Arc Flash and Electrical Safety News and Updates in 2024
A look back at developments and news in the world of Arc Flash and Electrical Safety during 2024.
Contents
CSA Z462:24
CSA Z462 is the Canadian equivalent of NFPA 70E, the Standard for Electrical Safety in the Workplace in the USA. CSA Z462, Workplace Electrical Safety, was once very closely aligned with NFPA 70E, however, the 2024 revision (the 6th edition) has some more impactful changes as it diverges from NFPA 70E in a number of areas.
One of the biggest changes is to Arc Flash PPE selection where all reference to "Arc Flash PPE Category" has been removed from the standard. Selection can now be made according to the "Arc Flash PPE Selection Table Method" which divides up PPE based on Arc Thermal Performance Value (ATPV) with minimum values of 4, 8, 25, 40 and 75 cal/cm2. This recognises that arc flash materials and clothing continue to advance and come with higher and higher ATPVs. The 2024 edition also officially recognises the concept of layering PPE to achieve a higher overall level of safety.
CSA Z462 is not well recognised in the UK, so we will continue to focus our attention on NFPA 70E.
Upcoming Changes to Standards
In 2025 it is expected that IEC 63491 "Live working – Guidance for end users for the selection of personal protective equipment against the hazards of an electric arc" and IEC 63232-2 "Live working – Hand protective devices against the thermal hazards of an electric arc – Part 2: Requirements" will both be published as part of ongoing work by the IEC's Live Working technical committee TC 78.
The Arc Flash Hazard and UK Guidance
In The IET's magazine Wiring Matters Issue 100, Mike Frain wrote a useful article setting out the current basis for addressing arc flash in the UK, noting that "legislation in the UK is primarily risk based, goal setting and non-prescriptive". As such, Duty Holders are expected to manage the risks specific to their site or operation and are best placed to determine how those risks are managed. Mike notes that Duty Holders are "expected to do so in a proportionate and practicable way" which ultimately means it is challenging to have a one-size-fits-all approach to arc flash risk management.
Mike's article goes on to detail several documents which can assist Duty Holders with managing arc flash risk, including:
Protecting Employees from Electric-Arc Flash Hazards
After almost 20 years, the Occupational Safety and Health Administration (OSHA) in the USA have provided updated guidance on the arc flash hazard for both employers and employees. The new guidance, available on the OSHA website, includes a 13-page guide for employers and 3 shorter reference documents for employees. It is intended to align with NFPA 70E and so is relevant to commercial and industrial electricians.
G+ Good Practice Guidelines – Arc Flash and Shock Labelling and Associated Signage in the Offshore Wind Industry
This "Good Practice Guideline" was developed and published by G+ Global Offshore Wind in partnership with the Energy Institute. Unfortunately, the document as published has multiple issues and we cannot recommend its use. It contains numerous references to outdated standards and practices, such as use of the Hazard Risk Category to identify PPE. This terminology was removed from NFPA 70E in the 2015 edition of the standard. We provided G+ with initial feedback on a draft of the document in early 2024, however, there was no engagement from G+ and the feedback provided does not appear to have been taken into consideration.
There were several industrial arc flash safety incidents in the UK that went to court in 2024 as well as prosecutions in the USA that resulted in fines being handed out by OSHA.
Aberla M&E Ltd
In May 2020 a cable jointer, Carl Lowery, was working with a colleague to install cables at the main switchboard of a new apartment building in Manchester. Part of the switchboard remained live during the work and a dropped metal nut rolled into an adjacent enclosure where it came into contact with live conductors causing an electric arc flash. Mr Lowery was blown backwards and received serious burns to his arms and face.
An investigation by the HSE found that the precautions taken to prevent objects or people from coming into contact with live parts were insufficient and that there was no procedural mechanism to prevent or appropriately risk assess work on or near live equipment.
Mr Lowery has had multiple surgeries and extensive ongoing treatment since the incident.
Aberla M&E Ltd pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc Act 1974 and were fined £40,000 at Manchester Magistrates' Court on 14th March 2024.
MHS Homes
In January 2023, an employee of a housing company based in Kent was undertaking a fence repair in a garden when they inadvertently struck an underground electrical power cable whilst using a concrete breaker. The resulting arc flash caused severe burns to the face of the worker.
An investigation by the HSE found that although excavations were often undertaken, MHS Homes never provided their employees any information about the location of underground services and had no procedure or equipment in place for safely detecting underground services.
MHS Homes pleaded guilty to breaching Regulation 16(2), by virtue of non-compliance with Regulation 25(4) of the Construction (Design and Management) Regulations 2015 and were fined £528,000 on 24th April 2024.
