Electrical safety begins with a thorough understanding of the risks. Among the most common risks are arc flash injuries.
An arc flash is an electrical explosion that can reach temperatures hotter than the sun's surface. It can cause severe burns, explosions, and electrical shocks. These injuries can be severe and life-threatening.
By understanding the three most common types of arc flash injuries, you can better protect yourself and your employees. Whether you’re an electrician, a maintenance worker, or simply curious about electrical hazards, this article is essential reading.
In case you didn't know, we've written a more extensive article on what an arc flash is. That said, we'll cover arc flashes on a higher level here.
An arc flash is the sudden release of electrical energy through the air. They occur when a high-voltage gap exists and there is insufficient insulation or isolation to contain the energy. It is not just a spark. An arc flash is an explosion that results from the ionization of air by an electric current.
During an arc flash, temperatures can reach over 35,000 degrees Fahrenheit, several times hotter than the sun's surface. Along with the extreme heat comes an intensely bright light.
The intense light of an arc flash can cause temporary or permanent blindness. This can disorient workers and hinder their ability to leave the hazardous area or get immediate help. The combination of heat and light creates a dual threat that can result in life-altering injuries.
Another critical aspect to consider is the force of the arc flash. The rapid release of pressure can generate a blast wave that is strong enough to throw workers across a room. This physical trauma can lead to a range of injuries, including broken bones, internal injuries, and concussions. The blast can also propel metal fragments and other debris, increasing the risk of puncture wounds and lacerations.
Loud noise generated during an arc flash can lead to substantial hearing loss. The sound can reach levels well above the threshold for safe exposure, leading to permanent damage to the ears.
Now that we've covered what an arc flash is, and why they're dangerous, let's look further at the most common arc flash injuries.
The most visible injuries from an arc flash are burns. The intense heat from an arc flash can reach temperatures up to 35,000°F, as previously mentioned. Burns can range from first-degree to third degree, with third-degree burns penetrating through the skin to muscles and bones.
While first-degree burns cause less damage and can heal more quickly, third-degree burns are more dangerous. Third-degree burns damage three layers of skin, and often damage sweat glands and nerve endings. Burns from arc flashes should be avoided at all costs.
For more reading on third-degree burns and how to treat them, see this article from the Cleveland Clinic.
Another common arc flash injury is a blast that rips through the air. The release of energy and the force created by this release cause these blasts.
The resulting pressure wave is a result of the sudden expansion of air due to the extreme heat generated by the arc flash. The blast is so powerful that it can throw workers across large distances, leading to severe physical trauma.
Even if a worker is wearing protective gear, the blast's force can cause them to hit walls, machinery, or other things. This can cause broken bones, concussions, and internal injuries.
Along with physical displacement, significant damage to the ears can result from extreme noise and pressure. The noise level during an arc flash can exceed 140 decibels, which is loud enough to rupture eardrums. The pressure wave can also cause a worker to lose focus and balance. This makes the situation even more difficult and could cause more injuries as the worker tries to get back in control.
Last, flying debris and shrapnel pose another critical risk. The blast can cause nearby materials to become projectiles, including metal fragments, tools, and even pieces of equipment. These objects can travel at high speeds and strike workers, causing cuts, punctures, and other serious injuries. The pressure wave and flying debris make the environment very dangerous, and even small objects can become deadly.
A third common arc flash injury is electrocution. This is common because arc flashes are the result of electricity passing through the air over a break in a current.
The immediate jolt of current through the body, known as electrical shock, remains a critical problem, even as we explore the broader range of arc flash injuries. When an arc flash happens, the electricity can go directly through a worker's body. This can cause many bad and even deadly conditions.
One of the most immediate and dire consequences is cardiac arrest, which can happen if the current travels through the chest. The heart's natural electrical rhythm can be changed, causing it to stop beating well. This needs medical attention right away to prevent deaths.
During electrical shock, severe muscle contractions pose another significant risk. These contractions can be so intense that they lead to bone fractures or dislocations. The sudden and strong contraction of muscles, especially in the limbs and torso, can put a lot of pressure on the bones.
This can cause injuries that may not be obvious right away but can cause problems for a long time. Sometimes, these contractions can also cause a person to be thrown or fall. This can cause more injuries, like head injuries or spinal damage.
