Understanding the Four Critical Boundaries

Arc flash protection is built upon a system of four distinct boundaries, each serving a specific protective function.

Limited Approach Boundary

The Limited Approach Boundary represents the distance from an energized component where
unqualified persons (those without proper electrical safety training) must not cross without escort. This
boundary serves as the outermost protective perimeter and is determined based on nominal system
voltage.
Unqualified individuals may only cross this boundary when they demonstrate a valid need and receive
continuous escort by qualified personnel. This first line of defense ensures that individuals without
proper training remain at a safe distance from potential electrical hazards.

Restricted Approach Boundary

The Restricted Approach Boundary establishes a more stringent protective zone that only qualified
electrical workers may enter. Within this boundary, specific PPE and insulated tools become
mandatory, and inadvertent movement must be prevented through proper work positioning. The risk of
electrical shock increases significantly due to proximity, and documented work permits are required
for any repair work inside this limit.

Arc Flash Boundary

Unlike the previous boundaries based on shock protection, the Arc Flash Boundary specifically
addresses thermal energy exposure. This critical boundary marks the distance at which
second-degree burns could occur during an arc flash incident. It requires determination through
incident energy calculations specific to each piece of equipment.
The Arc Flash Boundary may extend significantly farther than shock protection boundaries in certain
systems, sometimes reaching 20 feet or more for high-energy equipment. Anyone crossing this
threshold must wear appropriate arc-rated clothing and PPE matched to the estimated incident energy
levels.

Calculation Methodologies: Beyond the Simplified Tables

While NFPA 70E offers tables for estimating boundaries, comprehensive protection requires more
detailed calculation approaches.

Incident Energy Analysis Method

The incident energy analysis method applies IEEE 1584 calculation methodologies to determine
equipment-specific boundaries rather than relying on general categories. This engineering-based
approach accounts for system-specific factors including available fault current, protective device
clearing time, gap between conductors, working distance, system grounding configuration, and
enclosure type and size.
This method typically provides more precise PPE requirements and often reduces excessive PPE
compared to table methods. The calculations produce specific incident energy values measured in
calories per square centimeter (cal/cm²) at defined working distances, which directly correlate to PPE
arc ratings.
Organizations implementing this approach must maintain regular updates when system changes occur.
Modifications to electrical distribution systems, changes in protective device settings, or even routine
maintenance on circuit breakers can significantly alter arc flash boundaries, requiring recalculation and
relabeling.

Practical Implementation Strategies

Translating calculated boundaries into workplace practice requires systematic implementation
approaches that make abstract mathematical concepts visible and understandable in the field.

Equipment Labeling Systems

Effective labeling forms the cornerstone of boundary implementation. Equipment labels should clearly
display all relevant boundaries, indicate required PPE categories, and include incident energy values at
working distance. Consistency across the facility helps workers quickly recognize and interpret
boundary information regardless of which area they’re working in.
Advanced labeling systems incorporate color-coding for rapid recognition and may include QR codes
linking to detailed procedures for that specific equipment. Labels must include calculation dates for
verification and be constructed from materials capable of withstanding the environmental conditions
present in the installation location.

Temporary Boundary Marking

Maintenance and project work often require temporary boundary marking systems to create visible
reminders of invisible boundaries. Facilities typically deploy portable boundary tape stands at
calculated distances, with distinct colors representing different boundaries. Some organizations
implement digital projection systems for complex environments where traditional boundary marking
proves difficult.
Effective programs train workers on proper placement verification and create standardized boundary kit
contents available at job sites. Work permits should document actual boundary placement, particularly
in areas with overlapping boundaries from multiple energy sources.

Digital Boundary Management

Advanced organizations increasingly implement digital boundary tracking systems to enhance
traditional approaches. Mobile applications can display real-time boundary information specific to
equipment being serviced, while wearable technology can alert workers to boundary encroachment
before violations occur.
Some facilities utilize augmented reality displays showing boundaries in complex environments,
particularly useful in congested industrial settings. These systems often integrate with work order
management systems to ensure appropriate precautions appear automatically when work is scheduled
on specific equipment.

Training Methodologies for Boundary Awareness

Effective boundary training goes beyond concept explanation to develop practical application skills that
workers can implement in diverse field conditions.

Boundary Decision-Making Scenarios

Training should incorporate decision-making elements that reflect real-world complexity. Scenariobased exercises should present multiple boundaries requiring assessment, dynamic situations with
changing requirements, and emergency response protocols when boundaries are compromised.
Workers need clear understanding of authorization processes for boundary crossing and communication
protocols when working near boundaries. Documentation requirements for various boundary zones
should be practiced until they become second nature rather than burdensome administrative tasks.

Special Applications and Considerations

Certain situations require modified approaches to boundary management due to their unique challenges
or heightened risk profiles.

Complex Multi-Feed Equipment

Equipment with multiple power sources presents unique boundary management challenges. Safety
professionals must determine worst-case boundary scenarios accounting for all potential energy sources
and establish clear procedures for boundary hierarchy during partial de-energization.
Documentation systems must account for the complexity of these situations, with special labeling
requirements indicating multiple sources. Workers require specialized training on verification
procedures for all potential energy sources before boundaries can be modified or reduced.

Outdoor and Extreme Environments

Outdoor installations and extreme environments necessitate adaptations to standard boundary practices.
High-wind environments may require enhanced boundary marking methods, while wet or corrosive
atmospheres demand more durable marking solutions.
Extreme temperature environments affect both boundary implementation and PPE utilization. Cold
weather may require additional protective layers beneath arc-rated clothing, potentially affecting
movement and dexterity within restricted boundaries. Limited visibility conditions in outdoor settings
during night work or adverse weather require enhanced marking strategies to maintain boundary
awareness.

