HAZARD MANAGEMENT GUIDELINE - ELECTRICAL ARC FLASH - March 2019
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This publication is supported by AGL pursuant to an enforceable undertaking Intellectual property licence AEC grants SafeWork NSW a permanent, CONTENTS between AGL Macquarie ACN 167 859 494 irrevocable, royalty-free, worldwide, non- and SafeWork NSW, dated 16 April 2018. 1.0 PREFACE 4 exclusive license to use, reproduce, distribute, This document has been prepared by a cross electronically transmit, electronically 2.0 OBJECTIVES 6 section of Electricity generation industry distribute, adapt, and modify any materials practitioners and professionals and is developed as a result of this enforceable 3.0 SCOPE 8 endorsed by the Australian Energy Council undertaking. 4.0 CONSIDERATION OF HUMAN FACTORS 10 (AEC). The contribution of AGL Macquarie, Alinta Energy, Synergy, Delta Electricity, 5.0 ELECTRICAL ARC FLASH HAZARD MANAGEMENT 12 Stanwell, CS Energy, Hydro Tasmania, Snowy A commitment regarding linking the strategy 5.1 Overview of Hazard Management Process 12 Hydro, Thomson Bridge, Origin Energy, and promotion of benefits to the enforceable ENGIE, HIESN and Palisade Asset Management undertaking 5.2 What is an Arc Flash? 13 is appreciated. AEC is committed to ensuring that any 5.3 What is Arc Plasma? 15 This document was published by the promotion of a benefit arising from this 5.4 Other products of an Arc Fault 15 Australia Energy Council (AEC) Level 14, enforceable undertaking will clearly link the benefit to the undertaking and that the 5.5 When and where do electrical faults occur? 16 50 Market Street, Melbourne, VIC, 3000. undertaking was entered into as a result of the Table 1: Increasing arc flash risks with work activity 19 alleged contravention. 5.6 Incident Energy / Heat Flux 19 Disclaimer 5.8 Effective implementation of arc flash controls 20 This document refers to various standards, guidelines, calculations, legal requirements, 5.8.1 Labelling 20 technical details and other information. Table 2: Typical electrical worker activities and suggested risk controls 23 Over time, changes in Australian Standards, 6.0 DEMONSTRATION OF INDEPENDENT COMPETENCY IN PERFORMING industry standards and legislative THE FOLLOWING TASKS 29 requirements, as well as technological advances and other factors relevant to the 7.0 ADDRESSING THE HUMAN FACTORS 34 information contained in this document, Table 3: Typical human factor activities and suggested risk controls 36 may affect the accuracy of the information contained in this document. Accordingly, 8.0 MANAGEMENT OF CHANGE 38 caution should be exercised in relation to 9.0 ANNEXES 39 the use of the information contained in this document. Annex A: Arc Flash Risk Assessment and Control 40 Correspondence should be addressed to the Annex B: Arc-Rated Clothing and Personal Protective Equipment 47 GM Policy and Research, Australian Energy Annex C: Do’s and DON’T’s of Arc Flash Labelling 50 Council (AEC), Level 14, 50 Market Street, Annex D: Arc Flash Incident Energy Calculation Methods (‘Theory’) 52 Melbourne, VIC, 3000. Annex E: Calculating Incident Energy or Heat Flux (‘Practice’) 56 Annex F: Electrical Arc Flash Hazards Management Guideline Checklist 61 COPYRIGHT Annex G: References 62 © 2019 Australian Energy Council Annex H: Definitions 64
1.0 PREFACE 2 0 cal/cm 2 4 cal/cm 2 8 cal/cm 2 25 cal/cm 2 40 cal/cm Electric arc flash is a serious hazard which has This Guideline recommends minimum industry PPE PPE PPE PPE PPE CATEGORY CATEGORY CATEGORY CATEGORY CATEGORY the potential for personnel injury, equipment standards, is advisory only and does not damage and loss of business objectives. In Australia, it has been found that there is a need for increased awareness and greater substitute for, or override, any legislation, regulation or safety rules implemented by jurisdictional regulators or Energy Industry 0 1 2 3 4 education within the Energy Industry to operators. eliminate or minimise the risk of injury to Supporting and detailed technical information Icons in this guideline. Refer to Diagram 18 in Annex B for a more detailed description of correct PPE categories. persons from an arc flash. has been provided in several annexes to The guidance material on the elimination assist the development and implementation or minimisation of arc flash hazards across of Energy Industry organisations’ specific arc Australian workplaces is not available in flash hazard management systems. They have an accessible or practical form and is not been provided for the purpose of information available free of charge. Currently there are and guidance only. several national and international standards and a large volume of technical material published by standards organisations, industry associations and equipment manufacturers on Time to arc flash — 5 mS electric arc flash. There is a need however for Temperature of arc flash plasma — 5000°С a consolidated guideline that incorporates the collective electric arc flash hazard knowledge and experience and the presentation in an Metal Vapor easy-to-read guideline that can be easily accessed and shared by in the Australian Energy Industry. Further, there is a need for consideration of the general effect of human factors and of the specific requirements of young workers and workers deemed ‘vulnerable’ (such as workers with an inadequate amount of training or competency in arc flash risk controls) in the Energy Industry in managing electric arc flash hazards. Intense Light Sound Waves > 140 db Pressure Waves > 13.7 MPa Shrapnel Molten Metal Droplets Diagram 1. Arc flash effects 4 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 5
2.0 OBJECTIVES Supporting and detailed technical information has been provided in several annexes, namely: The objectives of this Guideline are to: This Guideline supports the objectives of >> Annex A: Arc Flash Risk Assessment the This Guideline supports the objectives >> Annex B: Arc-Rated Clothing and Personal >> Provide an effective hazard management of the National Electricity Network Safety Protective Equipment process and set of recommended Code (ESAA NENS 09) to promote nationally practices appropriate to the Australian >> Annex C: Do’s and DON’T’s of Arc Flash consistent practices within the Energy context, for application where electrical Labelling Industry for arc-rated clothing and Personal arc flash hazards may be encountered >> Annex D: Arc Flash Incident Energy Protective Equipment (PPE) for all work on across the construction, operation, and Calculation Methods (‘Theory’) or near electrical equipment where there is maintenance of electrical apparatus within a possibility of exposure to residual arc flash >> Annex E: Calculating Incident Energy or the Energy Industry. incident energy above 5J/cm2 (1.2cal/cm2). Heat Flux (‘Practice’) >> Progressively eliminate or minimise the risk of arc flash hazards through >> Annex F: Electrical Arc Flash Hazards improving understanding and application