Imagine the sharp, acrid scent of ozone that hangs in the air following an electrical arc—a stark reminder of the razor-thin margin between safety and catastrophe.

For Jacob, an experienced electrician, it was a typical day retrofitting an industrial control panel until a tool slipped. In an instant, a flash of brilliant light and intense heat erupted and engulfed Jacob in a ball of flames, the sound of the arc blast echoing through the facility. 

Thanks to his comprehensive personal protective equipment, Jacob emerged shaken but unharmed. His arc-rated jacket was singed, and his face shield was clouded from the intense flash, yet these barriers protected him from  severe injury—or worse.

This incident underscores a critical truth: the difference between a close call and a tragic accident often comes down to the quality and appropriateness of the PPE electricians wear. Inadequate PPE can result in dire consequences, from debilitating burns to life-altering injuries or fatalities. According to the Electrical Safety Foundation, electrical incidents continue to represent a troubling percentage of workplace fatalities, with many attributed to a lack of proper PPE.

Understand the work environment

Every electrical job is unique, and so are the hazards present. Before selecting PPE, it’s imperative to evaluate the work environment. What kind of electrical equipment are you dealing with? Are you working indoors or outdoors? 

Residential settings often include risks such as tight spaces and outdated wiring, requiring insulating gloves, safety glasses and flame-resistant (FR) clothing. In commercial spaces, electricians face complex systems with higher voltages, demanding PPE that balances protection with heat dissipation and dexterity. 

Industrial environments, characterized by high-voltage equipment and hazardous materials, call for robust PPE such as arc flash suits and respirators.

Additionally, external factors such as moisture, extreme temperatures and outdoor conditions dictate the need for waterproof, insulated or UV-protective gear to ensure safety and adaptability in diverse work scenarios.

Selecting proper PPE

This is not a guide to selecting exact PPE, rather an informative article about using NFPA 70E to discern working environments around energized circuits. The following tables in NFPA 70E offer a systematic approach to determining the appropriate PPE based on the specific conditions and equipment an electrician is working with. It is up to employers and individuals to assess each situation.

1. Identifying the arc flash PPE category

Table 130.7(C)(15)(a) for AC equipment categorizes PPE requirements. For instance, consider an electrician working on a 480V switchgear with a maximum available fault current of 35 kA and a maximum fault-­clearing time of 0.5 seconds.

Table 130.7(C)(15)(b) for DC Equipment provides similar guidance. Suppose an electrician is working on a 600V DC switchboard with a maximum available fault current of 10 kA and a fault duration of 1.5 seconds.

After establishing the arc flash PPE category in the these tables, the next step is to use Table 130.7(C)(15)(c) to select the specific PPE. In this table, we find arc flash PPE categories separated by arc ratings and associated protective equipment. In the first example of 480V switchgear, we find the equipment needed would fall under the Category 4 designation of 40 cal/cm². 

For the second example, a 600V switchboard, this situation would typically require PPE Category 4 according to the table. The electrician would need to wear arc-rated clothing with at least a 40 cal/cm² rating with other necessary protective equipment.

2. Working distance considerations

The working distance—or the distance from an arc source—is a critical factor in PPE selection. For example, if the standard working distance for a task is increased due to space constraints or equipment design, the incident energy exposure could be different, potentially requiring a change in PPE category. 

Regularly referring to the NFPA 70E tables ensures that electricians are adequately protected for the specific working distances they encounter.

3. Equipment-specific PPE

Different types of electrical equipment can pose varying levels of arc flash risk, necessitating specific PPE. For example:

Panel work: Regular maintenance or repair work on electrical panels, especially in commercial settings, typically requires PPE that protects against shock and arc flash hazards. This may include insulating gloves and arc-rated clothing appropriate for the panel’s voltage and fault current.

Switchboards and switchgear: These often involve higher energy levels than panel work. The PPE might need to have a higher arc rating, and tasks may necessitate full body protection, including arc flash suits, hoods and face shields.

Arc flash PPE clothing material

The selection of the right PPE for electricians involves careful consideration of the potential hazards and the properties of the materials from which the PPE is made. The NFPA 70E standard provides clear guidelines on these aspects, emphasizing the importance of the PPE’s arc flash category and its material characteristics.

Arc-rated materials are the backbone of effective PPE. Materials such as flame-­retardant-treated cotton, meta-aramid and para-aramid are designed to offer significant protection against thermal hazards. They act as a barrier between the wearer and the intense heat of an arc flash. Importantly, these materials are engineered to self-extinguish, meaning they stop burning once the source of ignition (the arc flash) is removed.

There are two main types of FR fabrics: inherent and treated. Inherent fabrics, such as aramids, are naturally flame-resistant, while treated fabrics are chemically treated to resist flames. Treated fabrics may lose some of their flame-resistant properties over time and with repeated laundering.

Certain materials pose a higher risk in the event of an arc flash. Fabrics such as nylon, polyester and spandex can melt and adhere to the skin when exposed to high heat, exacerbating burn injuries. Even when used as underlayers beneath arc-rated clothing, these materials are not safe for electrical work and should be avoided.

Layering for enhanced protection

A layered system of clothing can significantly increase the level of protection. For example, wearing an FR t-shirt beneath an arc-rated jacket can add an extra layer of safety. The air gap between layers provides additional insulation against heat.

The effectiveness of layering is measured by the total system arc rating, which might be higher than the sum of the individual layers’ ratings due to the air gap. It’s crucial to use the system arc rating to ensure adequate protection.