Continuous Process Environments

Facilities where shutdown is exceptionally costly require specialized boundary management
approaches. These organizations often implement remote monitoring and operation strategies to
minimize the need for boundary crossing during normal operations.
When boundaries must be crossed in these environments, enhanced PPE protocols and specialized
work practices help reduce risk while maintaining operational continuity. Many such facilities invest in
engineering controls specifically designed to reduce boundary zones, such as remote racking systems,
infrared viewing windows, and robotic inspection technologies.

Measuring Program Effectiveness

Evaluating boundary program effectiveness requires both leading and lagging indicators. Organizations
should track boundary procedure compliance rates, authorized versus unauthorized boundary crossings,
and worker competency assessment scores as leading indicators of program health.
Near-miss reporting related to boundary violations provides valuable insights for program
improvement, while PPE compliance verification at various boundaries helps identify potential training
gaps. Regular review of boundary documentation in work permits reveals how well theoretical
knowledge translates to field application.
Effective programs establish feedback mechanisms allowing qualified workers to suggest
improvements to boundary management systems based on field experience. This continuous
improvement approach recognizes that those working within the boundaries daily often develop the
most practical insights for enhancement.

Beyond Compliance to Culture

Effective arc flash boundary management extends beyond mere regulatory compliance, becoming
ingrained in organizational safety culture. By implementing comprehensive assessment protocols,
practical field applications, and engaging training methodologies, organizations transform abstract
calculations into tangible protection systems.
The most successful electrical safety programs recognize that boundaries represent more than
mathematical formulas or floor markings—they serve as critical decision points where worker
behavior, engineering controls, and administrative systems intersect to prevent catastrophic injuries.
Through proper implementation of these concepts, electrical workers can navigate hazardous
environments with the protection afforded by invisible but life-saving perimeters.

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Critical Electrical Safety Targets

Make sure these get done!

• De-energize. Unless the employer can justify live work, it is not permitted. Live testing and troubleshooting are allowed, but altering the circuit live is difficult to justify.
• Workers must be qualified for each electrical task they perform, and the electrical hazard they are exposed to.
• Workers must know how to perform a risk assessment, and how to reduce the associated risk.
• A worker must have access to and utilize the appropriate PPE for the electrical hazard.
• Employers need to ensure the worker has access to arc-rated PPE throughout the range of incident energy indicated by their incident energy analysis.
• Test-Before-Touch. A qualified worker must verify zero energy before contacting de-energized parts by performing the Live-Dead-Live test.
• While verifying zero energy, the qualified worker must utilize appropriate PPE and insulated tools.
• All PPE, as well as all tools and equipment with electrical insulation, must be inspected daily before each use.
• The owner of the electrical equipment is responsible for providing labels that include nominal voltage, arc flash boundary, and a method of determining the appropriate arc flash  PPE to be worn.
• Rubber insulated gloves must be electrically tested every six months.
• Arc-rated clothing and insulated gloves must fit the user, and provide full coverage.

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Introduction

This control panel is like thousands of control panels out in facilities today, and maybe even many in your facility. It controls a machine on the factory floor. It has four motor starters, individual circuit breakers for those motor circuits, ice cube relays, small fuses, and a control transformer. And on the door there are pushbuttons, indicating lights, rotary switches. In the lower right

corner of the panel is the main circuit breaker. With the door closed, we can still operate the breaker through the hole in the door. Pretty typical of many control panels. The question is how do we de-energize this panel to establish an electrically safe work condition.

Circuit Breakers

Circuit breakers have a line and load side. The line side is where the incoming power is connected. The load side is where the downstream loads are connected. In this case, the downstream loads are everything else in this panel and all of the motors and other components in the control circuit outside the panel. Everything downstream from this main breaker is being protected from over-currents by this breaker.

The question is, does this circuit breaker de-energize this panel? The answer is no. Opening this breaker de-energizes everything in this panel as well as the downstream loads, everything except for the line side of the breaker itself. When this circuit breaker is opened, turned off, the line side of the breaker is still hot. With the line side still energized by the incoming power, the panel has to be considered energized because the main breaker still has a shock and arc flash hazard. You could not use this breaker to establish an electrically safe work condition for this panel.

Electrically Safe Work Condition

To properly de-energize this panel to establish an electrically safe work condition, you would need to locate the circuit breaker or disconnect that feeds power to your control panel. Your lockout tagout procedures should indicate the location of this breaker or disconnect. Once that is found you would open that disconnect or circuit breaker and apply your locks and tag. Return to the control panel and follow through with all of the required lockout tagout procedures. The most important of which is the live-dead-live test to verify zero voltage. Always Test-Before-Touch. And of course, always wear the required PPE while verifying zero volts. Every circuit has to be considered energized until you’ve proven it’s not.

Troubleshooting Example 1

As a troubleshooting example, let us use a situation in which the operator of this machine reports that one of its four conveyors stopped running. You show up and ask the operator what led up to this problem, and they state that that conveyor has been making a lot more noise than usual. A squealing sound. You suspect a mechanical problem, and on an inspection of the conveyor pulleys, it is evident that a bearing has failed thus causing too much load on the motor. Next, we go to the control panel and see that it has an arc flash label that states an arc flash rating of 11 cal/cm2 and a voltage of 480. We must don the appropriate PPE to protect you from such an arc flash and voltage. Because we are only going to do a visual inspection and we are wearing the proper PPE we can proceed. We do an orderly shutdown of everything the panel controls then open the main breaker. We then open the control panel door and see that the motor starter has tripped for that motor. Everything else in the panel appears fine, we reset the motor starter, and close the door. We place our lock and tag on the main breaker, and we perform all other procedures required by our lockout tagout procedures and proceed to repair the bearing.