Management Guideline Checklist of arc flash hazards, their assessment and >> Annex G: References their control. >> Annex H: Definitions >> Provides an explanation as to how human factors (that being the interaction of individuals with each other, in teams, It is not the intent of this guideline to set out with equipment and with management a detailed procedure, and as such, procedures systems) and workplace safety culture should be developed by each Energy Industry and attitudes contribute and can be organisation in accordance with the principles influenced to eliminate or minimise the contained in this Guideline. risk associated with arc flash. This guideline is supported by an online video >> Advance the current arc flash literature on electrical arc flash hazards and potential with the specific requirements of people control measures to reduce or eliminate the deemed ‘vulnerable’ working within the risk of arc flash occurring. Like this Guideline, Energy Industry. the online video is published by the Australia Energy Council (AEC) Level 14, 50 Market >> Provide education on arc flash hazards and their assessment (through the Street, Melbourne, VIC, 3000. calculation of incident energy or heat flux and other technical information that is considered beneficial to the Energy Industry). 6 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 7
3.0 SCOPE These Guidelines apply when Energy Industry This guide does not cover specific live line workers are required to perform any activity work techniques, such as glove and barrier on or near electrical equipment where arc or bare hand live line techniques. flash and electric shock hazards exist [and Other workplace hazards and associated as a guide relates to minimum work on or controls required for effective hazard near energized equipment above Extra Low identification and risk management not Voltage (ELV) limits, i.e. 50 V ac (rms) or covered within these Guidelines are to be 120V dc (ripple free)]. identified and effectively implemented by Recommendations within these Guidelines risk assessment and subsequent application relate to core electrical arc flash hazard of the hierarchy of control, and as referenced management as well as electrical hazards in respective to applicable Acts, Regulations, (e.g. electrocution) and other workplace Codes of Practice, Standards and Guideline. hazards (e.g. working at height) where relevant. This guideline includes high voltage and low voltage. Arc flash risk is often incorrectly only associated with high voltage equipment. Whilst the probability of initiating an arc flash is greater the higher the voltage (due to the greater ability to breakdown insulation), arcs Operating/ can initiate at low voltage. Low voltage arc Racking flash often results in higher incident energy at the working position, due to the increased fault currents and a range of other factors. Other work Electrical Test work voltage H Cleaning V 7 × LV Diagram 2. Low Voltage is far more dangerious than High Voltage Diagram 3. Exposure to arc flash 8 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 9
4.0 CONSIDERATION OF HUMAN FACTORS Across Australia, the risk of arc flash incidents The types of human factors that can interfere or incidents involving electrical hazards with safe and effective electrical arc flash (such as working on energised equipment risk controls being implemented by electrical Vulnerable when permitted by law) are affected by any workers can include (but are not limited to): EXPERIENCE or ‘at risk’ range of human factors in people who perform 1. Training and competency: where electrical tasks as electrical workers. workers are not educated and competent On occasion, electrical work is performed by in the arc flash hazard, they are unaware Apprenticeship (under 25 yr old) Electrical worker’s working lifespan Retirement (65 yr old) people who are young (such as apprentices of the potential for an arc flash incident to who are largely less than 25 years of age) or cause harm ; who are deemed ‘vulnerable’ – perhaps as a 2. Errors, mistakes and lapses: where people result of their age, experience or length of Diagram 4. Vulnerable or ‘at risk’ worker make errors in process (across a very service, their level of skill and competence wide range of reasons) that results in or as a result of relevant and potentially compromising the effectiveness of an arc multiplied ‘human factors’ that are present flash risk control; across the Energy Industry. As these human factors may contribute to electrical incident 3. Complacency: both with the risks and WORKPLACE CULTURE TRAINING AND COMPETENCY and accidents the management of (and with the process of arc flash risk controls; Peoples whose actions are affected by the where people are not aware of arc flash interaction of (actual or perceived) workplace incidents or are unaware of the potential for training in) human factors is an important 4. Time pressure: where the ability to culture, being bullied or facing peer pressure an arc flash incident to cause significant harm issue for all electrical workers occurring in the properly implement an administration from team-members and/or their Supervisors / Team Leaders and a lack of accountability Energy Industry. control (such as a permit to work) is across all aspects of electrical works. ERRORS, MISTAKES AND LAPSES compromised; By definition, human factors are the wide where people make errors in process (across a very wide range of issues that affect how people 5. Violations: where people deliberately range of reasons) that results in perform tasks in their work (and non-work and willingly work ‘outside’ known MENTAL HEALTH compromising the effectiveness ISSUES AND CONCERNS of an arc flash risk control environments); how they interact with risk controls and expected skills and each other across teams, equipment and competencies. workplaces and how they interact with management systems and technology. Human 6. Information overload: where the HUMAN information is unclear, overwhelming or factors are the social and personal skills which duplicated to people leading to confusion FACTORS COMPLACENCY can complement (but also distract from) and errors (this often affects a contracted DISTRACTIONS that can interfere with both with the risks and with the process technical skills and they are important for safe workforce who are commonly assigned that are both work and non-work related and all the effectiveness of of arc flash risk and effective electrical work. higher risk work); lead to a ‘breaking’ or a risk controls across controls person’s concentration the electrical Electrical workers in the Energy Industry are 7. Distractions: that are both work and non- resulting in error (such as industry/Generation non-work related Sector deemed ‘vulnerable’ workers as they are a work related and all lead to a ‘breaking’ or distractions resulting from type of worker that has a greater exposure a person’s concentration resulting in error mobile phones) and