by Chris Dodds | Thorne & Derrick UK
ARC FLASH | Protecting Lives of Lighting Engineers Against Arc Flash Dangers
In the following article, we assess the types of Arc Flash risks and the prevention of those same risks through the implementation of effective Arc Flash Clothing & PPE for workers in the UK Highways & Street Lighting industry.
With guidance from the UK Health & Safety Executive’s HSG85, Engineering Recommendation G39/1 and the Highways Electrical Association (HEA), we provide advice on management procedures to facilitate a continued achievement of safe working practices.
The role of Risk Assessment Method Statements (RAMS) and Safe Systems Of Work (SSOW) are mentioned as key underpins to arc flash mitigation and worker protection.
In recognition of those dangers and working with ProGARM, the leading UK manufacturer of the Flame Resistant & Arc Flash Clothing, we show how together we ensure workers return home safe.
We hope to clear the current ambiguity of attitudes to the subject with some interesting statistics that in conclusion may or may not achieve that objective.
Let me know your thoughts later here or vote in our Poll below – so lets get started.
According to the UK Health & Safety Executive (HSE) most electrical accidents occur because people are working on or near equipment:
Arc flash can only occur on live cables, circuits or electrical equipment.
“Electrical arcing (sometimes called a ‘flashover’ or ‘arc flash’), perhaps as a result of a short circuit caused by unsafe working practices, can generate intense heat leading to deep-seated and slow-healing burns, even if it persists for a short time. The intense ultraviolet radiation from an electric arc can also cause damage to the eyes.
Often those working with or near electricity do not appreciate the risk of serious injury and consequential damage to equipment that can arise from arcing. Arcing, overheating and, in some cases, electrical leakage currents can cause fire or explosion by igniting flammable materials.
This can cause death, injury and considerable financial loss.”
Extract from HSG85 UK HSE Electricity At Work – Safe Working Practices.
The UK HSE is an independent regulator providing advice, guidance, news, tools, legislation and publications for work-related health, safety and illness issues.
♦ ARC FACT Electric arc causes an ionization of the air with arc flash temperatures generating a fireball reaching up to 35,000 degrees Fahrenheit. This is hotter than the surface of the sun.
Injuries are usually caused by the explosive effects of arcing current, and by any associated fire or flames that may result when a live cable is penetrated by a sharp object such as the point of a digging tool. Excavating around public utilities always carries the potential for those utilities to be damaged and for those involved to be seriously injured.
In particular electrical cables carrying low voltage domestic electricity can cause serious burns. It is therefore important that all those involved in excavation work comply with safe digging practices to ensure the safety of themselves and anyone else who may be close by.
➡ Further reading: HSG47 UK HSE Avoiding Danger From Underground Services
Street lighting engineers and operatives are exposed to arc flash risks if correct digging procedures are not followed while excavating underground electricity cables – operatives have suffered arc flash burns when digging with a hammer drill directly above an identified live buried cable. Upon making contact with a 415v street lighting cable, ‘arc flash’ occurred resulting in burns to the wrist and elbow and a visit to the hospital A&E – this could have been much worse. Never dig directly over an identified live buried service. Powered hand tools used close to live cables are likely to represent the greatest risk of injury.
Ad: Lucy Zodion | Feeder Pillars | Cut Outs | Isolators – The Street Lighting Specialists
In the street lighting industry arc clothing should be rated according to IEC61482 – under test method IEC6182-1-1 garments are tested and then categorized into 5 levels of protection as per the chart below. Typically Category 2 arc flash clothing covers workers for the majority of tasks however this should be dependent and based on risk assessment of the job in hand.
ProGARM recommend worker should be protected from arc flash by a helmet with full visor, insulating gloves and garments such as arc flash polo shirt, arc flash trousers and coveralls with Category 2 flash protection.
| Incident Energy Level (caVcm2) |
Hazard Risk Category |
PPE Type | Arc Flash Clothing & PPE Details (Basic Examples) |
| 0 – 3.9 | 0 | 0 | 1 full FR/ARC layers (covering all body), polycarbonate safety spectacles, lightweight cotton gloves. |
| 4 – 7.9 | 1 | 1 | 1 layer flame retardant (FR) work wear, helmet, polycarbonate safety spectacles, lightweight FR gloves. |
| 8 – 24.9 | 2 | 2 | As above but with 2 layer FR outer work wear that has wrist closures, and a full face polycarbonate visor. A FR single-layer balaclava may also be worn to protect the face. |
| 25 – 39.9 | 3 | 3 | 3 layer FR outer work wear and FR shirt, a full-face hood or visor with safety spectacles underneath, chrome leather gauntlets. |
| 40+ | 4 | 4 | Typically 4 layer FR outer work wear (as illustration), FR and electrically insulated footwear and suitable FR material spats to close off the ankle area, FR gloves or chrome leather gauntlets, a hood constructed from a triple layer of FR material with a sewn-in polycarbonate face shield with a minimum of 2 panels of suitable thickness with one coated with a gold film for UV protection. |
♦ ARC FACT The arc blast can rupture ear drums and project molten metal into the face and lungs without adequate PPE protection.