Troubleshooting Example 2

In the next example, the operator reported the conveyor wouldn’t turn on. There was no mention of a squealing noise. During our initial troubleshooting, we attempt to turn on that conveyor manually and we hear the motor starter turn on, or pull-in as we say,  inside the cabinet. But, the conveyor is still not moving. We don the appropriate PPE, open the control panel door and begin our visual inspection of the panel. We immediately notice the motor starter for conveyor four is showing signs of heat damage. A  dark smoke-like film is on the area covering the motor starter contacts. This, we know from experience, is an indication of poor contact being made by the starter contacts. The other starters don’t show this damage. Now we know we are going to have to remove and replace the starter or at least disassemble it for inspection and repair. In either case, we’ll need to completely de-energize the panel. At this time we’ll need to close the control panel door and open the main breaker. We then must go to the upstream circuit breaker for this panel, turn it off and apply our lock and tag. Upon returning to the control panel, wearing the appropriate PPE we open the control panel door. Using an appropriate volt-meter, we test that meter on a known live circuit, then measure incoming line leads phase-to-phase and phase-to-ground and do verify that we indeed have zero volts. We then retest the meter on a known live circuit to confirm the meter is still working. That is the Live-Dead-Live test. Now we can remove the PPE and begin our repair work. We find the contacts badly damaged from not making proper contact and the carbon buildup inside the starter is preventing the contact assembly from moving freely. We replace the motor starter, and now all conveyors are working fine.

A Shield May Not Work

Some people have suggested that if you add a plastic or metal shield to the main breaker that covers the energized line leads that should solve the problem. It actually can create a whole new problem. OSHA requires electrical equipment to be “accepted, or certified, or listed, or labeled, or otherwise determined to be safe by a nationally recognized testing laboratory.” Underwriters Laboratory is such a lab. If you add a plastic or metal shield to your breaker, it is no-longer UL Listed because it didn’t have your shield when tested. The shield could cause the breaker to operate differently than when it was manufactured and tested, resulting in an unsafe situation.

Control Panel Design

This next piece of advice doesn’t help you with existing control panels but could make your future panels safer and easier to work with where 70E is concerned. That advice is to ask the OEM of your new panels to put this main breaker in a separate box on the side of the panel. Putting the main circuit breaker in a separate enclosure is becoming quite common now, and manufacturers of these boxes are offering this option. Hoffman’s SEQUESTR line of enclosures is one such offering.

Circuit Breaker Panel Boards

I used a control panel as an example here, but all of this applies to circuit breaker panel boards as well, not just control panels. Opening the main breaker of a circuit breaker panel does not establish an electrically safe work condition. If you’re going to add a circuit breaker, for example, turning off the main breaker for the panel board is not sufficient. You will need to open the circuit breaker that feeds this panel to establish an electrically safe work condition.

Conclusion

In conclusion, it is essential that we know what does and what does not make an electrical panel electrically safe. It must be spelled out in your lockout/tagout procedures which disconnect, or circuit breaker removes power from the equipment that will enable us to create the electrically safe work condition. We will wear the appropriate PPE any time the equipment has an energized circuit component above 50V.

Relevant courses

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Avoiding tight fitting clothing is essential if that clothing is being worn to protect you against the thermal effects of an arc flash. NFPA 70E states that the worker must avoid tight-fitting arc flash gear and that loose fitting clothes provide more thermal protection because of the “air spaces.” I often see and hear about companies adopting the policy of one single arc flash suit should take care of all of our needs. The maintenance department can share the same suit. The policy of one arc flash suit for the entire maintenance department is a big mistake.

An arc flash suit is the heavier arc flash protection needed in incident energy exposures generally above 25 cal/cm2. Arc flash suit hoods are required for any energy above 12 cal/cm2. The issue is this. If one of the maintenance people in your group is 6 foot 4 inches tall and weighs north of 300 pounds and another worker is 5 foot 7 inches and weighs 160, they can’t wear the same suit. But, I have seen situations where this is precisely the case. It is an impossibility that two people with substantially different body types can wear the same suit, and for safety reasons, they shouldn’t be wearing the same suit.

The reason an ill-fitting suit is a problem is that loose fitting arc rated clothing gives you more thermal protection than tight clothes, and, in addition to that, the wrong size suit can obstruct movement preventing you from completing the task safely. What if a major league baseball team all had to wear the same size uniform? I don’t think the fielding, throwing or hitting would be as good because their movements would be restricted. Go Cubs. I am here to argue that an arc flash suit is more important than a baseball uniform. To ensure that everyone is fitted correctly and the equipment properly stored and cared for, professional teams employ an equipment manager. Maybe your facility needs an equipment manager. I know you aren’t working with the same equipment budget as the Yankees. But how nice would that be?

Besides restricting movement, sleeves that are too short can be an issue if you extend your arm and your sleeve no-longer reaches your hand; subsequently, your wrist and forearm become exposed. 70E requires that the arc flash clothing provides full coverage.

One of my favorite comedy scenes in a movie has to be the “Fat Guy In A Little Coat” scene in Tommy Boy. Not surprisingly, small of stature, David Spade’s sports coat did not fit Chris Farley, with hilarious results. Funny in a movie, not amusing with PPE.

Manufacturers and distributors, on their websites, have detailed sizing charts for assisting you in getting the arc flash suit that fits your body. Head to toe measurements are included, and there are different sizing charts for men and women. Most want your chest, waste, height, other manufacturers need your arm length, inseam, among other measurements. One manufacturer states in the sizing instructions that workers under 5’8” and taller than 6’4” need to have a custom suit. Other manufacturers offer sm, med, LG, XL, XXL, XXXL. You would have to figure where you are on this type of a scale.

Here are links to a couple sizing charts:  Oberon    National Safety Apparel

Arc flash suits are expensive, and I certainly understand why companies want to limit the costs of implementing NFPA 70E.  Your company needs to develop a plan for ensuring all qualified workers have the appropriate suit to wear.

Arc flash suits come in a variety of types. You can purchase bib overall type pants and an accompanying jacket and hood. There are regular type pants, with a jacket and hood. It is important that you shop around, look at many websites of manufacturers and distributors. Look at all of the sizing options and determine what is right for you.