are at increased risk of fatality or injury (such as non-work related distractions / incident than most - due to both the types resulting from mobile phones); TIME PRESSURE INFORMATION where the ability to properly of electrical work that they perform and 8. Mental health issues and concerns; OVERLOAD implement an administration in recognition of the many ‘human factors’ where the information is control (such as a permit to that interact with their safe and effective 9. Peoples whose actions are affected by unclear, overwhelming or work) is compromised duplicated to people performance of technical work in the Energy the interaction of (actual or perceived) leading to confusion and Industry. workplace culture, being bullied or facing errors (this often affects a VIOLATIONS contracted workforce who where people deliberately and willingly peer pressure from team-members and/ are commonly assigned work ‘outside’ known risk controls and or their Supervisors / Team Leaders and a higher risk work) expected skills and competencies lack of accountability across all aspects of electrical works. Diagram 5. Human factors 10 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 11
5.0 ELECTRICAL ARC FLASH HAZARD MANAGEMENT 5.2 WHAT IS AN ARC FLASH? The term Arc Flash comes from an earlier understanding that the burns from an arc An electrical arc fault is often referred to fault were similar to the flash burns from a 5.1 OVERVIEW OF HAZARD To achieve this, the following steps should to as an Arc Flash. welding arc. That is, the heat was transferred MANAGEMENT PROCESS be undertaken: Arc faults arise when current flows through to the individual by the radiant heat and light a. Understand the hazard the air between phase conductors or between (infrared – ultraviolet) from the arc. When workers are required to work on or phase conductors and neutral or ground. Put near electrical equipment, all reasonably b. Identify assets or asset groups with arc Recent research has shown that, although simply, an arc fault could be described as an practicable measures should be taken to flash hazard potential the radiant energy from an electrical arc unexpected, violent, electrical short circuit in protect workers from the harmful effects of c. Quantify the hazard (calculate the arc contributes to the energy received, the major the air that produces an arc and associated electric arc flash hazards through hazard flash incident energy on each asset or hazard to an individual comes from the plasma by-products. elimination and risk reduction. asset group) ejected by an arc. When arc faults occur, the resulting energy d. Assess the risk (using your organisation’s released may be enough to seriously burn risk management framework) or otherwise injure nearby persons, ignite e. Develop and implement risk treatments flammable materials (including clothing), using the hierarchy of controls and cause significant damage to plant and f. Validate control effectiveness equipment. g. Monitor and review. 1. Understand the HAZARD Air Plasma Cloud of Plasma Molten jets with hot gas “dust” droplets O¯, N¯, Cu+ (CuO smoke) shower 2. HAZARD RISK Identify assets or asset groups with arc flash HAZARD potential RD 3. HA ZA RI SK Quantify the HAZARD (calculate the arc flash incident energy on each asset or asset group) 4. Assess the RISK (using your organisation’s risk management HAZARD RISK A HAZARD is something that has the framework) potential to harm you. RISK is the likelihood of a hazard causing harm. Driven away 20,000°C Pressure 5. 6. 7. from source shock waves of supply by and defening Develop and implement RISK Validate control Monitor and magnetic sound treatments using the hierarchy effectiveness review. forces of controls Diagram 6. Hazard management process Diagram 7. What is an Arc-flash? 12 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 13
5.3 WHAT IS ARC PLASMA? 5.4 OTHER PRODUCTS OF Arc Plasma is the fourth (4th) state of matter AN ARC FAULT (solid, liquid, gas, plasma) and is probably Along with the thermal effects of plasma Copper Vapor 35,000 F best described as ‘super-heated ionised gas’. and radiated heat/light, an arc fault may also Molten Metal >1,800 F produce the following: The arc plasma ejected by an electrical arc Intense Light fault may be at temperatures more than >> Molten metal droplet spray and metal Hot Air > 500 F 5000 degrees (C) and has sometimes been vapour; Pressure Waves > 2000 lb/psf described as a “fireball or plasma ball” coming >> Ejected debris; Sound Waves > 140 db from an arcing fault. >> Pressure wave; Shrapnel > 740 mph Contact with this 5000-degree (C) plasma “fireball” may lead to serious burns. >> Noise. Importantly though, such contact may also The arc flash will melt and vaporise ignite non-arc rated clothing and other conductors and other material, which the Personal Protective Equipment (PPE) with sudden transition from solid to vapour results burning clothing and PPE known as significant in a pressure wave from the rapid expansion contributors to the seriousness of injury (for example copper expands 67,000 times in outcomes. volume transitioning from solid to vapour). Clothing and PPE often continue to burn and The high pressures can easily exceed hundreds subsequently continue to impact even after or even thousands of kilos per square meter the arc fault and contact with plasma have and can result in knocking workers off ceased. ladders, rupturing eardrums and collapsing a person’s lung. Material and molten metal are expelled away from the arc at speeds exceeding 1120 km/hr (700 mph) and are fast enough for shrapnel to completely penetrate the human body. The vaporised and molten metal presents a hazard from both contact and from the inhalation of hot and hazardous compounds. Arcs that occur in enclosures can be focused, resulting in a higher-pressure rise directed towards an enclosure opening (such as is often the case when a panel door is open and at the point where a person is likely to be positioned). Diagram 8. Other components of an Arc-flash 14 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 15