Source: Housing company fined more than £500,000 after worker suffers burns
New Earth Solutions (West) Ltd
In July 2021 a worker at a waste management site was using a metal crowbar to help him move heavy electrical cables when the crowbar came into contact with a live conductor causing an arc flash and electrical explosion. The man, who was working at height, suffered serious injuries as well as further injuries sustained from the fall.
The HSE investigation found that the worker had not received any training with respect to electrical work and that the task had not been properly planned or risk assessed with electrical equipment and cables remaining live.
New Earth Solutions (West) Ltd pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc Act 1974 and were fined £200,000 at Lincoln Magistrates' Court on 10th May 2024.
Source: Waste management company after worker suffers burns to body and face
Stanley Black + Decker, USA
A worker at a Stanley Black + Decker facility in Ohio, USA was replacing fuses on an industrial oven in December 2023 when an arc flash occurred. The worker was hospitalised with severe burn injuries.
Following an investigation by OSHA, the safety regulator in the US, the company was cited for multiple safety issues including a failure to train electrical maintenance employees undertaking maintenance on energised electrical equipment and failure to provide personal protective equipment.
OSHA proposed penalties totalling more than $222,000.
Source: Stanley Black + Decker cited by OSHA for electrical safety failures
Smith's Electrical Service and Repair LLC
Following investigation of an incident that took place in September 2023 an Alabama-based electrical contractor was fined more than $93,000 for exposing an electrical worker to shock and burn hazards.
An electrician received life-threatening burns when an arc flash occurred as he was guiding cables through an electrical cabinet. A cable end touched live components leading to the arc flash.
Smith's Electrical Service and Repair LLC were cited for three serious violations: failing to train workers to recognised hazards, permitting work on live electrical equipment without adequate training, and allowing workers to undertake work without the proper PPE.
There were other electrical safety incidents that resulted in court cases in 2024, showing that electric shock continues to be a major hazard. A summary of these incidents is provided below with links to more detailed articles included.
33kV Electric Shock
An electrical maintenance company were fined £80,000 after a worker received a 33kV electric shock whilst working on a live distribution tower in Wales. He suffered from severe electrical burns. The HSE also found the tower owner, National Grid Electricity Distribution (South Wales) Plc, guilty for failing to ensure work was being undertaken safely. They were fined £3.2 million for breaching Regulation 14 of the Electricity at Work Act 1989.
11kV Electric Shock
A scaffolding firm were fined £50,000 and their director given a suspended prison sentence after a scaffolder working for them brought a 6-metre scaffold pole into contact with an 11kV overhead power line. He suffered electric burns to both hands and fell from height, resulting in a broken leg.
11kV Electrocution
A contractor was fined £30,000 after a delivery driver, delivering crushed concrete to a worksite, put the vehicle's crane arm into contact with an overhead 11kV power line leading to the driver's electrocution.
Bowen Basin Mine, Queensland, Australia
February 2024 – An electrical worker at an underground coal mine accessed a live 11kV enclosure without following site procedures. An arc flash occurred causing the worker to receive serious burns to their left arm and right hand. The worker was hospitalised. A safety alert issued for Resources Safety & Health Queensland made recommendations for site senior executives, supervisors and electrical workers.
Injured PersonEV Charging Station, Baxter MN, USA
May 2024 - An electrical technician was testing a 400A circuit breaker installed at an EV Charging Station. He was unaware that the circuit was energised and clamping his test equipment onto the circuit breaker resulted in an arc flash. He suffered full-body third degree burns and various other injuries and was immediately airlifted to hospital where he was placed into a coma ready for extensive surgeries.
Injured PersonHonolulu, Hawaii, USA
June 2024 – whilst power workers were working to restore supplies to customers following an outage, an arc flash occurred inside a manhole leading to further supply disruption. Although there were four utility workers in the manhole at the time, no injuries were sustained. It is thought that the arc flash occurred at a splice connecting two high voltage cables when power was restored.
Equipment DamageTownville, South Carolina, USA
July 2024 - A contractor working for Upcountry Fibre and Blue Ridge Electric Cooperative on broadband internet installation was severely injured by an arc flash from an electrified line. They were taken to the Augusta Burn Center for treatment.
Injured Person
The incident followed an electrocution the previous week in nearby Anderson, SC, when a worker with the Anderson Regional Joint Water System was fixing a broken air conditioning unit and cut through a live wire.
FatalityMaryneal Quarry and Mill, Texas, USA
August 2024 – An electrician was working on a 4.16kV motor control centre when an arc flash occurred. The incident occurred 9th August with the victim dying from the injuries received on 22nd August. In the fatality alert released by the Mine Safety and Health Administration they cited best practices including LOTO, use of correct equipment and arc rated PPE, and establishing safe procedures prior to beginning work.