A comment I have heard on more than one occasion is, “I don’t want to wear an arc flash suit that someone else has been sweating in.” Good point, I wouldn’t either. Let me state right now, that in my opinion, the only live work we should be doing in an arc flash suit is verifying zero volts during our live-dead-live test required for lockout tagout. Our first step in providing protective measures after we have completed a risk assessment is the elimination of the hazard. Working de-energized. This, of course, will require us to establish an Electrically Safe Work Condition (ESWC). So hopefully no one is wearing an arc flash suit for an extended period of time. I do realize on really hot and humid days you don’t have to wear them very long before you are sweaty.

Arc flash suits have to be stored in such a way that they won’t become damaged. A dedicated cabinet, storage closet or bags will help limit the damage. Some people turn them inside out to help them dry and avoid mold and the suit getting stinky. One helpful accessory that is available is a cooling unit which is a blower that mounts to the suit and provides air flow throughout the suit as you wear it. Another accessory is cooling vests designed to be worn under an arc flash suit.

Your facility needs to have suits in various sizes so all qualified workers are protected through the range of arc flash exposures. This is an expensive garment performing the critical function of protecting the wearer from a high energy arc flash event. A lot of thought needs to go into the proper sizing of arc flash suits and how many we need to buy.

Our Training That Addresses This Issue

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Practical Guide To Arc Flash and NFPA 70E

By: Daryn Lewellyn

I began my first job in electrical maintenance when I was hired in at Terre Haute Malleable and Manufacturing Company in 1984; a long-since-closed iron foundry in Terre Haute, Indiana. It was a one-hundred-year-old facility, dark, with dirt floors made of sand and coal dust and known by the workers as The Malleable. Some of my most memorable work experiences happened in the four short months I worked there. I remember not receiving any electrical safety training.

I remember when an older electrician named Bill gave me the arc flash training. It wasn’t called arc flash training because none of us had ever heard that phrase before. We didn’t know what happened when panels blew up or that it had a name. The information was given as somber advice while we were standing in front of a large disconnect. Bill said, “When you open or close one of these big disconnects don’t stand in front of it. Stand off to the side, use your left hand, turn your head and it might not hurt to duck a little.” I asked why and he said, “sometimes these things blow up.” That was good advice then and is still relevant today.  The problem was that in 1984 that advice was the entire arc flash class. That was all we knew. Several years later I was repairing a variable frequency drive when part of it exploded when I closed the breaker. I was standing off to the side and was not injured. Thanks, Bill.

Thirty years ago we wrapped electrical tape around screwdrivers and called them insulated. We thought the plastic dipped handles on our Klein lineman’s pliers made them safe. Channel locks were fuse pullers. We wore polyester shirts and gold chains, and our only PPE was a hard hat, steel-toed shoes and safety glasses.

A lot has changed in regards to electrical safety and electrical safety training in the decades since. Arc-rated clothing has replaced our polyester shirts, voltage-rated insulated tools have replaced electrical tape, and most importantly, awareness of electrical hazards has replaced our ignorance. We can no longer work as we did back then, and we have to receive training on electrical hazards. In the ten years, I worked in factories, my employer never gave me formal electrical safety training. The first electrical safety class I was a part of I was the instructor.

In this Practical Guide To Arc Flash and NFPA 70E, I hope to simplify parts of the standard. This guide is not going to answer every question you have, and it doesn’t address every article in 70E. What I am hoping to accomplish with this guide is to help you understand the standards’ most impactful sections and to give you guidance on whether your facility needs more work on your overall electrical safety program.

As I travel the country providing 70E training and consulting for my clients, I have recognized a need for a guide like this. I wrote this guide for qualified workers, managers, and supervisors to assist them in making people safer while working around electrical hazards. Whether you call the training electrical safety training, 70E training, or arc flash training, it is a good idea to read this guide first as it may generate some good questions to have clarified during your training.

Access To The 70E Standard

Every facility, company or organization needs an easily accessible copy of 70E. I like the pdf version because it’s searchable and you can access it over a network.

I also think the 70E Handbook is a handy tool. It has interpretations, explanations and added material, not in the 70E standard. The Handbook can be purchased as an eBook and read on a tablet, Kindle or your phone. Wherever I am, I have 70E and the handbook on my phone. I also keep the OSHA regulations 1910.301 – 308, 1910.331 – 335, and 1910.399 at my fingertips, and all searchable.

Electrical Safety Responsibilities

Both OSHA and 70E agree on what the employers’ and the employees’ responsibilities are when it comes to electrical safety. Both require the employer to establish, implement, and document electrical safe work practices and procedures. And to train their employees on them. The employee’s responsibility is to comply with these work practices. These work practices will include many things, such as de-energizing equipment, PPE, risk assessments, approach boundaries, etc. The priority of these work practices must be the elimination of the hazard. De-energize the circuit, use the live-dead-live test to verify that it is de-energized.

Using arguments like we can’t afford the downtime, production won’t let us shut it down, and the boss or client say’s we have to work live, do not work anymore. These things are money issues and have no place in the decision-making process when we are de-energizing equipment. When a facility decides to work energized because it might save money they needlessly put workers in a possibly fatal situation. The world will not end if you experience a short downtime.

Exposure To Electrical Hazards

If a worker is about to begin a task that will be exposing them to electrical hazards a few things need to be clear. First, the worker has to be qualified for the work they are about to undertake. They must be able to demonstrate that they understand the equipment operation and construction, have received training on the hazards present, and have been trained on how to reduce the associated risks. The employer must document when the qualified worker received electrical safety training and the contents of that training when they demonstrated their proficiency with the work practices, and retain the documentation for the duration of their employment.

A helpful way to prepare for this is to imagine OSHA walking into your facility and asking if the worker they see using a voltmeter is qualified for the work they are doing. How would you answer and what documentation would you be able to provide to make your case?

Next, assuming we have determined the worker is qualified, we need to look at the task they are about to perform. Let us use as an example of adding a circuit breaker to a 480/277 volt panel-board labeled “Panel-A.” OSHA and 70E agree that we can’t do this work energized. Thirty years ago we may have inserted or removed a circuit breaker while the panel was live. But not today.