Engineering Recommendation G39 is a Model Code of Practice covering Electrical Safety in the Planning, Installation, Commissioning and Maintenance of Public Lighting and Street Furniture. G39 scope covers low voltage electrical installations (up to 1000V), the associated inherent risks, hazards and requirement for implementation of thorough and proper PPE to protect workers against electrical injuries.
Under obligation of law the employee must provide a Safe Systems of Work (SSOW) to enable safe working where hazardous work processes are present, for instance the risk of arc flash when working in the vicinity of live conductors in a cable trench during jointing of utility cables.
G39 does not mandate PPE requirements – this is the absolute responsibility of the employer (or if you’re the employer, the employee and vice versa).
However, leading industry bodies including the Highways Electrical Association would always recommend arc flash clothing and protective PPE where this is available.
Despite this a recent study by ProGARM in conjunction with the British Safety Industry Federation (BSIF) revealed a shocking level of widespread industry ignorance with 25% of employers attributing the sole responsibility to the employee, not the employer, to self-protect against arc flash.
Worryingly, 50% expect the employee to also self-educate through personal research.
Perverse as it may sound, try Googling “how to save my life against arc flash“. Over 43 million search results to wade through – some contradictory, some misleading.
This employer-employee confrontation across the knowledge gap is exacerbated by government passivity, resulting in an unresolved tension with workers endangered daily due to lack of understanding and ultimately absence of UK legislation – until legal action is taken, as in the USA, the stand-off prevails and the risk pervades.
More findings from the BSIF report:
Established providers of training courses covering G39, such as the Highways Electrical Association, ensure engineers working in highways environments such as street lighting are equipped with the knowledge, awareness and practical key skills when working in the vicinity of DNO electrical equipment.
Arc flash clothing is commonly worn when working on overhead power lines, during the removal and replacement of DNO cut-out fuse carriers, jointing live cables and the commissioning, maintenance and repair of distribution feeder pillars.
G39 training courses ensure delegates work in a safe and responsible manner to comply with company obligations and legislative policy.
Noting the recent swing in the UK HSE view of risk management through significance it would be reasonable to conclude that Arc Flash Clothing & PPE including visors and suitable head / hand wear, on a balance of risk vs cost vs availability should be specified – otherwise offending management or neglectful decision makers could face fines or imprisonment.
In addition to this Electricity at Work Regulations 1989 place a duty on an employer to protect against the risk of death or personal injury from electricity in work activities.
EAWR places a legal responsibility on employers and employees, as duty holders, to ensure that electrical systems used at work under their control are safe.
“Employers and workers must comply with the EAW Regulations in so far as they relate to matters within their control. You should check that workers are following the rules and correct procedures. Sometimes, some or all of these checks may be delegated to the supervisor of the work. Even in organisations with effective written safety rules and safe systems of work, regular and systematic management checks of the work are necessary. This is particularly important if the work is being done in the field, on another occupier’s premises, or by peripatetic workers.”
Extract from HSG85 UK HSE Electricity At Work – Safe Working Practices.
ProGARM | Functional Arc Flash Clothing, Protection & PPE For Everyday Wear
In the UK risk assessments are undertaken to identify, mitigate and eliminate workplace risks and then additionally a method statement is prepared to control residual risks – this is known as RAMS and demonstrates safety precautions have been sanctioned to protect employees against worksite hazards and comply with Law.
Pictured: 4 Core Waveform LV Cable Terminations Into Schneider Feeder Pillar. Image: Darren Street (D&R Cable Jointing).
5 Simple Steps To Assessing Risk Of Arc Flash Incident
With respect to arc flash protection a company risk assessment would cover PPE requirements at the planning stage before any works commencing – typically an electrical engineer would isolate and test energised equipment is dead and absent of voltage prior to removal of incoming mains power supply.
Working dead with secure electrical isolation eliminates arc flash risk completely, but working on or near live exposed conductors or electrical equipment occurs because it is difficult, even impossible, to programme work to allow all job tasks to be carried out where cables and equipment are dead:
In these conditions, arc flash clothing and protective helmet with insulating gloves should be worn – if in doubt contact us to discuss your requirements.
Utlities in the UK undertake live cable jointing using insulated tools to prevent interruption to multiple occupancy buildings and businesses. Shown pictured, a live 185sqmm Consac to 185sqmm Wavecon low voltage mains repair straight joint has been installed to restore power to 13 industrial units “off-supply” in Reading. The fault was a “phase to phase” fault with two cable faults on a 1 meter section of cable.