5.5 WHEN AND WHERE DO Any activity in the vicinity of energised ELECTRICAL FAULTS OCCUR? conductors has the potential for arc flash, but arc flash most commonly happens when Unintended and uncontrolled electrical a person is working on an energised circuit arc faults may occur in several workplace or equipment (knowing it is energised or locations and circumstances, and during believing it is not). The risk increases by the a range of activities. degree of interaction with the energised equipment. The diagram below indicates the increase in risk in the performance of tasks: Work on the Vicinity of Inspection Operating Inspection Testing voltage, Work on the Racking Restoration Commissioning Racking Restoration equipment equipment (panel closed) equipment (panel open) including proving equipment (panels closed) (panel open) after a fault or ACTIVITY (isolated, proven (panels closed) de-energised (isolated but operation of de-energised and not proven de- equipment with earthed) energised) possible defect RISK Work on plant, Person standing Person standing in Person operating Person inspecting Person testing Person removing Person racking Person switching Person switching Person racking Person switching with isolations near electrcial front of electrical equipment with open panel, using open panel, using component from circuit breaker, electrical electrical circuit breaker, electrical locked and equipment panel, reading a operating handle IR thermometer multimete open panel, panel closed, with equipment on equipment on for panel open with equipment on tagged, earths meter on the front using insulated racking handle the first time racking handle after a fault applied, barriers panel screwdriver and signs AFTER FIRST TIME FAULT PLANT ISOLATIONS ON ON ON EARTH Workers in Workers in Workers in Workers in Workers in live Workers in live Workers in live Workers in Workers in Workers in Workers in Workers in standard PPE standard PPE standard PPE operating PPE work PPE (helmet work PPE (helmet work PPE (helmet operating PPE operating PPE operating PPE operating PPE operating PPE (helmet, safety (helmet, safety (helmet, safety (helmet and face and face shield, and face shield, and face shield, (helmet and face (arc flash suit) (helmet and face (helmet and face (helmet and face glasses, ankle to glasses, ankle to glasses, ankle to shield, safety safety glasses, safety glasses, safety glasses, shield, safety shield, safety shield, safety shield, safety wrist hi visibility wrist hi visibility wrist hi visibility glasses, balaclava, balaclava, ankle to balaclava, ankle to balaclava, ankle to glasses, balaclava, glasses, balaclava, glasses, balaclava, glasses, balaclava, clothes, safety clothes, safety clothes, safety ankle to wrist hi wrist hi visibility wrist hi visibility wrist hi visibility ankle to wrist hi ankle to wrist high ankle to wrist hi ankle to wrist hi boots) boots) boots) visibility clothes, clothes, insulated clothes, insulated clothes, insulated visibility clothes, visibility clothes, visibility clothes, visibility clothes, insulated gloves gloves, safety gloves, safety gloves, safety insulated gloves insulated gloves insulated gloves insulated gloves with leather over boots) boots) boots) with leather over with leather over with leather over with leather over gloves, safety gloves, safety gloves, safety gloves, safety gloves, safety Safety observer Safety observer Safety observer boots) boots) boots) boots) boots) with LV rescue kit with LV rescue kit with LV rescue kit 16 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 17
TABLE 1: INCREASING ARC FLASH RISKS WITH WORK ACTIVITY 5.6 INCIDENT ENERGY / HEAT FLUX Second-degree burns (also called ‘Partial Thickness Burns’) are possible The amount of energy that strikes an on unprotected skin from exposure to arc individual during an arc fault is termed fault incident energies. The onset of a second- incident energy (sometimes referred to as degree burn on unprotected skin is likely to Epidermis heat flux) and is usually measured in Joules/ occur at an exposure of 1.2 cal/cm2 (5 J/cm2) cm2 (or calories/cm2). for one second. Dermis Hypoermis The arc energy is the energy in the arc, but Therefore, 5J/cm2 (1.2cal/cm2) is an important (fat) the incident energy is the energy that reaches incident energy level threshold for arc fault Muscle an individual or surface at a distance from hazard management. the arc during an arc fault. The duration of an Bone arc fault is usually quite short and is primarily 5.7 RISK MITIGATION – determined by the time it takes for over HIERARCHY OF CONTROLS current protective devices to operate (i.e. open the circuit). The model Work Health & Safety (WHS) Regulations require duty holders to work In general, the higher the fault current through the Hierarchy of Controls when and/or the longer the protection clearing time, managing health and safety risks. and/or and the shorter the distance from the arc, the greater the incident energy. The ways of controlling risks are ranked from Calculation of arc flash incident energy is the highest level of protection and reliability 2.5 cm = 5 J/cm2/second covered in Annex D: Arc Flash Incident to the lowest – details of arc flash risk control Second degree burns occur at 6 J/cm2 Energy Calculation Methods. measures are included in Annex A: Arc Flash (1.2 cal/cm2) Risk Assessment. Second degree burns equates to damage through the epidermis, into the dermis layer of the skin Results in redness, blistering and pain. Blistering may lead to permanent scars. 1 HIGHEST ELIMINATE MOST 1 Incident energy is the temperature 2 SUBSTITUTE 2 produced (in cal/cm2) at the distance (usually eighteen inches) from the arc 3 Level of ISOLATE Reliability 3 flash. health and of control safety measures. 4 protection. ENGINEER 4 5 ADMINISTRATE 5 6 LOWEST PPE LEAST 6 Hand 1 inch over It takes 1.2 cal/cm 2 flame for 1 second to create a second equals 1 cal/cm2. degree burn. 1. Eliminate the hazard 4. Reduce the risk through engineering controls 2. Replace the hazard with something safer 5. Change/control the way people work 3. Separate the hazard from people 6. Protect the worker Diagram 11. Arc flash control measures Diagram 10. Second degree burns 18 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 19
5.8 EFFECTIVE IMPLEMENTATION >> Administration – such as permits to work, signs, barriers and similar processes which Label example OF ARC FLASH CONTROLS HEADER stays constant ensure consistent work methods that With arc flash, where the hazard cannot be eliminated, it is often a combination of control minimise risk; DANGER measures used to mitigate the hazard. Whilst >> Administration – such as labelling; DANGER ARC FLASH HAZARD As per OCE, ENG, G01, 01 greater details are outlined in Annex A: Arc >> Personal Protective Equipment (PPE) ARC FLASH HAZARD As per OCE, ENG, G01, 01 Equipment Coal Handling Plant 415V SWBD A Pass LS Flash Risk Assessment, this is typically: and Clothing. Name: Voltage Level, Fault Current, 5.8.1 LABELLING 415 45.35 >> Elimination – elimination, where possible, INTERNAL AREA Volts: kA: is the most effective risk control / Door OPEN To clearly communicate the arc flash risk on may change Incident Energy Cal/cmˆ² 12.4 Arc Flash Boundary, m: 1.90 mitigation method. >> This means working on energised electrical equipment, it is recommended that 3 WARNING 3 electrical equipment is properly labelled. equipment when: WARNING Arc Flash Hazard | Wear Category 3 PPE It is recommended that the Energy Industry Arc Flash Hazard | Wear Category 3 PPE (a) it is necessary in the interests of health considers all labels as needing to meet the • Bus name or equipment name and safety that the electrical work is • Bus voltage level requirements of Danger Signage (Danger FOOTER stays constant • Activity to be performend carried out on the equipment while the signs communicate a