Arc Flash: a critical safety risk in Electrical Installations

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Arc flash is one of the most dangerous yet often underestimated hazards in electrical systems. It can result in severe injury, equipment damage, and significant operational disruption, making it a critical consideration in both design and maintenance phases.

Key statistics from North America:

• Between 5 to 10 arc flash explosions occur daily
• 1 to 2 fatalities are reported each day
• Medical costs for severe electrical burns can exceed $4 million per incident
• Businesses may face over $30 million in fines, litigation, and lost revenue

Despite growing awareness, arc flash risks are often underestimated, particularly in low-voltage switchgear, where 66% of fatalities involve qualified electrical workers.

Understanding the risk:

Arc flash is not a minor spark; it is a violent release of energy caused by a short circuit through ionized air. It can result in:

• Intense heat and pressure
• Molten metal and shrapnel
• Severe burns and trauma

These events can occur during normal operation, due to insulation aging, foreign object intrusion, or human error, even in well-maintained systems.

Recommended approach:

Schneider Electric advocates for a design-first strategy to mitigate arc flash risk:

• Integrate arc flash risk into Occupational Health & Safety (OH&S) systems (ISO 45001)
• Apply the Hierarchy of Controls
• Utilize proven technologies
• Refer to the updated IEC 60364-4-42:2024 standard for low-voltage installations

→ Access the Electrical Worker Safety Guide : Explore practical tools, decision trees, and real examples to support safer system design!