1st Reporting
Arc flash training is critical for anyone working on or near live equipment. However, understanding what that means, how close a worker might get, and the required training type can be confusing. After all, arc flash can kill, and we all want to go home safe at the end of our shifts, so it’s critical to find out everything we can about this serious hazard and the training involved with its prevention.
Arc flash training helps professionals stay safe when working with or around electrically powered equipment. The equipment’s power source is above 50 volts, so the potential for arc flash exists.
In this guide, we will discuss the basics of arc flash, the training associated with its prevention, and further details you’ll want to know as a manager or supervisor of those who may face this workplace hazard. We’ll talk about assessing for the risk and some great ways to document training, arc flash risk assessments, and any other electrical or safety-related incident or inspection.
What is Arc Flash?
Fundamentally speaking, arc flash is when electricity arcs outside the intended pathway due to a short in the electric circuit.
What Causes Arc Flash?
Typically, an arc flash occurs due to user error, like a tool getting too close to a live circuit. However, arc flashes might also happen if components in a circuit become loose or faulty. Even dust and condensation can cause an arc flash, so safety is paramount.
You can think of arc flash as mini lightning. The problem with lightning is that many objects don’t respond well to it and tend to explode. This aspect of the resultant arc flash typically causes the most damage due to the expelling of heat and shrapnel when a component explodes due to an electrical arc.
Arc flash can cause building fires, electrical fires, extreme burns, and even death if a person is too close when an arc flash occurs.
Arc Flash Causes Summary:
- Dust
- Condensation
- Component failure
- Corrosion
- User error:
- Dropping tools
- Dropping materials (like metal shavings when drilling into a panel)
- Accidental touches and brushes against energized components
- Installation errors
What is Arc Flash Training?
Arc flash training is specialized training to help professionals understand the dangers and precautions regarding the arc flash event. The training typically lasts around a day; at the end, the professional should be competent in determining arc flash risk potential and complete an arc flash risk assessment.
Who Needs Arc Flash Training?
All electricians should require arc flash training as a component of their license certification.
Furthermore, arc flash training is appropriate for anyone who:
- Works on or near electrically-powered equipment where that power is above 50 volts, and there is a risk of exposure to live components.
But wait, doesn’t that mean anyone near a regular 120-volt circuit needs arc flash training? No, your normal 120-volt circuit at home or office isn’t something you work on live. That is to say that I hope you don’t go near a live circuit. The defining factor is an electrically-powered circuit.
Looking at the above, we now have some definitions we need to address. We need to clarify three things:
- What is the meaning of on or near electrically-powered equipment?
- How does one know the voltage?
Let’s look at the answers to these questions briefly.
On Or Near Electrically-Powered Equipment
We need to assume that there is an exposed conductor. That is to say, we all pick up something powered – a vacuum, touching the power button on a computer monitor – typically powered by the standard 120 volts in North America or the 240 volts in Europe. The idea with arc flash risk potential is that the electrical components do not have protective covers or that a worker could be exposed to electrical hazards during regular operation.
So, for example, any high voltage fuse box where live circuits are exposed if the panel door is opened. In this scenario, if the circuits are de-energized before the fuse box, then a worker can open the fuse panel without fear of arc flash (upon verification of de-energization, that is). However, they still must maintain the appropriate level of training; arc flash training is only necessary if the worker is exposed to the circuit’s live components.
Getting back to the ‘on or near’ concept, we need to understand how regulatory bodies define it. OSHA and the NFPA represent distance as the approach or protection boundaries. The boundary concept works as follows.
Arc Flash Boundaries
- The closest point is the energized component. We can assume this is a ‘direct touch’ position where the electric short is virtually guaranteed.
- The following distance from the energized component is known as the Prohibited Approach Boundary. This distance refers to the space where an arc would be expected given the voltage and thus is considered as dangerous as direct contact.
- Our following distance from the energized component is called the Restricted Approach Boundary. The Restricted Approach Boundary defines the space from the energized part where an arc is possible but not necessarily guaranteed. Therefore, we consider this boundary the edge of high risk versus absolute risk.
- Following the Restricted Approach Boundary, we find the Limited Approach Boundary. This boundary defines the distance from an energized component where a moderate risk of arc flash and shock exists. However, this zone is what we might call a medium to high risk, and arcing is not guaranteed, but still possible in the right conditions.
- The last distance is known as the Flash Protection Boundary. This boundary defines the distance between where an arc flash could occur and where a worker would only suffer a second-degree burn.
How To Determine Arc Flash Safe Distance
To determine the boundary for arc flash, we must evaluate the incidental energy of an arc flash event. Typically this calculation uses the baseline of 1.2 calories per cm2. That is, at 1.2 cal/cm, a worker will survive with 2nd-degree burns, as mentioned above in the boundary descriptions. If you really want to do the math, it’s a bit more complicated. Here’s the IEEE 1584 formula:
DB = [(4.184 × Cf × Ein × (t/0.2) × (610x/EB)]1/x
Where:
- DB = Distance in millimeters of the Arc Flash Boundary
- Cf = Calculation factor of 1.5 for voltages < 1 kV
- Ein = Normalized incident energy
Again, the best bet is to ensure you have an electrician, engineer, or another professional qualified to ascertain the arc flash boundaries. But who doesn’t like a little math?
Labeling Electrically-Powered Equipment
OSHA and Arc Flash Warnings
OSHA regulations don’t make any particular example of arc flash or stipulate training or warning requirements beyond equipment placards stating equipment voltage, wattage, or other relevant data. The intent is that no one will open the live equipment to expose themselves to energized components unless they possess the appropriate training and subsequent certification (like an electrician or electrical engineer with arc flash training).