Earlier in the year the MSHA released a Safety Alert reporting on 11 miners receiving injuries due to electric arc flashes in the six months prior to June 2024. The safety alert included images of damaged equipment and PPE.
Fatality6.6kV Switchgear Failure, UK
A post by Pleavin Power Ltd on LinkedIn showed the aftermath of what appears to be an energetic arc flash event that has caused significant damage to a 6.6kV switchboard.
Equipment DamageSamara Oblast Substation, Russia
October 2024 – dramatic footage (see this Youtube video) was shared of an arc flash that occurred whilst a worker was inserting a high voltage circuit breaker truck into a substation switchboard. The worker, who appears to be wearing appropriate arc flash PPE, including a face shield, escapes the building with a colleague in time to watch the substation and a nearby oil-filled transformer go up in flames. According to reports the fire was tackled by 20 firefighters and 4 fire trucks and left residents without power for several hours.
Equipment DamageProlec, Waukesha, USA
December 2024 – An employee of Prolec GE Waukesha, a manufacturer of power transformers, was found dead at the scene of an incident which is believed to have been an arc flash event. OSHA and others are investigating.
FatalityLow Voltage Switchgear Failure, UK
A post by Specialist Switchgear Ltd on LinkedIn showed the aftermath of a damaging arc flash at the main incomer of a low voltage MCCB distribution panel.
Equipment DamageArc Flash Awareness Day (Online)
The inaugural Arc Flash Awareness Day was organised by ProGarm and took place online on 7th June 2024. A series of talks were given by industry figures focusing on what an arc flash is, how it can be assessed, how the risk can be reduced and finally how PPE can be selected and used.
The video of each talk can still be accessed on the event website: Arc Flash Awareness Day 2024
In the lead up to Arc Flash Awareness Day we gave a presentation to the IET Scotland North local network branch in Aberdeen covering arc flash in the energy industry. It drew on our experiences working within the industry to explain where arc flash can occur and how it can be effectively managed. We used a recent incident in the Norwegian offshore sector as the basis for discussion.
Global Electrical Safety Conference, London (UK)
Skanwear put on their second Global Electrical Safety Conference, this time at the London offices of the Institute of Engineering and Technology on Savoy Place. We exhibited during session breaks and had many interesting conversations about electrical safety and arc flash.
We also attended the various conference sessions which brought together a range of speakers and topics of interest. These included:
- Bill Bates, a former Principal Electrical Inspector with the HSE, who shared his views on electrical safety including analysis he had done of electrical incidents looking at the types of incident, underlying causes and the activities being undertaken.
- Gareth Lock, delivered a fascinating presentation on operating safely with people, providing insights on safety culture and complacency and the need to move forward after incidents occur (by learning) rather than going backwards (by placing blame).
- David Armour, presented insight into an arc flash incident that occured within the onshore wind industry and is still under investigation. It touched on some fundamental principles of safe working such as clear identification of equipment and the danger that arises when assumptions are made.
All About Arc Flash Conference, Birmingham (UK)
Transmag UK organised the one-day All About Arc Flash Conference which was held near Birmingham in September. The conference took a holistic look at arc flash management, diving deeper into some of the mitigation technologies and providing a number of case studies.
The sessions and exhibitors were all of interest, but in particular it was a pleasure to meet and speak with Jim Phillips who came over from the USA especially to give the keynote speech, whilst Mike Frain was presented with a lifetime achievement award for his contributions to electrical safety.
ETAP Spark, Global Digital Conference (Online)
ETAP's global conference was once again held online and was changed up this year to have several different presentation tracks running simultaneously. Arc flash was once again a prominently featured topic and at present you can still rewatch the following sessions on their online conference platform:
Should Motor Starting Be Evaluated When Mitigating Arc Flash? - a case study using ETAP to look at the fault contribution from large motors and a discussion of mitigation options that may be applicable.
Arc Safety Convergence with AC & DC Arc Flash - an overview of the capabilities offered by ETAP for both AC and DC systems.
DC Arc Flash for Battery Energy Storage Systems - a case study looking at the DC arc flash hazard within BESS. The session covered short circuit characteristics of storage batteries and how ETAP's transient DC arc flash approach can be used to determine the energy involved.
SafetyOn Stakeholder Forum, Edinburgh (UK)
The 2024 SafetyOn Stakeholder Forum was held in Edinburgh in early December 2024. SafetyOn is the UK onshore wind healthy and safety organisation that compiles injury and fatality data, and produces guidance intended to improve safety within the industry.
The forum provided an opportunity to share the progress that had been made during the past 12 months and set out the agenda for year ahead. The United Kingdom's Health and Safety Executive shared an interesting presentation which called attention to recent electrical incidents, including an arc flash occurence in a wind turbine. It is expected that SafetyOn will release the report looking at Electrical Safety Safe by Design early in 2025.