Arc Flash Prevention
Electricity is extremely dangerous in manufacturing settings, where personnel work on and around live electrical systems. Arc flash prevention is key. Even when your systems are well maintained, the very nature of power distribution can put your facility at risk of arc flash — a quick burst of energy with potentially fatal and destructive results. Changes on your plant floor or to the utility supply increase your risk over time, especially if these adjustments aren't reflected in a holistic plant electrical distribution model, but the hazard can develop in any facility at any time.
According to the National Fire Protection Association, “Shock, electrocution, arc flash and arc blast are responsible for one fatality every workday in the U.S., and some 8,000 workers are treated in emergency rooms for electrical contact injuries each year.” In addition to these tragedies, employers suffer the costly consequences of facility damage, unexpected downtime and OSHA citations. Arc flash prevention should be a top priority for every manufacturer.
MAVERICK has developed special expertise and capabilities in arc flash prevention through our 10 years of supervising electrical work across industries for global clients. Whether your plant is a heavy energy user or generates its own power, we understand your energy demands and know how to design and maintain systems that support your operations. Not only do we use the industry's most accurate assessment software to identify arc flash hazards, but we have the capabilities to deliver the improvements that will mitigate your risk.
By implementing a comprehensive arc flash prevention program in your facility, MAVERICK can:
- Perform an extensive arc flash hazard analysis in your facility.
- Calculate incident energy levels and the personal protective equipment (PPE) needed to guard against injury.
- Recommend improvements for arc flash hazard risk mitigation.
- Implement improvements such as coordinated trip times, selectable breaker trip settings, ultraviolet light detection and zone-selective interlocking.
- Provide the appropriate arc flash hazard labels to ensure OSHA, NFPA and NEC compliance.
- Fully train your personnel on arc flash prevention.
- Conduct ongoing maintenance and future state analysis.
- Improve the overall safety of your employees and facility.
Partner with MAVERICK to establish an arc flash prevention program at your plant.
Arc Flash Hazard Analysis
The injuries and damage from arc flash can end up costing you millions of dollars over a period of many years. You truly might not be able to afford operating without an arc flash prevention program in place.
MAVERICK can help you implement an arc flash prevention program that will ensure the safety of your employees and your bottom line. This program always begins with an arc flash hazard analysis. The cost of the analysis is minor compared to the value of operating with confidence.
MAVERICK's arc flash hazard analysis usually takes about six weeks, depending on the size of your facility, and comprises five basic steps:
- Onsite evaluation — We meet with your personnel, review your current operating settings and assess any existing documentation.
- Data analysis — Our team analyzes the data from the onsite evaluation and creates a dynamic model of your electrical distribution system that can be maintained and referenced for years to come. After finalizing the model, we generate reports to determine your equipment's incident energy levels and to recommend the right personal protective equipment (PPE) needed to guard against injury.
- Report and review of the findings — MAVERICK presents a final report and a list of prioritized recommendations, allowing time to address specific questions and clarify next steps.
- System labeling — We produce and install arc flash labels in compliance with NFPA 70E. Each one communicates the hazard category, the flash hazard boundary and the incident energy for a particular piece of equipment so that all of your personnel know the danger and PPE required for working on and around it.
- Training — MAVERICK provides complete personnel training in compliance with OSHA and NFPA 70E requirements. Training topics include: how to read and understand the arc flash labels, how to wear and maintain PPE, and awareness regarding your facility's particular danger areas.
- Ongoing maintenance — MAVERICK will work with your team to maintain the developed plant model, reducing your risk and allowing for holistic modifications to your distribution network as future changes occur.
Following the arc flash hazard analysis, MAVERICK can provide a variety of other services to ensure proper implementation of your arc flash prevention program. These services may include supervising electrical work, performing other improvements and providing maintenance for long-term safety. With MAVERICK at your side, you'll always operate with confidence.
Arc Flash Prevention Case Studies
MAVERICK's personnel have implemented arc flash prevention programs for manufacturing and process facilities across all industries. Read some of our case studies below.
New One-Line Drawings and Arc Flash Prevention for Food Manufacturer
Over time, one Fortune 500 food manufacturer developed power sag issues that led to production shutdown, scrap generation and fire safety concerns. The facility's one-line electrical drawings were outdated, so MAVERICK's experts surveyed the facility and created new drawings. They completed short-circuit and equipment duty studies to evaluate the electrical switchgear. An arc flash hazard analysis revealed the proper PPE rating levels, and power system documentation helped determine which upgrades would correct the power sag issue. The customer invested $225,000 in this solution and experienced a 12-month payback due to reduced scrap and increased safety.
Arc Flash Hazard Analysis for Food Manufacturer
After five years of system changes and upgrades, one Fortune 500 food manufacturer needed to undergo a new arc flash hazard analysis. As part of the analysis process, MAVERICK's experts identified numerous opportunities for improving system coordination without increasing the personal protective equipment (PPE) rating levels.
Arc Flash Prevention for Bakery
A Fortune 500 bakery had an ungrounded power distribution system that operated at 240 volts. Some electrical distribution equipment in the facility was over 50 years old and at a high risk for arc flash. MAVERICK's experts undertook a system study in order to upgrade the plant's electrical distribution system to a 480-volt grounded system. They also completed preliminary short-circuit and arc flash studies, along with a construction plan and bid package to accomplish the changeover with a minimum loss of production.
Arc Flash Prevention Resources
Explore the links below for more information about arc flash prevention, safety and compliance.
OSHA Requirements for Arc Flash Protection
Read OSHA's explanation of its requirements for providing a safe work environment.
National Fire Protection Agency (NFPA) Standard for Electrical Safety in the Workplace
Read a description of the NFPA 70E standard for arc flash prevention.
National Institute for Occupational Safety and Health Arc Flash Awareness Information
Download the CDC's Arc flash awareness pamphlet.
Canadian Standards OSH Electrical Safety Information
Describes safe work practices, use of energy control systems, and personal protective equipment around hazardous electrical equipment.
CDC Arc Flash Awareness Video
Watch an educational video about the dangers of arc flash in the work environment.