Credit: Cable Jointer – Grant Butler 33kV/11kV HV & LV Cable Faults Jointer at SSEN
T&D distribute Flame Resistant & Arc Flash Clothing to local authorities, private lighting contractors (Highways Agency & NERS), ICP’s and DNO’s.
ProGARM are a the leading UK manufacturer of high quality Flame Resistant & Arc Flash clothing, garments and workwear – they work successfully with their UK Distributor Thorne & Derrick to save lives and reduce accidents.
T&D are national distributors LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – we service UK and global businesses involved in cable installations, jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.
“At ProGARM our mission is protect lives through the manufacture and supply of exceptional quality Arc Flash and Flame Resistant Clothing. Being the only specialist Arc Flash protection manufacturer in the UK we focus on providing the best protection possible to those who work at risk of Arc Flash on a daily basis with our inherent, specialist garments and industry-leading innovation. Supporting Utilities, Power Generation, Rail & Petrochemical industries we work with Thorne & Derrick to educate, inform and supply those who work at risk everyday allowing us to keep protecting lives throughout the UK & beyond.
When lives are at stake, trust a specialist.” Mark Lant, Sales Manager at ProGARM – Protecting Lives through ARC Flash & Flame Resistant Clothing solutions.
Arc Flash Protection | Polo Shirts | Jackets | Coveralls | Trousers | Helmets | Gloves
Closing Thought – EU statistics show that between eight and ten arc flash accidents occur in the UK every week. Protect yourself, contact us to learn how.
Thorne and Derrick are proud to be distributors of ProGARM arc flash coveralls and protection.
We can help – should you require arc flash calculators or advice on the type of clothing and protection available please do not hesitate to contact us.
MULETAPE Calculator | selecting the right tape for the pulling of cables
NEPTCO is a global leader in the manufacturing of materials used for the Detection & Pulling of Cables, including MULETAPE, for a wide variety of commercial and industrial applications. This Blog demonstrates how the correct tape for pulling cables can be selected, with the MULETAPE calculator.
MULETAPE is a unique pull tape designed to reduce damage to the underground plant – resulting in improved efficiency, and enhanced worker safety.
To see the benefits of using MULETAPE over traditional cable pulling methods, see our Blog: MULETAPE V ROPE
NEPTCO tapes, distributed by Thorne & Derrick, are manufactured with a low stretch polyester material that distributes heat across its wide, flat profile. This improves efficiency and prevents “snap back”, which occurs when a rope under high tension elongates and either breaks or snaps back; often injuring the installer.
A variety of reel lengths of the cable pulling tape is available to suit any installation. Available in a variety of strengths (up to 6,000 lbs or 2727 kg) which enables extensive application use.
MULETAPE pulling tape for wires and cables is a laboratory and field tested for strength, temperature and chemical resistance, low elongation, low coefficient of friction (slips easily even on long pulls), and long life.
Cable weight is the biggest influence in MULETAPE recommendations, followed by the number of bends and finally the conduit size.
Pulling tension is a cumulative calculation with each bend in the conduit run contributing to more drag as the pull goes on. It is important to consult the cable manufacturer’s specifications for the maximum pulling tension before installing the cable. If pulling tensions are more than the maximum recommended limit, an intermediate pull box or manhole will need to be placed. MULETAPE is offered in tensile strengths varying from 400 to 6000 lbs.
Pulling forces vary depending on fill ratio, terrain and underground architecture; actual field conditions should be considered. The tension calculator below is intended to be used as a guide.
POINT TO POINT LOOK UP TABLE – FOR BEND ANGLE, DEGREES
| Bend Angle, Degrees | |||||||
| 0 | 15 | 30 | 45 | 60 | 76 | 90 | |
| Single Cable | 1 | 1.11 | 1.23 | 1.37 | 1.52 | 1.69 | 1.87 |
| Multiple Cable | 1 | 1.14 | 1.3 | 1.48 | 1.69 | 1.92 | 2.19 |
It should be noted that pulling tension can vary on the same pull. It is important to determine the starting point that will exert less strain on the cable. Usually, lower tension can be achieved by placing the cable reel closer to the shortest 90-degree bend. It might be helpful to make a sketch of the conduit run, showing bends.
The following is an example of a 460-foot pull of a 3 single conductor #2 15kV in 4” PVC conduit. The cable weighs 1.85 lbs. per foot. Please note the tension changes depending on the starting point of the pull.
As you can see from the examples above, pulling from point J to A results in a lower overall pulling tension; consequently, assuming the recommended knot is tied, a lighter duty MULETAPE can be used to complete the job.
To apply these formulas in your cable pulling application, follow these steps:
MULEKNOT + MULETAPE = a winning combination!
The weakest point of MULETAPE is the knot, and a poor knot can severely impact the tensile performance of the pulling tape. We recommend a MULEKNOT™ or blood knot, which can provide 80% of the rated tensile strength of MULETAPE.