OSHA and 70E both require circuits above 50 volts be de-energized before work proceeding. Unless de-energizing would cause increased or additional hazards, such as life support systems at a hospital, or alarm systems. We are also allowed to work energized if it is infeasible to de-energize the circuit. I can tell you OSHA doesn’t believe many things are infeasible. Measuring voltage during the commissioning and startup equipment, measuring voltage and current during troubleshooting, for example, are allowed because it is infeasible to measure voltage and current if the circuit is de-energized. Just because it is acceptable doesn’t mean you have to permit it. Many companies do not. We may also have to work de-energized on circuits below 50 volts if they present a potential arc flash hazard.

OSHA requires you to work energized in one critical task. Lockout/Tagout. One of the steps of LOTO is verifying you have zero volts on the circuit you just de-energized. You must consider every conductor energized until you verify zero energy. When you are validating zero voltage, we have to regard this as live work. What if you opened the wrong disconnect. That happens all of the time. Perhaps the most important things we preach to our clients is, “Test Before Touch,” and, of course, wear PPE while you’re doing it. Every circuit has to treated as energized until we have proven it is not.

Job Safety Planning

Before a task has begun that will expose workers to electrical hazards, such as our example of adding a circuit breaker to a 480/277 volt panel, a qualified person must create a job safety plan(JSP). The JSP has to include a description of the job and tasks, shock and arc risk assessments, and work procedures, special precautions, and energy controls. Once you have the plan created a job briefing needs to take place. Annex I of 70E has a helpful job briefing and planning checklist.

Approach Boundaries

Your electrical safety training must stress these boundaries, so every qualified fully understands what they mean. Approach boundaries operate as their name implies; as you approach a piece of electrical equipment with exposed energized circuit parts, there is a point at which the risk of injury becomes great enough that additional rules apply. Two shock-protection approach boundaries will be a central part of your shock protection; those are limited and restricted. They each have their own rules. There is also an arc flash boundary that marks where a second-degree burn is likely to occur on bare skin if an arc flash occurs. Each of these boundaries marks a spot where an increase in awareness, blocking access, work permits and PPE are going to be required. These boundaries mark the line where the likelihood of an injury and it’s severity increase. Barricades, an attendant, or tape are needed to identify the first encountered boundary.

The Limited Approach Boundary

The limited approach boundary is a distance from the employee to an exposed energized circuit part within which a shock hazard exists. The typical nominal AC voltages that a maintenance person would be working on of 120, 208, 220, 240, 277, 380, and 480 all have a limited approach boundary of 42 inches. For higher voltages, please refer to the latest edition of 70E. No unqualified person is allowed inside the limited approach boundary unless a qualified person is escorting them. Crossing this invisible boundary triggers the need to establish an electrically safe work condition.

Electrically Safe Work Condition (ESWC)

You have established an ESWC when you have disconnected the equipment, locked and tagged the disconnect, tested to verify an absence of voltage, and, if necessary, temporarily grounded the equipment. The temporary ground is something typically used in circuits above 1000 volts.

Restricted Approach Boundary

This boundary triggers the need to insulate the worker from the exposed circuit parts by utilizing insulated rubber gloves, insulated tools, sleeves, shields, etc. Unqualified workers are not allowed within the restricted boundary or to take any conductive material or tool within this boundary. There is no listed restricted boundary for 120 volts AC, 70E says to avoid contact. You must wear insulated gloves, use insulated tools when contacting live 120-volt circuits. The earlier mentioned voltages of 208, 220, 240, 277, 380, and 480 volts AC have a restricted boundary of 12 inches.

Arc Flash Boundary

This boundary is a distance at which a worker could suffer a 2nd-degree burn in 1 second to exposed bare skin. We must utilize proper PPE for arc flash protection when inside this boundary. The arc flash boundary is independent of the shock protection boundaries. Where your restricted and limited shock boundaries are 12 inches and 42 inches respectively, the arc flash boundary might be 50 feet, or it might be 1 inch.

Shock risk assessment

We have to perform a shock risk assessment, starting with identifying the shock hazard, which in the example of adding the circuit breaker will be 480 volts. We know our limited approach boundary will be 42 inches and the restricted 12. We will need to de-energize the upstream circuit breaker that feeds “Panel A.”

Turning off the main circuit breaker of “Panel-A” de-energizes all of the circuit breakers in “Panel-A,” but it does not de-energize “Panel-A.” A common misconception. The line side, the side of the breaker with the incoming power, normally the top of the breaker, will still have 480 volts even when turned off. A shock and arc flash hazard would still be present. To de-energize “Panel-A”, we will need to go to the upstream circuit breaker that feeds “Panel-A.”

At this point we have every breaker in the panel opened, including the main. We’re not ready to remove the front cover yet because the line side of the main circuit breaker is energized. The line side of the breaker is the incoming power, and a label on the panel indicates it is fed from MDP-3” and off we go to find “MDP-3.”

We go to the upstream main distribution panel “MDP-3” and find a circuit breaker labeled “Panel-A” and open the circuit breaker and put on our lock and tag.

Upon returning to “Panel-A” to begin removing the cover, we must first put up our barricades. The arc flash label indicates that the arc flash boundary for “Panel-A” is 72 inches. The barricades have to be set at least that far from the equipment to prevent workers from wandering into our work area. Instead of using a barricade a second worker can be employed as an attendant to warn others to stop them from approaching too closely. Ideally, use both a barricade and an attendant. If our arc flash boundary was less than the limited approach boundary, which is 42 inches, your barrier could be set as close as 42 inches. Always set the barricade at the first encountered boundary.

You might be thinking we’re not going to need barricades because “Panel-A” is de-energized. “Panel-A” is not de-energized because we haven’t proven it yet. All we know for sure is we have moved the handle on a circuit breaker in the “MDP-3” panel from the on to the off position. You must treat every circuit, wire, panel or piece of equipment as energized until we have proven it isn’t. Always test before touch.