hazard, condition or • Incident energy level equipment is energised, or situation that is likely to be life threatening). • Arc flash boundary • PPE Example: It may be necessary that life- It is recommended that the Energy Industry saving equipment remain energised and considers all labels provide the critical risk operating while electrical work is carried information clearly, concisely and consistently. Diagram 12. Arc flash label design out on the equipment. Whilst minimum size of labels cannot be (b) it is necessary that the electrical recommended, it is a recommendation of this equipment to be worked on is energised Guideline that labels are located so they are in order for the work to be carried out clearly visible, well placed and include all the properly, or information required in international arc flash Effective Risk HAZARD documents and in a format consistent with (c) it is necessary for the purposes of Australian requirements. The details included Control Measures testing required under clause 155, or in the labels are shown in the illustration below (d) there is no reasonable alternative however as a minimum, it is recomended means of carrying out the work that all Arc Flash Hazard labels across the Australian Energy Industry include >> Substitution –Replacing the higher risk (as a minimum): activity with a lower risk. Replacing a standard switchboard with one that has >> Bus Name or Equipment Name; been designed and tested for arc-resistant >> Bus Voltage Level; 1 Energised Electrical Equipment construction >> Activity to be performed; (HAZARD) >> Isolate – isolation of hazard which can >> Incident Energy Level; be achieved by working on de-energised (and earthed) electrical equipment or >> Arc Flash Boundaries; and 2 Arc Flash Prevention Measures - Elimination (For maintenance personnel) using techniques like remote switching/ >> PPE Level Required for varying activity • Isolation • Prove deenergised racking and switchboard status (for example door • Earthing (HV conductors) • Isolation and earthing check and confirmation open / door closed). >> Engineering – such as arc resistant 3 Electrical Equipment • Barriers and signs Arc Flash (INCIDENT) • Permit issue switchboards designed to contain >> PPE – which protect people from the - Remote operation • Arc flash mitigation - Prevention of inadvertent energisation - LOTO and redirect the arc flash. Alternately, incident energy if all other controls fail measures - Arc flash protection incorporating faster protection settings and an arc flash occurs. OUTCOME - Arc resistant panels - Optimised protection settings - Arc flash incident energy reduction 4 Person Injured by - Arc flash boundaries during maintenance work using remote Arc Flash - PPE - Insulated tools and test equipment Whilst the effective implementation of rackable circuit breakers. (OUTCOME) arc flash controls in aged plants can be >5J/cm2 arc flash incredibly troublesome, some practical incident energy recommendations have been provided in Annex A: Arc Flash Risk Assessment. Diagram 13. Layering of controls 20 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 21
22 that stage. this Guideline. Electric Arc Flash Hazard Management Guideline the de-energisation, isolation and prove It is not the intent of this guideline to set The table demonstrates that the preferred out detailed risk controls, and as such, risk and what control measures are effective at elimination of hazards is only possible after Energy Industry organisation in accordance controls should be developed, implemented This table provides an example where typical operators of the equipment. The table should be considered as a guide and is advisory only. steps required for electrical work (LV and HV) with the principles or risk control contained in and monitored and regularly reviewed by each deenergised, which still results in hazard to the TABLE 2: TYPICAL ELECTRICAL WORKER ACTIVITIES AND SUGGESTED RISK CONTROLS CONDITION LEVEL OF RISK* OF BOARD *REFER TO DIAGRAM 11 - WHAT TO TASK ENERGISED ARC-FLASH CONTROL LOOK OUT FOR PANELS MEASURES STATE Work scoped Energised Closed Correct understanding of the work 3 Work identified to be done Confirmation bias may exist Work inspection Energised Open Plant is energised and is at risk of arc flash. Plant may require inspection to The inspection must not place the persons inspecting at fully determine the scope and 4 5 6 risk. If it does, it should be treated work instructions, or to correctly design the isolations. Risk Assessment and Work Energised Closed Work instructions and risk assessments can be limited by instructions prepared the knowledge and experience of the persons creating 3 5 them. Check and challenge to ensure all the work and Work instructions and risk risks are identified. assessments completed Isolations designed Energised Closed The design of the isolations determines the effectiveness of the Elimination control. Inaccuracy or lapses have a Isolations and earthing required potential major impact. making the work area safe need to be designed. 3 Should be checked by another person to ensure accuracy Checking drawings for accurate information Identifying all possible energised supplies Approval of the work, risk Energised Closed The approval process is to ensure the work scope, risk assessment and isolation design 3 assessment and isolation design process have been as per company procedures completed correctly and thoroughly. De-energisation (remote) Unknown Closed Ensure other personnel are not in the vicinity and at risk; Switching of plant by means that 3 5 Ensure remotely operated plant is confirmed to have does not require the operator to operated correctly. stand in the arc flash boundary De-energisation (local) Unknown Closed Ensure only load breaking rated plant is used to break load currents; Switching of plant that require the 4 5 6 Electric Arc Flash Hazard Management Guidelines operator to stand in the arc flash Operator should position themselves to stand to the side boundary of plant where possible, to reduce the direct incident energy from and arc flash. 23 Isolations applied Unknown Open Locks and Tags best practice; Application of isolations as per Ensure 3 phase devices all phases operated correctly; company procedures. 4 5 6 Ensure correct isolations devices identified, operated correctly and confirmed in the correct state. Prove circuits deenergised Deenergised Open Include all circuits that workers may be exposed to. Prove the tester, before and after testing. 4 5 6 If the isolations are not correct, the prove deenergised test may cause an arc flash. Earths applied to HV conductors Deenergised Open If the conductor is energised, the earthing will cause an and where required 4 5 6 arc flash. Permit issued/job briefed Deenergised/ Open Permit issue is the formal acknowledgement by the work earthed party that they correctly understand the permit conditions Work party correctly briefed on and will adhere to all safety instructions. the safety precautions required for the work to be undertaken. If 1 5 6 Last chance to confirm the safety precautions are correct under a permit, the correct permit and the work can be completed safely. issue is adhered to. Complacency and inattention at this step place the work party at risk. Work party undertakes the work Deenergised/ Open Ensure work party is either competent to perform the as per the work scope. earthed work, or adequately supervised. 