The MULEKNOT is designed to maximize the pulling strength of NEPTCO MULETAPE, while providing a simple, reliable method of splicing lengths of tape in the field. Using the MULEKNOT instead of a traditional bowline knot can greatly increase the pulling strength of the splice and/or connection.
For more information on the MULEKNOT, please see the attached data sheet.
Further Reading
Thorne & Derrick International are the UK’s leading stockist and supplier of Cable Pulling & Cable Laying Equipment for the installation of underground cables and overhead lines up to 400kV – the products support cable pulling teams to install LV MV HV cables into trench, cable duct, risers and all forms of cable containment.
Medium voltage power cables manufactured by Prysmian have been accredited by the British Approvals Service for Cables (BASEC) as meeting the requirements of BS 6622 and BS 7835.
The cables’ third-party accreditation will give designers and installers of a wide range of power distribution networks additional assurance in the quality and safety of Prysmian Medium Voltage (MV) power cable from 6.6 kV right up to 33 kV.
The accreditation covers Prysmian’s MV cables with XLPE insulation and PVC sheaths manufactured to British Standard BS 6622, and Prysmian’s MV power cables with a low smoke zero halogen extruded outer sheath (LSOH), manufactured to British Standard BS 7835.
These British Standard cables are available from Prysmian with stranded copper or aluminium conductors, XLPE with either bonded or strippable screens, copper taped, as single core with aluminium wire armour or three-core with galvanised steel wire armour.
The company has been manufacturing cables in Britain for all voltages for over 100 years and MV cable at its Wrexham factory since it opened over 50 years ago. The cable’s accreditation by BASEC after over five decades of production serves to highlight the quality and performance inherent in Prysmian cable from the outset.
“Certification by BASEC, is confirmation that Prysmian has led the way in cable technology and quality for many years,” says Martin Boorman, Prysmian’s National Sales Manager. “Engineers and network owners can now have even more confidence in our UK manufactured MV cables,” he adds.
BASEC is an independent certification body for the cable industry. It is accredited by the United Kingdom Accreditation Service to provide certification to National, European and International cable product standards. The tests were undertake n in BASEC’s dedicated UK testing laboratory, or were witnessed by BASEC engineers, to certify the MV power cable’s conformity to the British Standards.
Contact T&D for medium voltage cables to IEC 60502-2 international standards including N2XS2Y / NA2XS2Y, NA2XS(F)2Y RE, NA2XS(F)2Y RM and NA2XS(F)2Y RM cable – should you require specification or technical support about 11kV-33kV cable accessory and installation requirements or advice on the terminating, jointing or duct sealing at MV-HV please call us.
T&D also distribute Medium & High Voltage Electrical Safety Equipment including insulating matting, voltage detectors, phase comparators, insulating gloves and life saving intervention kits to ensure the safe installation of MV-HV power cables into electricity substations working at 11kV/33kV up to 400kV transmission grid networks.
11kV 33kV MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors | Cold Shrink & Heat Shrink
Florida Power & Light Company, the principal subsidiary of NextEra Energy Inc., is a Juno Beach, Florida-based power utility – and the largest electric utility in the state – serving roughly 4.7 million customers and 9 million people in Florida.
1. A decade since Hurricane Wilma FPL continue to make the power grid stronger – installing Smart Grid devices in Miami…
2. FPL building stronger electric grids – installing poles that withstand winds up to 130mph in Lee County…
3. Severe weather expected through the night – FPL linemen work non-stop as long as it’s safe…
4. Be prepared – FPL utility teams gearing up for the storms to strike…
5. FPL lineworkers install Smart Grid devices in Fort Myers to make the electric grid stronger and smarter…
6. FPL building a stronger electric grid, installing poles in Hialeah to withstand winds up to 145mph…
7. FPL lineworkers install Smart Grid devices in BrevardCounty to make the electric grid stronger and smarter…
8. FPL building a stronger, smarter electric system – installing Smart Grid devices in Boca Raton…
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Includes access to our popular JOINTERS BLOG with contributions from utility professionals, linesmen and cable jointers working on MV HV EHV cables and overhead lines typically at 11kV, 33kV, 66kV and up to 132kV.
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Image Coutesy of: Zhizhen (Tony) Huang- Fujian Ruisen Chemical Co. Ltd – Sales Manager
Further Reading
Subscribe now to our POWER NEWSLETTER– a monthly email circulation packed with news, projects, videos, technical tips, training information, promotions, webinars, career opportunities and white papers.
Includes access to our popular JOINTERS BLOG with contributions from utility professionals, linesmen and cable jointers working on MV HV EHV cables and overhead lines typically at 11kV, 33kV, 66kV and up to 132kV.
15,000+ Subscribers. ➡
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