IESO, LLC recently published an arc flash article (http://iesollc.com/wordpress/2009/06/22/arc-flash-safety-history-and-requirements/) on our website.  We continue to recommend the rigorous analysis proscribed by IEEE 1584, and warn against “quickie” or generic solutions.  This safety alert illustrates a real-world example of why that is.

An industrial facility recently asked IESO, LLC to evaluate arc flash results from another consultant who reportedly used a customized program developed in-house.  The facility management team was concerned about the lack of time that the consultant spent on-site (less than five hours), the minimal review of electrical components and the generic results.  Labels for all electrical components were identical whether for buss plugs, MCC panels or substation switchgears, and the facility staff had serious doubts that they got what they paid for.

Our review of selected components at the site revealed highly inaccurate information on nine of 10 labels.  For example:

• calories per square centimeter understated by 200-450%
• protection boundaries inaccurate for calories generated
• PPE requirements dangerously low for the potential arc flash generated
• unrestricted components that should have been listed as “Extremely Dangerous – Do not Work on while Energized”

This is literally a case where a program that allegedly met OSHA requirements was inadequate to the point of threatening employee life and safety.  There is no doubt in our minds that following a serious injury or fatality, a thorough investigation would find the facility and the consultant at fault or even negligent.

We advise all facilities to review their arc flash program elements to determine whether calculations are adequate and protective of your employees and contractors.  Look for warning signs such as obviously underpriced, little or no time spent at the site or “one-size-fits-all” results.  Ask your consultant or corporate safety staff for a review of selected components.  If they did not or will not use the more demanding IEEE 1584 standard, insist on a detailed explanation.  You do not want to find yourself having to defend a weak program to OSHA or a jury after the fact.

Joe O’Nan is a Health and Safety Specialist at IESO, LLC with over 25 years experience in EHS and project management.  He is NFPA-trained in arc flash analysis and the NEC, and has extensive experience in electrical safety, hazard and job safety analysis, accident investigation and safety-related training.  Dr. Scott Harris is the Senior Risk Manager for IESO, LLC.  His experience covers over 27 years of Environmental, Health and Safety Management in Federal and State government, consulting, general industry and University instruction.

Last 5 posts by Scott Harris

• Arc Flash: Who's Training the Trainers? - May 31st, 2010
• Joint Commission Requirements for NIMS in Healthcare - May 13th, 2010
• OSHA Looking Hard at Healthcare Worker Infectious Diseases - May 10th, 2010
• Arc Flash Alert for Healthcare - May 4th, 2010
• Lift Platform Safety Alert - May 1st, 2010

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