Additional considerations

While protection is paramount, comfort and durability also matter. Uncomfortable or ill-fitting PPE can distract from work or even lead to noncompliance. Durable materials ensure that PPE maintains its protective properties over time. In some work environments, such as hot or humid conditions, breathable FR fabrics can provide comfort and safety.

Always ensure that PPE materials meet relevant standards. For arc-rated clothing, standards such as ASTM F1506 and NFPA 70E provide guidelines on the required material properties.

Case studies/application examples

Let’s look at a few scenarios that illustrate how electricians can use NFPA 70E tables and material considerations to select appropriate PPE for different work environments.

Indoor panel work: An electrician is tasked with servicing an energized 480V AC electrical panel in a commercial building. According to Table 130.7(C)(15)(a) of NFPA 70E, this scenario falls under PPE Category 2. The recommended PPE from Table 130.7(C)(15)(c) may include:

• An arc-rated shirt and pants with a minimum arc rating of 8 cal/cm² or an arc-rated coverall
• An arc-rated face shield (with wrap-around guarding) and an arc-rated balaclava to protect against thermal hazards. The face shield should have an arc rating suitable for the exposure (typically a minimum of 8 cal/cm² for Category 2).
• Heavy-duty leather or insulating gloves appropriate for the voltage level. Leather protector gloves should be worn over insulating gloves for mechanical protection.
• Leather or dielectric footwear, or other if tested to demonstrate no ignition, melting or dripping at the minimum arc rating for the category
• The selected arc-rated clothing should be made from flame-retardant-treated cotton or aramids to provide a thermal barrier. The material should be breathable and allow for flexibility, considering the indoor setting.

Outdoor substation maintenance: Maintenance work is required at an outdoor electrical substation, involving energized 15-kV equipment. PPE selection based on NFPA 70E falls under Category 4, which is considered high-risk. The required PPE selection could include:

• A complete arc-rated flash suit with a hood. The suit should cover the entire body and have a minimum arc rating of 40 cal/cm².
• Arc-rated rubberized gloves with leather protectors to protect against electrical and mechanical hazards
• Dielectric boots to safeguard against step and touch potential hazards common in substation environments
• Given the high-risk category, the suit material should be robust, flame-­resistant and capable of withstanding the extreme thermal energies possible in a Category 4 arc flash. Also, arc-rated jackets, high-­visibility apparel or rainwear for working outdoors in the elements should be worn if needed.

Industrial motor control work: An electrician needs to perform troubleshooting inside a live 250V DC motor control cabinet (MCC) in an industrial plant. Working on this MCC involves exposure to significant electrical hazards, and carries an available fault current rating of 10 kA, giving it a PPE category of 3. In this scenario, the required PPE could include:

• An arc-rated long-sleeve shirt, jacket, pants and coverall with a minimum rating of 25 cal/cm²
• An arc-rated hard hat with face shield and an arc-rated flash suit hood for additional protection
• Insulated gloves rated for the specific voltage level encountered at the MCC, with leather-protectors to safeguard against mechanical wear and tear
• The arc-rated materials should be durable to withstand the industrial environment and provide sufficient thermal protection. Given the intense and potentially hazardous nature of industrial settings, materials resistant to oil, grease and other industrial substances are also important.

Care and maintenance of PPE

Now that we understand more about selecting appropriate PPE, let’s discuss taking care of the equipment. The significance of PPE care and maintenance cannot be overstated, as it ensures the gear’s functionality and reliability, which are crucial in the face of electrical hazards. Here’s an expanded look into maintaining the integrity of PPE, tailored to the varied needs and rigors it must endure.

Before each use, a visual inspection must be conducted. This includes checking for cuts, tears, burns or any signs of wear that could compromise the PPE’s protective qualities. For example, arc-rated clothing should be free from oil or grease, which can alter its protective properties. Each type of PPE may have unique care instructions.

• Helmets: Check for cracks or degradation, especially after impacts.
• Insulating gloves: Stretch and inspect for tears or punctures; air testing can help detect holes.
• FR clothing: Examine for any contamination that could compromise its flame-resistant properties.
• Safety glasses: Ensure lenses are free from scratches that could impair vision.

Maintaining the integrity and effectiveness of PPE is crucial for an electrician’s safety. For arc-rated clothing, improper laundering can reduce its protective capacity, so specific detergents and washing conditions may be recommended. Repairs should use materials that maintain the PPE’s protective qualities, such as using arc-rated fabric for patching arc-rated clothing. However, it is often a best practice to simply replace damaged PPE immediately to ensure maximum protection of workers.

PPE should be stored in a clean, dry area away from direct sunlight, high temperatures and chemicals. For example, helmets should be placed where they can’t fall, and rubber insulating gloves should be stored flat or hung by the cuffs to prevent distortion.

Conclusion

Proper PPE selection is a compliance issue, but more importantly it is a fundamental aspect of an electrician’s safety protocol. Understanding and using the NFPA 70E standards for PPE selection equips electrical professionals with the knowledge to protect themselves effectively. As the electrical industry evolves, so do the standards governing it, so electricians must continually update their knowledge and practices in selecting and maintaining PPE. Remember, the goal is not just to complete the task at hand, but to return home safely each day.

Stelzer is a master electrician from Austin, Texas. As the CEO of Electrician U, he’s dedicated to revolutionizing the trade industry through education, offering comprehensive courses, hands-on tutorials and insight. Under Dustin’s guidance, the platform aims to empower electricians with the knowledge and skills needed to excel in their craft. To learn more about Electrician U, use this QR code or visit ElectricianU.com.

iStock