Qualified Personnel
Further to the above point, OSHA assumes that only qualified personnel work on energized equipment and that the equipment is de-energized before maintenance or other services. If a circuit is de-energized, there is no fear of arc flash. However, it takes a certain level of competence to work on any electric circuit, so anyone working on powered equipment must know the causes of arc flash and how to avoid it.
How To Effectively Prevent Arc Flash
The best way to effectively avoid arc flash is to have a certified master electrician ensure that your facility and equipment are up to speed. Furthermore, arc flash training can cost time and money, so ensuring that equipment doesn’t pose a threat in the first place is the obvious best solution. However, if your industry or operations put workers in harm’s way by the nature of the work, then arc flash training is a must.
Training aside, let’s look at ways your organization can proactively mitigate arc flash potential in your facility and operations.
Arc Flash Risk Assessment
If you aren’t sure whether or not your team requires arc flash training, you need to complete an Arc Flash Risk Assessment. Using an Arc Flash Risk Assessment Form, your qualified personnel can efficiently complete a risk assessment to determine the need for further arc flash training and mitigation.
Who Can Complete An Arc Flash Risk Assessment?
Anyone exposed to live circuits above 50v should have arc flash training. However, to determine the arc flash risk potential, only certain personnel can be allowed to complete the risk assessment. We recommend that for arc flash risk assessments, you employ the skills of a licensed professional electrical engineer. If you have any doubts, just look at the equation noted above and asked yourself if you want to bother.
High-Resistance Grounding
One of the most effective ways to prevent an arc flash is by utilizing high-resistance grounding on arc flash potential equipment. What is it? It uses a current-limiting resistor in the neutral part of the circuit. This form of grounding limits the current when a short occurs, limiting the potential for arc flash. Unfortunately, not every system utilizes this relatively simple addition to the circuits, so in many cases with older systems, they are an addition.
Effective Hazard Communication
Warning Labels
Communication is the key to safety. However, as mentioned, there is little legislation to force employers to provide arc flash warning labels. However, high-voltage labels and live circuits both require warning labels.
According to NFPA 70E, any equipment that may need adjustment, assessment, service, or maintenance while powered needs to have appropriate arc flash warning labels. Otherwise, voltage and other data must be visible on the equipment placard.
Inspections and Risk Assessments
If it isn’t evident by now, let’s clarify that one of the best ways of preventing incidents like arc flash is through proper inspections and risk assessments. Maintaining facilities and equipment in accordance with NFPA requirements is a must in 2023 and beyond. We don’t live in a world where equipment lasts forever, and with that in mind, all equipment needs to have inspections and safety assessments multiple times throughout the equipment life cycle. For this and other safety reasons, we created a tool perfect for your team to document your inspections, the 1st Reporting app.
The 1st Reporting app is a perfect companion for your inspections, and although we hope you don’t need it, emergency incidents like arc flashes. Our app works on nearly any device and empowers your team to complete reports right from their mobile devices. Similarly, its powerful management dashboard and custom form builder make it easy to implement branded and customized solutions.
Appropriate Arc Flash Training – Your Questions Answered
There are a lot of questions about arc flash training that are yet to be answered. So, we’ve put together this handy arc flash training FAQ to help.
Does The OSHA require Arc Flash Training?
Technically, no, and yet, yes. Here’s how: OSHA 1910 stipulates that any worker who may come into contact (or close enough proximity) with electrical hazards must possess the appropriate training. Therefore, we can infer that if workers’ responsibilities place them near live components, they must have arc flash training. However, OSHA does not specify the exact nature of the training, nor does it mention arc flash training. But I don’t think that means that team members don’t need it should they come into contact or proximity to live components during their regular work responsibilities.
Does Arc Flash Training Expire?
Arc flash training is good for three years. However, there are circumstances where it becomes required (or at least an excellent idea in some cases) before three years:
- If there is a change to NFPA 70E requirements.
- If there is an equipment change.
In other words, use common sense. If circuits or legislation have been modified, it’s time to reassess. Similarly, retraining is a must if a person misses something critical and causes a near-miss incident.
How Often Does Osha Require An Arc Flash Study?
You should complete arc flash studies, also known as arc flash risk assessments, every five years or anytime a circuit is modified or serviced. Even replacing existing parts with OEM parts warrants an evaluation. Furthermore, if possible, the equipment should be de-energized, and all connections and components checked to ensure the security and stability of the circuit.
What Is The Best Tool For Documenting Inspections and Incidents?
Naturally, we’re going to say the answer here is 1st Reporting. After all, our team of professionals has spent countless hours, days, weeks, and months toiling away to get it right. What is 1st? Our inspection, audit, and incident reporting companion provides a straightforward user interface to complete one of the many industry forms, checklists, or reports in the app database.
Need something custom? Not a problem. 1st has a fully operational custom form builder built-in standard to the application platform. So, you can easily create customized inspection and incident forms right from the comfort of your office computer. Then, you can easily create teams and add users to the app, so they can use the forms you created.
1st Reporting makes it simple for your team to report incidents or inspection observations fast and efficiently, right from their mobile device.
With dynamic forms that change depending on user input or dynamically linking forms to reports, the sky is the limit, and the possibilities are endless. Join the efficiency revolution and digitize your inspections, audits, and incident reports with the power of 1st in your corner.
