & CABLESo GFCI VS DOUBLE-INSULATEDo GROUNDING

o RESETTING OVERLOADS AND CIRCUIT BREAK

PROGRAM DESCRIPTION : PROGRAM TOPICS :

E LECTRICAL S AFETY FOR U NQUALIFIED P ERSONNEL

Call Us Today! (800) 242-6673 or Visit Us At www.Lewellyn.com

Program Benefits: Increase your safety aw arenessLearn how O SH A Standards can w ork for youBe able to spot hazards and avoid accidentsPossibly prevent the death or injury of a co -

f w orker or yourself

Prerequisite: NoneStandard Class Size: Up to 20

Program Length: 4 hoursCEUs: 0.4

Please call one of our training specialists about tailoring thisprogram to your specific needs.

N_C110


17/19

Contact Us:


Other Information


18/19

COMPLETE NFPA 70E COMPLIANCE ARC FLASH ANALYSIS SOLUTIONS

WHAT - WHY - WHEN - HOW - WHO

WHAT

What is Arc Flash Analysis? Arc Flash Analysis is one of the major steps ofbecoming compliant with NFPA 70E.What is NFPA 70E? NFPA 70E is a standard that is currently being used byOSHA to ensure that employers are addressing Electrical Hazards.

WHYWhy should I care about NFPA 70E? Proper Implementation of NFPA 70Ecould save the lives of your employees.Why should my company care about NFPA 70E? Proper Implementation ofNFPA 70E will eliminate the exposure of lawsuits and OSHA fines - and itsthe right thing to do.

WHENWhen should you and your organization comply with NFPA 70E? Rightnow! Proper NFPA 70E Compliance is a lengthy process. The longer youwait the longer your employees and your organization are in danger!

HOWHow do I comply with NFPA 70E? All aboard! Complete compliance withNFPA 70E is much much more than completing an engineering study andplacing some stickers on your equipment. This is a cultural change that willaffect every aspect of your organization. Anything less than completecompliance is a complete waste of time and money.

WHOWho can help my company achieve Complete Compliance with NFPA 70E?Lewellyn Technology because we are DIFFERENT!Advantages of using Lewellyn Technology:

- Lewellyn Technology is a SAFETY company- We will help you keep your employees safe- We believe in removing hazards- We do not sell electrical equipment, fuses, circuit breakers or PPE - we have no ulterior

motives- We follow ALL of the standards written on the subject - NFPA 70E, 2005 NEC, IEEE1584, & 1910.331 to 1910.335- We have more experience and have completed more projects than any company in the

country- We have In-House experts- Quality is more important than speed- Our instructors teach safety with passion- We consider our customers to be partners in the process - we can only lead the cultural

change, your company must live the change

??

W H Y c h

o o s e L e w e l

l y n

T E C H N O L O G Y

Lewellyn Technology - PO Box 618 - Linton, IN 47441 - 800.242.6673 - www.lewellyn.com


19/19

Contact Us:

www.lewellyn.com or 800 242 6673

Arc FlashClients

- AES- ALCAN Packaging- Ball Plastics Corporation- Ball Metal Division- Banner Packaging- Bemis Company, Inc.- BIMBO Bakeries

- Curwood- Cargill Meat Solutions- ConAgra Foods- Dial Corporation- Guantanamo Naval Base,

CUBA (Department ofNavy)

- Lockheed Martin Missiles

and Fire Control- MACTAC- Nestle Waters of NA

- Occidental Petroleum Corp- OPW Fueling Components- Owens-Illinois- Pfizer Inc- Philip Morris USA- Pratt & Whitney

Rocketdyne

- Rockwell Automation- Schindler Elevator Corp- Siemens Medical- Spartech- Synthes- Tyco Healthcare- Wyeth Pharmaceutical

References available uponrequest.

Documents

Arc Flash Resource Guide-Whitepaper