10 Most Common PPE Mistakes in Electrical Arc Flash

Top 10 Mistakes

Electrical Workplace Safety

1. The 100 cal/cm² Delusion: The “err-on-

the-side-of-safety-mistake”

Electrical Workplace Safety How Bad is Bad?

Electrical Hazards – Arc Flash

Watch the disconnect door.

How much protection would work in this arc? Is over protection a good idea? What works best here, PPE or work practices or a combination?


Avoiding Mistakes

• Overkill on PPE “sounds” smart but it has two negatives – Sends the wrong

message – If the workers don’t

believe you they may cut corners when no one is watching.

– Watch out for salesmen’s little lies…

– Better safe than sorry?? – Better safe and right

Match PPE to the hazard

Top 10 Mistakes


2. “We got ‘dem kits” programs OR

“We have coveralls” programs


Avoiding Mistakes

• Making the program cheaper or easier for management or the safety department or for enforcement may not be the most cost effective or the best program.

• A natural program that becomes a worker’s habit is the most reliable.

• Tends to over protect or not protect at all.

• Match the kit to the level – Don’t buy 100 cal kits for everyone.

• Arc rated daily wear is better than a “coverall program.” – Darlene’s story

Make the program easy for the worker

Level 2 Kit

Top 10 Mistakes


3. The “get-a-Size-12-Class-2-rubber-glove-for-

all-arc –exposures” Program


She needs smaller gloves

He needs special coveralls/suits

Top 10 Mistakes


4. The “Flame Resistant(FR)-labeled-clothing-is-all-I-need-in-

the-electric-arc” delusion.

Electrical Workplace Safety Arc Rated or “FR”?

Arc-Rated PPE – Clothing

Vertical Flame Test (ASTM D6413) not good enough alone.



Beware of: • “FR until washed

or dry cleaned” • Melting “FR” • “FR-treated”

acrylics, polyester, nylon

Got Arc-Rating?

Because of the misuse of the term FR, NFPA 70E removed the term favoring arc-rated.

Electrical Workplace Safety “FR” Melted Onto the Head


Electrical Workplace Safety Rainwear


Not all FR rainwear is arc rated. Any FR rainwear with a melting substrate will usually increase

worker injury.

Top 10 Mistakes


5. “We bought this PowerPoint” Programs


• Generic training doesn’t always get to the finer points.

• Site specific written programs are critical • Unique hazards must be considered

– FR cotton and 20% body burns from sodium hypochlorite.

– Aramids and welding spatter. – Melting polyester in cleanrooms.

• Train + Audit + Knowledgeable Management = A Great Program

Top 10 Mistakes


6. The “buy-everyone-an-arc-flash-suit-and-do-

calculations-later” delusion


• Assessment will not change the level of protection but it will change how often you need to wear it.

• Don’t put off PPE purchases waiting on assessment

• Daily wear for all electrical workers • Suits for high level exposures • Operators work in natural fiber or are rated

gear depending on level of exposure.

Don’t put off PPE purchase but

Top 10 Mistakes


7. Focusing on Arc Flash rather than Shock


• Shock is the number one killer of the electrical hazards.

• More bang for the buck with right PPE than engineering. Most important engineering is done by proper installations, maintenance then equipment upgrades. Engineering out the arc flash hazard is not always an option.

Top 10 Mistakes


8. Ignore specialty Gear


Avoiding Mistakes

• ASTM F1506 – Hairnets/beardnets – Cleanroom gear – Gloves (Proposed separate Standard) – Disposable FR Wear

• ASTM F1891 – Rainwear – Chemical gear + Chemical Standard

• ASTM D2413 + D1116 – Shoes (EH or DI or leather, etc.)

• Other Specialty PPE must be evaluated by the AHJ

Don’t forget specialty gear

Top 10 Mistakes


9. Safety Department Can Do it On Our Own,

Safety Myopia: “The Daisy Chain

Delusion”


Avoiding Mistakes

• The five people you need to do proper hazard assessment for electrical – Trouble making electrician – Nicest electrician – Smartest electrician – Electrical Engineer – Safety Person

The Electrical Safety Team


Safety-Related Work Practices Sometimes we only look for what we know…

Daisy chaining power cords is prohibited by OSHA, Sir.


Three Types of Audits Required

Observations required to do the following: • Identifies:

• Demonstrate task proficiency

• Retraining needs • Supervisory level • Part of evaluating Qualified

Persons

Supervisory Safe Work Practice Inspection

NFPA 70E 110.2(D)(1)(f)

Minimum annual supervisory work practice inspection to monitor safe work practices


Three Types of Audits Required

Better practice: Separate from Supervisory Audit. Observations required to do the following: • Prove procedures work • Identify:

• Procedures that don’t work • Changes that should be

made • Retraining needs

Annual Field Work Audit

Site audit looks at the site’s practices and could include NEC auditing and NFPA/OSHA auditing 110.4 (H)(2)

Best practice: Separate from Supervisory Audit. • Year One: Internal by

local safety/electrical dept.

• Year Two: Cross-pollinate using another professional from another plant or industry

• Year Three: Outside Audit by competent auditor


Avoiding Mistakes

• Documented electrical safety program audit (not more than every 3 yrs.) NFPA 70 E 110.3 (H)(1)

• Must reviewed Arc Hazard Assessment minimum of every five years. – Updates required if major

modifications or renovations. – Required for calculations or if

Tables used. – Should include audit of labeling.

Electrical Safety Program Audit & Hazard Assessment Audit


Safety-Related Work Practices

Habit 1 Always verify absence of voltage & use VR gloves & tools.

Habit 2 Establish worker safety boundaries from shock & arc flash.

Habit 3 Always wear arc-rated daily wear and a face shield.

Habit 4 Always use GFCI with cord connected tools & extension cords.

Habit 5 When feasible create an electrically safe work condition.

Habit 6 Plan your jobs, use standards to identify greater hazards, & adopt controls & PPE to mitigate hazards.

Habit 7 Measure, audit & continuously improve electrical safety processes.

7 Electrical Safety Habits™

Top 10 Mistakes


10. Fill in the Blank...


For more information on electrical arc PPE, for help on selecting the proper arc

PPE or for a custom quote, Contact your local

Magid Glove & Safety Sales Representative

1-800-444-8030 www.magidglove.com


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10 Most Common PPE Mistakes in Electrical Arc Flash