Now, as we are readying ourselves to open the cover of “Panel-A,” we must address what the PPE requirements for this panel are. Part of our job safety plan would be to read the label on the equipment to determine the PPE needed for this panel. We know it is a 480 volt AC panel and we will be crossing the restricted boundary as we verify zero voltage. Therefore Class 00 gloves, which are rated at 500 volts AC, would be needed. They will also be required as we remove the cover as we likely will be within the restricted boundary at that time as well. Many times, as we remove the cover our tools are still in our hands, so we must use insulated tools rated for the voltage.

The tools and gloves have to be inspected daily before each use. In fact, any piece of equipment you use that has insulation, such as power-tool cord, extension cord, meter leads, tools, and the PPE you wear as a garment has to be inspected by you daily before each use. You must remove them from service if they show any sign of damage. The gloves must be electrically tested every six months. As with all PPE, it is essential that they fit the wearer. Don’t make the mistake of buying only one set of gloves for everyone to share. The companies that manufacture or sell gloves have sizing instructions on their websites. Don’t use gloves that are rated for a much higher voltage than you will ever need. If your workers are only going to be working on 480 volts, don’t buy them 1,000-volt gloves.

For arc flash protection we see that “Panel-A” has an incident energy of 13 cal/cm2 with an arc flash boundary of 72 inches.

The Live-Dead-Live Test

We will be performing a “live-dead-live” test. OSHA and 70E require us to verify zero energy at the panel. You must choose an appropriate voltmeter, test it on a known live circuit to verify the meter is functioning correctly. Then, check the circuit we want to work on to ensure it is de-energized, and then retest the meter. If the meter worked properly before and afterward, it was probably working during the test.

Non-Contact Voltage Detector

Non-contact voltage detectors, although very useful for a lot of things, cannot be used for the verification of 0 volts during lockout/tagout. OSHA and 70E both require us to measure the voltage between all phases, that is L1 to L2, L1 to L3, & L2 to L3, and each phase to ground. A non-contact device cannot do that. They work on the principle of capacitive coupling and require a complete current path from your hand holding it through your body to ground.

PPE Required

What Is An Arc Flash

An arc flash occurs during a short circuit in which current flows through an air gap. It could be started by the accidental dropping of a tool, a worker making a connection between an energized conductor and ground or another phase, or with a bad connection in your electrical system. Anytime current is flowing through an air gap it creates tremendous heat that can quickly burn a worker or ignite their clothing. When the initial shorting of the circuit occurs, the current flows through, in this example, a dropped tool. A dropped tool is a sufficient conductive path to cause the short circuit, but it is not a path that can withstand the available fault current. As thousands of amps of current begin to flow through this bad connection, an air gap is created as the tool melts away. The current is now flowing through what is known as plasma, and plasma is a great conductor. As the plasma ball grows, it begins to short out more of the circuit parts. What might have started as a short to ground is now a short circuit of all phase conductors. All of this takes place in milliseconds. The energy from this event is what engineers calculate during an arc flash incident energy analysis. The amount of available fault current, clearing time of circuit breakers and fuses, and other factors determine what this incident energy will be.

Arc Rated Clothing

All arc rated clothing is flame resistant but not all flame resistant gear is arc rated. Clothes made for flash fire, for use in the petrochemical industry, for example,  are flame resistant but not arc rated. Electrical workers must have arc-rated clothing.

On the label of arc rated gear, it will have an Arc Thermal Protection Value (ATPV) or an Energy Breakopen Threshold (EBT). ATPV and EBT are both evaluated in the same test, ASTM F1959. The first one to be reached is the reported arc rating. To the end user, it just doesn’t matter which it has. One is not better than the other. The thing you want off the label is the incident energy value or the Category number, regardless if it is ATPV or EBT.

Two Methods For Determining The Arc Rated Clothing Needed

The two methods are the Incident Energy Method and the PPE Category Method. Arc-rated clothing is labeled with both because the manufacturer doesn’t know which you will be using.

You must use one or the other, and you can’t mix them on the same piece of equipment. That is you can’t have equipment with an arc flash label that says it has 19 cal/cm2 incident energy and call it a category two panel. If you have the incident energy on the panel it means you have done an arc flash incident energy analysis and your panel is a 19 cal/cm2 panel and the clothing system worn while exposed will need to have a minimum value of 19 cal/cm2. The clothing category doesn’t play into it at all.

Incident Energy Analysis

This method is one in which electrical engineers have calculated an arc flash energy for your panels based on real data collected from the field. It is typically thought to be the more accurate method, although, because of many factors, predicting arc flash energy is not an exact science. The engineers are relying on your over-current protective devices, your fuses and circuit breakers, to operate as designed. The people collecting the real data from your facility have no way of knowing if the circuit breakers have been appropriately maintained over the many years of operation.

PPE Category Method

This method uses a set of tables to determine what the estimated arc flash energy and arc flash boundary are going to be. This method does not use real-world field data from your facility. It estimates all panels of a particular type to be the same no matter what facility they’re in. To use these tables, you must know the kind of equipment, voltage, clearing time of the over-current protective device, and the maximum available fault current. Finding the voltage and equipment type is easy. Clearing time and fault current are going to require electrical engineers to get involved. The data that will need to be collected, such as wire length, wire size, transformer data, and the calculations the engineers will have to make to arrive at your clearing time and available fault current is essentially the same for doing a full incident energy analysis.

For years many employers have used the tables and ignored the requirements for knowing the clearing time and available current.

