19 February 2025
What is arc flash protection?
Arc flash protection is a critical aspect of electrical safety, designed to prevent the dangerous consequences of an electrical arc flash event. In industries where electrical systems are integral, ensuring proper wearer protection is vital to safeguarding workers and maintaining operational integrity. This guide aims to provide a complete overview of what arc flash protection is, how it works, and the measures that can be taken to minimise risks - from proper safety training to adequate arc flash clothing.
what is arc flash?
Before we look into the dangers of arc flash and how to protect against it, let’s explore what arc flash actually is.
Arc flash is a flashover of electric current. When an arc fault occurs, light and electricity are released into the air. When this reaches another conductor or the ground, an explosion occurs that creates a wave of heat that can burn and melt anything nearby.
The effects and impact of an arc flash can be similar to those of a bomb, and cause significant and lasting damage to people, buildings and equipment.
It’s also important to remember that arc flash is different from other electric risks, as arc flash doesn’t always subject the body to an electrical current. Electrocution will commonly impact the rhythm of the heart, whereas arc flash is the risk associated with an uncontrollable energy release.
what’s the difference between arc flash and arc blast?
In addition to arc flash, there is also something called arc blast. Although they sound the same - and while they are related - they are two different results of an electrical discharge.
Arc flash - as we mentioned above - is the energy released from an electric arc which lets off strong heat and light, and can cause burns.
Arc blast refers to the pressure wave that is created by an arc flash. This pressure can cause a significant amount of damage to anything nearby, including people, equipment and structures. Both arc flash and arc blast cause pose a serious hazard to workers who regularly deal with electrical systems.
What causes arc flash?
Arc flash occurs when there are failures in electrical insulation or circuits, leading to a breakdown in the insulation around electrical conductors. This causes a fault in the circuit, allowing a live current to travel through the air rather than through the intended wire or pathway.
There are a number of reasons why this could occur:
poor maintenance
Arc flashes can sometimes be as a direct result of poor maintenance. As electrical equipment ages over time, it can deteriorate, causing the insulation to fail and increasing the risk of an arc flash. Loose connections can result in arcing or overheating, potentially causing an arc flash.
environmental factors
Certain environmental factors - such as dust, moisture, condensation and build up of debris - can all cause issues with electric insulation, and increase the risk of arc flash.
human error
Human error as a causation can refer to a number of things, such as equipment failure, improper work practices, failing to follow procedure, or failing to wear appropriate protective gear when working with electrical systems. There is also the possibility of other human-related errors, such as the incorrect installation or wiring or equipment, or touching of energised circuit parts, all of which can contribute towards an arc flash event.
Employees working with electrical equipment should also be aware of the warning signs that an arc flash could occur, such as noise or excessive heat.
what are the dangers of arc flash?
There are two serious consequences of arc flash:
- Burns
- Blast injuries
Blast injuries can range in severity from cuts and bruises to more serious injuries, such as internal contusions and broken bones. Burns can be life-threatening and can require extensive treatment.
In terms of surroundings, the arc blast and fire that can occur as a result of an arc flash can cause a wave of pressure which can lead to significant structural damage, which can compromise the building’s safety and lead to costly repairs. Fire can not only damage equipment, but if it encounters hazardous chemicals or vulnerable materials, it can create smoke, pollution and toxic smoke.
what are the UK’s requirements for arc flash protection?
In the UK, arc flash protection is covered under a number of health and safety regulations, with the main ones being the Electricity at Work Regulations 1989, and BS EN 60903:2020 for electrical protective equipment. UK guidelines focus heavily on ensuring proper risk assessments, the implementation of safety measures, and the use of appropriate protective equipment.
risk assessment
The first step in arc flash protection is conducting a thorough risk assessment to identify the potential arc flash hazards. According to the Health and Safety at Work Act 1974 and the Electricity at Work Regulations 1989, employers must assess risks to workers' safety and health. This includes determining whether an arc flash hazard exists, estimating the severity of potential incidents, and evaluating the risk based on fault currents, equipment types, and operational procedures.
protective equipment standards
The UK follows the BS EN 60903:2020 standard for electrical PPE, including arc flash protective clothing. This standard covers a range of gear designed to protect workers from electrical risks, including arc flash, such as:
- Arc-rated clothing (jackets, trousers, coveralls, gloves, and hoods)
- Face shields and helmets designed to withstand the thermal and mechanical energy released in an arc flash
- Gloves that are specifically rated for electrical work and capable of withstanding high voltages and thermal exposure
- Arc flash clothing is generally rated according to its arc thermal performance value (ATPV) or arc flash protection boundary, which helps determine the level of protection needed for specific tasks
work procedures and safety
The Electricity at Work Regulations emphasise the need for safe working practices when dealing with electrical systems, including:
- Follow lockout/tagout (LOTO) procedures to de-energise equipment before working on it.
- Maintain safe working distances and establish clear arc flash boundaries (i.e., the minimum distance a worker can be from live parts to avoid exposure).
- Are trained in the recognition and mitigation of arc flash hazards, as well as in the proper use of PPE.
- In addition, the use of arc flash warning labels on electrical equipment is a crucial part of the safety measures. These labels indicate the potential risk of an arc flash, the PPE required, and the incident energy level in calories per square centimetre (cal/cm²), which helps inform the level of protection needed.
maintenance and inspection
Regular maintenance and inspection of electrical systems and PPE are required under both the Health and Safety at Work Act and BS EN 60903. Electrical equipment, such as switchgear, transformers, and circuit breakers, should be regularly checked for signs of wear, damage, or degradation that could increase the risk of an arc flash incident.
training and competency
Workers involved in electrical work need to have specific training to ensure they are competent in working with live equipment. This includes understanding the risks of arc flash, proper use of PPE, and safe work practices. The Competence in Electrical Safety guidelines typically cover these aspects, ensuring workers are trained in arc flash awareness and the correct procedures to follow.
the 4 Ps model
An effective way to prevent arc flash is through the use of the 4P Model, which stands for:
- Predict
- Prevent
- Protect
- Publish
Protect
This step involves identifying and calculating the potential risks of an arc flash.
Prevent
This refers to mitigating the use of principles of prevention or the hierarchy of controls in designing, planning, or eliminating the risk of arc flash.
Protect
This step refers to reducing the risk of injury through the use of PPE or proper protection if the hazard cannot be removed.
Publish
Refers to the collection information for risk assessment and use in training, as well as providing safety warning labels where the risk cannot be eliminated or removed.
Ultimately, arc flash protection is not just about meeting legal obligations; it's about encouraging a culture of safety and awareness within a business, where workers are equipped with the knowledge and tools they need to protect themselves should they be required to work in high-risk electrical environments. By prioritising safety, proper equipment, and training, employers can significantly reduce the likelihood of an arc flash, and help ensure the wellbeing of their workforce.
Here at alsico, we design and supply high-quality workwear solutions for a wide range of sectors and purposes, including electrification, wearer protection, healthcare, contamination control, general workwear and more. Contact us today for more information about our standard uniform range, or to arrange a consultation about our bespoke uniform design service.
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