HAZARD MANAGEMENT GUIDELINE - ELECTRICAL ARC FLASH - March 2019

Page created by Greg Chen
 
CONTINUE READING
HAZARD MANAGEMENT GUIDELINE - ELECTRICAL ARC FLASH - March 2019
ELECTRICAL
ARC FLASH
HAZARD
MANAGEMENT
GUIDELINE

March 2019
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
You can also read