1 5 6 Beware of scope creep, which may result in work beyond what the risk assessment and isolation design allowed for. Permit relinquished and cancelled Deenergised/ Open Permit holder and operator should check and confirm the earthed state of the plant, to ensure it is safe to reenergise. Work party relinquishes permit 1 5 6 and the operator cancels Left tools, earths or incorrectly replaced covers or fittings can result in arc flash upon reenergisation Earths removed Deenergised Open As soon as earths are removed, HV conductors are unsafe. Removal of earths from 1 5 6 All earths must be removed, as reenergisation on an earth conductors will result in a short circuit and potential arc flash risk. Isolations restored to allow plant Unknown Open Ensure restoration of isolation will not inadvertently to be energised 4 5 6 energise the plant as this can result in the isolation failing. Reenergisation (remote) - Energised Closed Ensure other personnel are not in the vicinity and at risk; Switching of plant by means that 3 5 Ensure remotely operated plant is confirmed to have does not require the operator to operated correctly. stand in the arc flash boundary Reenergisation (local) Energised Closed Ensure only load breaking rated plant is used to break load currents; Switching of plant that require the operator to stand in the arc flash 4 5 6 Operator should position themselves to stand to the side boundary of plant where possible, to reduce the direct incident energy from and arc flash. Electric Arc Flash Hazard Management Guidelines Operational testing Energised Open Plant is energised. Plant may require checking 4 5 6 and testing to ensure operating 24 correctly
6.0 DEMONSTRATION OF INDEPENDENT COMPETENCY IN PERFORMING THE FOLLOWING TASKS Supporting information has been provided in several ‘informative’ annexes to assist with the Whilst definitions of electrical work (and electrical workers) differ across all Australian States minimum competency requirements of Energy and Territories, it is the intent of this guideline to recommend the minimum competency Industry organisations’ as they progress their requirements for workers who are (or have the potential to be) exposed to the harmful effects of specific arc flash hazard management system. electric arc flash hazards. The annexes provided are for information and It is recommended that the Energy Industry considers, as a minimum, the following: guidance only. TYPE OF MINIMUM COMPETENCY MINIMUM EDUCATIONAL TYPE OF MINIMUM COMPETENCY MINIMUM EDUCATIONAL WORKER REQUIREMENT REQUIREMENT WORKER REQUIREMENT REQUIREMENT Electrical Engineers >> Arc Flash Risk Assessment >> Registered and / or Operators >> Arc Flash Risk Assessment >> Registered and / or >> Arc Rated Clothing and Australian recognised >> Arc Rated Clothing and Australian recognised Personal Protective Equipment qualification in Electrical Personal Protective Equipment Operator Qualification (including the limitations of Engineering (including the limitations of >> Electrical Plant Specific arc flash PPE and incorrect Arc >> Instruction, Supervision, arc flash PPE and incorrect Arc Operator Training Flash PPE) Information or Training in Flash PPE) >> Instruction, Supervision, >> Arc Flash Labelling Human Factors >> Arc Flash Labelling Information or Training in >> Arc Flash Incident Energy Human Factors Calculation Methods (‘Theory’) Electrical >> Arc Flash Risk Assessment >> Registered and / or >> Calculating Incident Energy or Contractors >> Arc Rated Clothing and Australian recognised Trade Heat Flux (‘Practice’) Personal Protective Equipment based Qualification >> References (including the limitations of >> Instruction, Supervision, arc flash PPE and incorrect Arc Information or Training in >> Definitions Flash PPE) Human Factors Electricians >> Arc Flash Risk Assessment >> Registered and / or >> Arc Flash Labelling >> Arc Rated Clothing and Australian recognised Trade based Qualification >> References Personal Protective Equipment (including the limitations of >> Instruction, Supervision, >> Definitions arc flash PPE and incorrect Arc Information or Training in Flash PPE) Human Factors >> Arc Flash Labelling Health & Safety >> Electrical Arc Flash Hazards >> Registered and / or >> References Practitioners / Management Guideline Australian recognised >> Definitions Professionals Checklist qualification in WHS (or related discipline) >> Instruction, Supervision, Information or Training in Maintenance >> Arc Flash Risk Assessment >> Registered and / or Human Factors >> Arc Rated Clothing and Australian recognised Maintenance Qualification Technical Trainers >> Arc Rated Clothing and >> Registered and / or Personal Protective Equipment Personal Protective Equipment Australian recognised (including the limitations of >> Specific and / or directly (including the limitations of qualification in WHS (or arc flash PPE and incorrect Arc related industry experience arc flash PPE and incorrect Arc related discipline) Flash PPE) >> Instruction, Supervision, Flash PPE) >> Instruction, Supervision, >> Arc Flash Labelling Information or Training in >> Arc Flash Labelling Information or Training in Human Factors Human Factors >> References >> Definitions 28 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 29 Electric Arc Flash Hazard Management Guidelines 30
7.0 ADDRESSING THE HUMAN FACTORS WORKPLACE CULTURE TRAINING AND COMPETENCY Human factors play a significant role in how The recommended actions for organisations Peoples whose actions are affected by the where people are not aware of arc flash interaction of (actual or perceived) workplace incidents or are unaware of the potential for people organise, manage and conduct various to consider if human factors are or have the culture, being bullied or facing peer pressure an arc flash incident to cause significant harm activities and how they respond to various potential to interfere with the effectiveness of from team-members and/or their Supervisors / Team Leaders and a lack of accountability situations. In the context of electric arc flash, risk controls are outlined below. All suggested across all aspects of electrical works. ERRORS, MISTAKES AND these human factors and consideration of Human Factor risk controls have been LAPSES where people make errors in ‘vulnerable’ people has gained considerable provided are for information and guidance process (across a very wide attention. only and are still subject to a risk assessment range of reasons) that results in MENTAL HEALTH compromising the effectiveness