Additionally, long-term neurological effects can occur following an electrical shock. Chronic pain, often described as a persistent burning or tingling sensation, can develop in the affected areas. Cognitive issues, such as memory loss, difficulty concentrating, and mood changes, may also arise.
These effects can significantly impact a person’s quality of life and ability to return to work. It is crucial for those who have experienced an electrical shock to undergo thorough medical evaluations and follow-up care to address both the physical and neurological impacts of the incident.
Arc flashes can cause many other injuries, including hearing loss, vision problems, and breathing problems, as well as burns and blast injuries.
One of the most overlooked results of an arc flash is flash blindness. Flash blindness is another significant but often temporary injury. The intense light produced by an arc flash can temporarily blind workers, even if they are not looking directly at the source. This condition, known as photic shock, can last for several minutes and can be disorienting, leading to accidents or falls.
While flash blindness is usually not permanent, it can have serious immediate consequences. Employers should ensure that workers are aware of this risk and are trained to respond appropriately in the event of an arc flash.
Arc flashes also pose significant respiratory risks. The extreme heat and electrical discharges can generate toxic fumes and gasses, such as nitrogen oxides and ozone. Inhalation of these fumes can cause respiratory issues, including irritation, inflammation, and, in severe cases, chemical burns in the lungs.
Adequate ventilation and the use of respiratory protection, such as N95 masks or full-face respirators, are crucial in environments where arc flashes are a possibility. These measures can help prevent long-term health problems and ensure that workers remain safe and healthy.
This section highlights the diverse risks associated with arc flashes through the injuries mentioned. While burns and blast injuries are more immediately visible, the potential for hearing damage, vision impairment, and respiratory issues underscore the importance of comprehensive safety measures.
Effective strategies to mitigate the risks of potential arc flash injuries are imperative in the workplace. One of the most critical measures is the use of arc-rated Personal Protective Equipment (PPE). This specialized gear is designed to protect the skin from the intense heat and light generated during an arc flash.
Arc-rated PPE includes flame resistant clothing, face shields, and gloves. These materials are tested to withstand very high temperatures, as well as open flames. They can greatly reduce the severity of burns and other heat injuries. To create a safe working environment, all workers need to have and be taught how to use PPE correctly.
Using insulated tools, in addition to PPE, is another critical preventive measure. Insulated tools are made to protect the worker from live electrical parts. This helps to reduce the risk of direct contact and electrical shock. These tools should be regularly inspected and maintained to ensure they remain effective.
Employers should also consider using non-conductive materials whenever possible to further minimize the risk of an arc flash. By using insulated tools and arc-rated safety gear, workers can create a strong defense against the dangers of electrical work.
Implementing lockout/tagout (LOTO) procedures is a proactive approach to preventing arc flash injuries. LOTO ensures that circuits are de-energized, and cannot be accidentally re-energized while maintenance or repairs are being performed. This process involves isolating all energy sources, locking them out with approved devices, and tagging them with warning signs.
Training staff on how to do LOTO correctly is important. It can make the difference between a safe work environment and a potentially deadly one. Regular drills and refresher courses can help reinforce the importance of these procedures and ensure that all employees are prepared to handle electrical equipment safely.
Generally, workplace safety training must be properly treated when arc flash injuries are prevalent. Training employees to recognize hazards and practice safe work methods is a fundamental aspect of preventing arc flash incidents. Employees should be able to identify potential arc flash risks, understand the importance of maintaining a safe distance from live electrical parts, and know how to use the proper tools and equipment.
These protective measures—arc-rated PPE, insulated tools, LOTO procedures, staff training, and warning labels—when incorporated, can significantly improve the safety of electrical work environments in organizations. Each of these steps is important for protecting workers and reducing the risk of arc flash incidents. This helps make the workplace safer and more productive.
Are you confident you're prepared for even the most common arc flash injuries? Is your team able to avoid the common pitfalls that lead to such injuries?
Let us know how you're thinking about reducing the likelihood of arc flash injuries in your organization. If there's something we can't help with directly, we'll connect you with someone that can. We only want you and your team to work safely.