When to wear PPE

We are required to use Table 130.5 in 70E 2018 for estimating the likelihood of an arc flash event in the equipment that we will be servicing. The table lists equipment and tasks and indicates the likelihood that an arc flash might occur.  This table gives specific tasks, such as Thermography and visual inspections, a pass and says during these tasks there isn’t a likelihood of an arc flash. And further protective measures are not required, including PPE. It also states there are times when the equipment is in the “Normal Operating Condition” that there won’t be a likelihood of an arc flash. Myself, some colleagues in the field, and many of my clients are ignoring this. In our opinion, if the equipment has an arc flash incident energy of 1.2 or above, and you are within the arc flash boundary, PPE should be a requirement no matter what you are doing. And, if an employee is interacting with the equipment, even if the equipment is closed, such as opening or closing breakers, PPE will be utilized. The “Normal Operating Condition” includes a requirement that the equipment is properly maintained and has been used in accordance with the manufacturers’ instructions. How would any employer be able to verify that on a piece of equipment that has been around for many years? In my opinion, you should utilize arc flash PPE indicated by the equipment label any time the equipment doors are open, and you are within the arc flash boundary, and anytime you are interacting with the equipment even if doors are closed.

Your arc flash training needs to include when your facility requires arc flash PPE.

We see the equipment label on “Panel-A” indicates 13 cal/cm2 of incident energy which requires us to wear PPE of at least that arc rating. From table 130.5(G) we see we will need a face shield, hard-hat, balaclava, hearing protection, safety glasses, leather footwear, and because we’ll be within the restricted approach boundary, insulated gloves with leather protectors. We must ensure we aren’t wearing any conductive jewelry and that our undergarments are made of non-melting fabric. The t-shirt you wear under your arc rated clothing has to be made of natural fibers such as cotton. They make arc rated long and short sleeve t-shirts which are ideal for use as an undergarment.

You need to make it clear during your arc flash training, what your PPE procedures are. Does everyone get their own hard-hat, face-shield, and balaclava? Are we using arc rated PPE that we rent or do we own it? Do the employees have to launder it at home and what are those laundering instructions. What about arc flash suits for the high incident energy levels. Where are they kept? One size doesn’t fit all. If one worker is 6 ft 4 inches tall and weighs 250 pounds is going to wear the same arc flash suit as another worker who is 5 foot 7 inches and weighs 130 pounds. No, that won’t work. When a worker is going to exposed to energized work as during verification of zero energy they need to be fully aware of what to wear and where to find it and be comfortable in the knowledge that it is going to be appropriate for their body.

Resources for more information on PPE

Salisbury , Westex, Bulwark, Ariat, Oberon

Your Training

As I’ve said, the employer must provide electrical safe work practices, practices like those in 70E, and then train employees on them. That training needs to be a classroom, instructor-led training that encourages and answers questions. A test of some type and a certificate of completion. Online training should only be used as a refresher course. Your electrically qualified need to be retrained at least every three years.

Document when the training occurred, who was in attendance, and who the instructor was. The contents of this electrical safety training must be documented for future OSHA visits or company safety audits.

Our NFPA70E/Arc Flash Training

Summary

Electrical safety is quite simple. The employer provides safe work practices, trains the employee, and the employee follows them. The employer as well must follow these practices and insist workers priority will always be de-energizing the equipment. The employer also needs to provide proper PPE for the tasks involved. Hopefully, the only energized work, anyone, does at your facility is verification of zero energy during lockout tagout.

This Practical Guide To Arc Flash and NFPA 70E does not cover every detail of the 70E standard. But, hopefully, it will help simplify the standard for those using it in the field.

1. Provide electrical safe work practices.
2. The centerpiece of those work practices must be the elimination of the hazard. Establishing an Electrically Safe Work Condition.
3. Train your people on those work practices. Your electrical safety training, arc flash training is the glue that holds your electrical safety program together.
4. Ensure your employees are qualified for the electrical tasks they are about to perform and the hazards for which they are exposed.
5. Provide proper PPE for the hazards your people will face. Make sure that PPE fits the individual.
6. A qualified worker must conduct a job safety plan and there must be a job briefing prior to work beginning.
7. Conduct proper risk assessments prior to work beginning.

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This new one-hour online 70E for managers class covers those things that a manager needs to know to effectively manage an electrical safety program. If your direct reports include electrically qualified workers this class can help you comply and create a safer working environment. We’ll cover the topics that managers and safety professionals have to be diligent about when managing workers around electrical hazards.

Link to Online 70E For Managers

The post NEW 1-Hour Online 70E For Managers And Safety Professionals appeared first on ElectricalTrainingPro.com.

Course Description:

This course is approximately 2-hours with a timed test at the end. A certificate is given upon successful completion.

What You Will Get Out Of This Course
Workers taking this 2-hour online refresher course will learn the latest in electrical safety standards and regulations. This training goes toward satisfying your OSHA training requirement and will produce workers more aware of the hazards and how to reduce the risk. This course reflects the evolution of NFPA 70E in the direction of risk assessment and hazard elimination. The hierarchy of risk control, shock and arc flash hazard PPE selection are covered in detail. OSHA 1910, as well as NFPA 70E 2018 edition, will be discussed. This course is a refresher course for people who have previously attended instructor-led, full-day, classroom 70E training. Your people will walk out of this class better prepared for work involving electrical hazards.

More Information – Online Refresher

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Watch for next years conference February 26-28, 2019.

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When selecting arc flash PPE using the category method; the fault current and clearing time parameters are key to doing it correctly. It’s time we got serious about these parameters

NFPA 70E permits either of two methods be used when selecting arc flash PPE. The PPE category method, which relies on tables, or the incident energy analysis method, which calls for an electrical power system analysis to be performed by electrical engineers. What many don’t realize is that because of the parameters in the PPE tables both methods require a power system analysis.

When using the PPE category method for selection of arc flash PPE, you must ensure that your equipment is within the clearing time and fault current parameters listed in the tables. If your circuit is not within these parameters, the standard states you can not use these tables and instead you must use the incident energy analysis method.

An electrical power system analysis involves electrical engineers using engineering software, and data collected in the field, to create a model of the electrical distribution system of your facility. This data includes transformer information, wires sizes, fuses, breaker model numbers and settings, all overcurrent-protection devices, etc. Collecting, modeling and analyzing this data can be time-consuming and costly; which is why many facilities struggle with getting it done. This study would provide you with your available fault current and clearing times that you must have to use the PPE category tables. Just a bit more work by the engineer and you would have a complete incident energy analysis.