per team, site or workplace. Increasingly there is growing awareness for ISSUES AND CONCERNS of an arc flash risk control consideration of the general effect of human factors and of the specific requirements of people deemed ‘vulnerable’ and currently HUMAN working in the Energy Industry. The human factors involved in incidents / accidents FACTORS COMPLACENCY DISTRACTIONS both with the risks around electrical arc flash incidents in the that are both work and that can interfere with and with the process the effectiveness of Energy Industry are: non-work related and all risk controls across of arc flash risk lead to a ‘breaking’ or a controls the electrical >> Workers being inexperienced or having person’s concentration resulting in error (such as industry/Generation never received formal training (or been non-work related Sector deemed competent) in electrical arc flash distractions resulting from mobile phones) hazards and the expected risk controls; >> Workers making unintentional errors TIME PRESSURE because of performing familiar tasks INFORMATION where the ability to properly OVERLOAD implement an administration out of habit or whilst on ‘auto-pilot’ or where the information is control (such as a permit to perhaps because they are complacent or unclear, overwhelming or work) is compromised duplicated to people have made a mistake; leading to confusion and errors (this often affects a VIOLATIONS >> Workers making intentional errors or contracted workforce who where people deliberately and willingly violating the procedures of safe work; are commonly assigned work ‘outside’ known risk controls and higher risk work) expected skills and competencies >> The self-imposed or actual pressure and stress of insufficient time, high workloads and interruptions / distractions; >> Technical / other information overload Diagram 14. Human factors (this includes when safe work procedures are ambiguous or confusing); >> When personal stress or mental health factors (such as relationship breakdown, death of a family member etc) are involved or are involved to a level that workers are not used to dealing with; and >> When the workplace contributes to an unsafe workplace culture. 34 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 35
TABLE 3: TYPICAL HUMAN FACTOR ACTIVITIES AND SUGGESTED RISK CONTROLS HUMAN FACTOR CONSIDERATION OF HUMAN FACTOR RISK CONTROL HUMAN FACTOR CONSIDERATION OF HUMAN FACTOR RISK CONTROL Training and >> Commit to an implementation of the minimum competency Information >> Simple english documentation and signage Competency requirements when working on / around electrical arc flash hazards Overload >> Local signage >> Instruction, Supervision, Information or Training in Human Factors >> Removal of detail not required by person undertaking activity >> Appropriate worker selection and monitoring to the ongoing >> Diligence towards the creation of simple software systems and suitability of workers selected to perform relevant works processes toward Permit to Work Systems and other isolation tasks Errors, Mistakes >> Verification activities. Isolation, plant ID and activity required Distractions >> Ensure levels and type of supervision matches the actual (or and lapses >> Appropriate worker selection and monitoring to the ongoing potential) of arc flash hazards and risk suitability of workers selected to perform relevant works >> Stop and think processess (Take 5) >> Stop and think processess (Take 5) >> Ongoing safety observation process (Behavioural based) >> Ongoing safety observation process (Behavioural based) >> Management, Team Leader and Supervisor and Peer walkdowns >> Management, Team Leader and Supervisor and Peer walkdowns Mental Health issues >> Ensure levels and type of supervision matches the actual (or Effective QA documentation – Switching or job instruction and concerns potential) of arc flash hazards and risk >> Interlock and control – error tolerent equipment >> Stop and think processess (Take 5) >> Ongoing safety observation process (Behavioural based) Complacency >> Ensure levels and type of supervision matches the actual (or potential) of arc flash hazards and risk >> Management, Team Leader and Supervisor and Peer walkdowns >> Commit to arc flash awareness activities by way of alerts, training, >> Employee Assistance Programs (EAP) and other Mental Health refreshers, tool box talks, and lessons learned (post industry First Aid assistance in the event of worker disclosure of mental incidents and accidents). health issues and concerns Time Pressure >> Executive and Senior Management oversight Workplace >> Cultural audit >> Proper planning and resourcing for activities Culture and other >> Accountability process implement for all levels of business organisational / >> Higher risk activities emphasised in risk assessment team factors >> Ensure levels and type of supervision matches the actual (or >> Management, Team Leader and Supervisor and Peer walkdowns potential) of arc flash hazards and risk >> Stop and think processess (Take 5) Violations >> Ensure levels and type of supervision matches the actual (or >> Ongoing safety observation process (Behavioural based) potential) of arc flash hazards and risk >> Management, Team Leader and Supervisor and Peer walkdowns >> Accountability process implement for all levels of business >> Executive oversight of competing business drivers 36 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 37
8.0 MANAGEMENT OF CHANGE 9.0 ANNEXES The effective management of change is Annex A: Arc Flash Risk Assessment especially important within the Energy Annex B: Arc-Rated Clothing and Personal Protective Equipment Industry because it supports communication, teamwork and the effective coordination of Annex C: Do’s and DON’T’s of Arc Flash Labelling activity toward the elimination or minimisation Annex D: Arc Flash Incident Energy Calculation Methods (‘Theory’) of risk of injury to persons from an electrical arc flash hazard. Annex E: Calculating Incident Energy or Heat Flux (‘Practice’) Any organisations management of change Annex F: Electrical Arc Flash Hazards Management Guideline Checklist method should be applied to any electrical Annex G: References arc flash hazard management program and in conjunction with Annex F: Electrical Arc Flash Annex H: Definitions Management Guideline Checklist. 38 Electric Arc Flash Hazard Management Guideline Electric Arc Flash Hazard Management Guidelines 39
ANNEX A: ARC FLASH RISK ASSESSMENT AND CONTROL WHS RISK MANAGEMENT REQUIREMENTS FOR REQUIREMENTS ENERGISED WORK: ASSESSING THE RISK OF ARC FLASH TO ASSESS THE RISK, CONSIDER: For work on or near energised electrical 1. A documented risk assessment; equipment (including the isolation, testing for 2. Area clear of obstructions to allow for The WHS Act and Regulations require persons >> What is the potential impact of the deenergised, and restoration of the equipment who have a duty of care to ensure health and hazard? easy access and exit; required for safe access), works must be safety to ‘manage risks.’ This eliminates or >> Severity of the electrical hazard assessed for risk. 3. Point of supply clearly marked, labelled minimises health and safety risks so far as is such as direct contact causing and capable of being operated quickly reasonably practicable. As per Work Health & Safety Regulation 34 (with exceptions); electrocution, fire or explosion Duty to Identify Hazards requires a duty Risk assessment involves considering what causing serious burns or death. 4. Following consultation with a person with holder to identify of reasonably foreseeable could happen if someone is exposed to a >> Number of persons exposed to management control of the workplace; hazards (including arc flash hazards). hazard and the likelihood of it happening. the hazard 5. Inadvertent contact prevented; WHS regulation 35 requires risk management As per Model Code of Practice - Managing >> Likelihood of the hazard causing harm 6. Carried out by a competent person; to eliminate, and if not possible, to minimise Electrical Risks in the Workplace (published >> Likely, unlikely, possible or would it be risks “so far as is reasonably practicable”. 7. With tools, testing equipment and PPE as approved code of practice under Section a rare event As per Work Health & Safety Act Division suitable for the work, properly tested and 274 of WHS Act), a risk assessment is to be >> Frequency of exposure 4 Section 157 electrical work on energised maintained in good working order; prepared. Control/mitigation measures are to be put in place to reduce the level of risk so OTHER FACTORS THAT MAY AFFECT electrical equipment – when permitted, is not 8. In accordance with a SWMS; and far as is reasonably practicable. CONSEQUENCES & LIKELIHOOD ARE: carried unless: 9. With a safety observer, competent RISKS CAN ARISE FROM THE >> Equipment working conditions a. It is necessary to do carry out the work in to implement control measures and (wet condition, outdoors, confined space) the interests of health and safety. rescue the worker if necessary (with FOLLOWING: the exception that not required if work For example, it may be necessary that >> Work practices (isolations, permits) >> The properties of electricity (in the form life-saving equipment remain energised identified there is no serious risk and and availability of work procedures to of a hidden risk) as electrical currents and operating while electrical work is consisting only of testing carry out electrical maintenance are mostly invisible, have no smell or carried out; Until the arc flash hazard has been eliminated sound (noting that some equipment does >> Experience, skill and capability of relevant b. It is necessary that the electrical or isolated, personnel inside the arc flash emit a sound when energised such as workers. equipment is energised in order for the limit should be using PPE appropriate for the Transformers and HV lines); energy level (cal/cm2). work to be carried out properly; >> Work environment such as wet weather, c. It is necessary for the purposes of testing Electrical equipment shall be treated as confined spaces and hazardous required under clause 155; energised until it is isolated and proven atmospheres; d. There is no reasonable alternative means deenergised. >> Competency of the individual carrying out of carrying out the work. CONTROLS FOR ARC FLASH the electrical work. Work should be carried out in accordance of TYPICALLY RELY TO THE FOLLOWING the requirements for energised work. PRINCIPLES: >> Reduction of arc flash energy; >> Reduce the exposure of personnel to the arc flash; >> Protect people from the arc flash though application of the Hierarchy of Controls; >> Increase the commitment to experience, skills and capabilities of relevant workers. 40 Electric Arc Flash Hazard Management Guideline - Annex A Electric Arc Flash Hazard Management Guidelines - Annex A 41
HIERARCHY OF CONTROL RISK MITIGATION – ISOLATION ARC FLASH BOUNDARIES Isolation of arc flash risk involves the Arc Flash Boundaries are the distances separation of personnel from the energised from energised equipment that should be electrical equipment and conductors. maintained to manage arc flash risk. 1 HIGHEST ELIMINATE MOST 1 Isolation is most effective for personnel The boundaries are set around two key who do not need to operate or work on the criteria: 2 SUBSTITUTE 2 electrical equipment. >> The distance for the standard levels of Level of Reliability Some controls that may isolate the arc flash 3 ISOLATE 3 PPE to protect the person; health and of control risk are: safety measures. >> The amount of energy a person in the 4 ENGINEER 4 >> Restrict proximity to energised electrical working position will be exposed to protection. plant; during an arc flash. 5 ADMINISTRATE 5 >> Restrict switch rooms and substations to The determination of the appropriate authorised personnel only; boundaries is by the reviewing Annex D – Arc 6 LOWEST PPE LEAST 6 >> Use Arc Flash boundaries; Flash Incident Energy Calculation Methods. 1. Eliminate the hazard >> Restrict access when switching or live The boundaries are defined as: 4. Reduce the risk through engineering controls 2. Replace the hazard with something safer 5. Change/control the way people work work is undertaken; >> Arc Flash boundary (outer boundary): 3. Separate the hazard from people 6. Protect the worker >> Use remote switching and racking The flash boundary is the farthest equipment; established boundary from the energy >> Follow permit to work system and source. If an arc flash occurred, this Diagram 15. Hierarchy of controls diagram to re-draw in new style electrical safety procedures; boundary is where an employee would be exposed to a curable second-degree burn >> Keep away from the arc flash boundary. (1.2 cal/cm2). RISK CONTROL / MITIGATION – RISK MITIGATION – SUBSTITUTION ELIMINATION Substitution requires a hazard to be replaced Elimination is the most effective risk control/ with a less dangerous hazard. With electrical mitigation method. The elimination of arc equipment, there is little opportunity to flash risk requires that there is no exposure of substitute. personnel to energised electrical equipment, either by the physical separation for the energised equipment, or by the effective isolation (and earthed if high voltage) and proof that electrical conductors are 0 deenergised. Whilst the isolation and earthing of conductors eliminates the risk, the process to isolate, prove deenergised and earth conductors still has arc flash risk. 4 CONTROLS THAT MAY ELIMINATE THE ARC FLASH RISK ARE: 2 1. 0 7m >> Eliminate the need to be near energised electrical conductors – relocate the work. 3 .4 >> Isolate and earth conductors, so they are no longer energised. 3m Diagram 16. 3D/Isometric to show boundary and people with PPE 42 Electric Arc Flash Hazard Management Guideline - Annex A Electric Arc Flash Hazard Management Guidelines - Annex A 43
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