From NFPA 70E Table 130.7(C)(15)(a) a 480-volt panelboard calls for category 2 arc rated PPE. The table further states the parameters of 25,000 amps of available fault current and a two-cycle fault clearing time. If your fault current or clearing time is outside of these parameters, it is possible the Cat 2 PPE recommended will fall short of the protection you need. There is no way of knowing these parameters without doing a power system analysis?

Another example would be an upstream current-limiting fuse protecting the panel you are about to open for troubleshooting. The informational note to Table 130.7(C)(15)(a) states that a current-limiting fuse has a typical clearing time of .5 cycles if it is within the current limiting range. This is an informational note and not part of the standard language however someone might be tempted to use this clearing time as their clearing time without knowing if the fault current is within the current limiting range of the fuse. Current-limiting fuses are very fast acting fuses and can reduce arc flash energy but only if there is enough current to drive the fuse into its current limiting range.

When selecting arc flash PPE the standard doesn’t allow us to assume we are at a .5 cycle clearing time. We have to verify we are and we can’t do that without getting electrical engineers involved.

The most important thing to keep in mind is that this is the same information you would have to collect and almost all of the calculations you need to perform an incident energy analysis. Just a little more work by the engineer and you will have a complete incident energy analysis. At this point, you would have no use for the tables. Most often the incident energy analysis recommends less PPE be worn, gives you a chance to mitigate the arc flash energy and is a better method.

Selecting arc flash PPE by either method is never an exact science. There are too many variables and unforeseen circumstances. The more of these variables you can control the more accurate your selection will be. One thing is for sure, wearing arc rated PPE helps reduce injury from arc flash. We need to do all we can to make sure we are wearing the proper PPE.

Relevant ETP Training
nfpa.org

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70E Electrical Safety Calendar Reminders

Mark your calendar, there are things we are required to do on schedule. Training, audits, visual inspections, testing, etc. are required by NFPA 70E to be accomplished on a strict schedule. We have gathered those here to help remind you when these things need to be done.

Electrical Safety Program Audit

Intervals not to exceed 3 years

An audit of your program must occur at least every 3 years to verify the principles and procedures are still in compliance with 70E. Article 110

Field Work Audit

Intervals not to exceed 1 year

Fieldwork must be audited at least once a year to verify that the principles and procedures in the electrical safety program are being followed. Article 110

Lockout/Tagout Program and Procedures

Intervals not to exceed 1 year

Your lockout/tagout program and procedures must be audited at least annually to verify they are in compliance with Article 120 of 70E. At least one LOTO in progress must be covered. This audit must include all of your procedures for all of your equipment. Not just your overall program. The purpose of this audit is to identify and correct deficiencies in your program & procedures, training, and execution of loto procedures. Article 110

Electrical Safety Retraining

Intervals not to exceed 3 years

Many things can trigger retraining or the need for additional training that is not related to a calendar date. Among them are non-compliance discovered during normal supervision or the annual fieldwork audit, new equipment, unfamiliar tasks and work practices and a change of duties. You need to be aware of this complete list in 70E. Otherwise, your qualified electrical workers must be retrained every 3 years. Article 110

Lockout/Tagout Procedures Retraining

Intervals not to exceed 3 years

Retraining is also triggered by a change in procedures or if the annual audit indicates that the employee is not complying. Article 110

Incident Energy Analysis

Intervals not to exceed 5 years

The analysis must be reviewed for accuracy at least every five years. The analysis must be updated when a change is made to the electrical distribution system that could affect the results. Article 130

Equipment Labeling

Intervals not to exceed 5 years

The equipment label includes nominal system voltage, arc flash boundary and arc flash PPE selection information such as incident energy or PPE category. Each label and the supporting data must be reviewed for accuracy at least every 5 years. Article 130

Visually Inspect Protective Equipment & Protective Tools

Interval not to exceed 1 year

Equipment such as grounding equipment, hot sticks, rubber gloves, sleeves, and leather protectors, test instruments, blanket and similar insulating equipment, insulating mats and similar insulating equipment, protective barriers, external circuit breaker rack-out devices, portable lighting units, temporary protective grounding equipment, dielectric footwear, protective clothing, bypass jumpers, insulated and insulating hand tools must be visually inspected before initial use, each use thereafter and as service conditions require. Article 250

Insulation Test Of Protective Equipment & Tools

Interval not to exceed 3 years

The equipment listed in the previous entry that is used as primary protection from shock hazards and requires an insulation system to ensure protection of personnel, shall be verified by the appropriate test and visual inspection to ascertain that insulating capability has been retained before initial use, and at intervals thereafter, as service conditions and applicable standards and instructions require, but in no case shall the interval exceed 3 years. Article 250

Visually Inspect Personal Protective Ground Cable Sets

Intervals not to exceed 1 year

Inspected as service conditions require and at least annually. Article 250

Contact Release Refresher Training,

Shall occur annually

Workers exposed to shock hazards and those responsible for safe release shall be trained on methods of safe release. Article 110

First Aid And CPR

Frequency satisfying the certifying body

Those responsible for responding to medical emergencies must be trained in first aid, emergency procedures, CPR and automatic external defibrillator (AED) if provided. Employees responding might be a second person, safety watch or a craftsperson. Article 110

Verification Of Contact Release & Emergency Response Training

Annually

This training must be verified annually to confirm it is current. Regardless of how often the training is required, it must be verified that each employee is current. Article 110

Test Of Abnormal Battery Conditions Alarm

Annually

Instrumentation that provides alarms for early warning of abnormal conditions of battery operation, if present, shall be tested annually. Article 320

This has been created as a helpful reminder for those managing electrical safety programs. It is not a substitute for NFPA 70E. This piece includes paraphrasing and truncated standard language. You must access NFPA 70E for details and what is required at each of these intervals.

I hope the 70E Electrical Safety Calendar Reminders will be helpful. For more information on dates.

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