a summary of testing, requirements, and relevance · pdf fileshirt & pant burns. ......

Stacy Klausing

A Summary of Testing,

Requirements, and

Relevance

The Arc Flash Hazard

Arc Flash Hazard

• Plasma temperature can reach 10,000° F• Fatal burns can occur at distances over 10 feet• Over half of all arc flashes occur at 277 volts

What Is an Arc Flash?

an electrical breakdown of a gas which produces an ongoing plasma discharge, resulting from a current flowing through normally nonconductive media such as air

– Wikipedia

3

Open Air Arc

1.• Mainly infrared

radiation and some hot gases

• Most common type

20 cal/cm2 electric arc in open air 12" away from worker

4

Ejected Arc

10.2kA, 8.2 cycles, 17.3kA peak current, 34"distance from worker

2.

• Arcs can be worse when they are ejected plasma

5

Watch the disconnect door.3.

• Energy can be two to twelve times greater in an arc-in-a-box situation

Arc-in-a-Box6

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“Tracking” Arc

4.

• Arc conducts through skin and “pops out” between skin and clothing

• Can cause ignition of unrated natural fibers

• Usually occurs at higher voltages 8kV, 8kA, 10 cycles Tracking Arc on power line

Unrated cotton t-shirt under 8 cal/cm² AR work shirt

FR/AR Market

• Diversity of Covered Equipment and workers– Cranes, hoists, welders, X-ray equipment, carnival

and circus equipment, swimming pool heaters and lighting, elevators, dumbwaiters, escalators, moving walks, wheelchair lifts, electric signs, transformers.

– Almost every industry has covered workers from HVAC workers to hotel and hospital maintenance workers

– Workers, operators, and electricians everywhere work with or disconnect electricity.

The 70E Market

The property of a material whereby combustion is prevented, terminated, or inhibited following the application of a flaming or nonflaming source of ignition, with or without subsequent removal of the ignition source.

--NFPA 2113

Problem with this definition is that it doesn’t define the ignition source.Training Note: NO performance requirements (ASTM D6413)

Flame Resistance

Arc Flash Background

• Over 2,000 people admitted into burn centers each year with severe electrical burns

• ~80% of electrical injuries are arc flash, many from ignition of flammable clothing

Why is Arc Flash Such a Concern?11

Results of 10-year study of 120,000 workers in the electrical industry:

• 125 electrical injuries per year

• 77% arc injuries

• 21% permanent disabilities

• 2.4% fatalities

Study Findings

Based on ED France data, IEEE Presentation from M. Capelli-Schellpfeffer, M.D.Electrical Trauma Research Program (University of Chicago)

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U.S. Fatalities with Potential Arc Component

Statistics from BLS website. Analysis by Hugh Hoagland ArcWear.com. To see calculations, visit www.arcwear.com/stats.mht.

2000 2004 2009 2012NFPA 70E Edition:

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*Due to classification/coding changes, data from 1992-2010 analyzed by “contact with electrical current” and data from 2010-2014 analyzed by “exposure to electricity”

0

50

100

150

200

250

300

350

US

Fata

litie

s w

ith A

rc C

ompo

nent

The Right Stuff Makes a Difference14

Source: American Burn Association (1991-1993 Study)

Cha

nce

of S

urvi

val,

%

0

20

40

60

100

Age Range, Years20-29 30-39 40-49 50-59

80

25% Body Burn 50% Body Burn 75% Body Burn

Arc Exposure w/arc-rated clothing

Shirt Burns

Shirt & Pant Burns

Probability of Survival15

16

WI Food Plant Accident

<20 cal/cm2 Indura® UltraSoft® Shirt Indura® Denim Jean vs. Non-FR Cotton

Ignition, The Greatest Hazard100% Cotton vs. ARC 2 Clothing

Standards and Product

Evaluations

• Inherent FR thread required for construction– Tested at 260°C for melting

• Small and large scale testing

• Findings cannot increase extent of injury– Metal covered on inside

• NFPA 70E has levels based on F1506– NFPA 70E accepts F1506 but adds a few requirements– Labeling Requirements

• Arc Rating (designated as ATPV or EBT)• Tracking ID & Manufacturer Name• Size, Care Instructions, Fiber Content• A statement of compliance with ASTM F1506

ASTM F1506 Specification

How Do You Get an Arc Rating?

Protection Strategies » Arc Flash

Calorie: Amount of energy required to raise the temperature of one gram of water one Celsius degree

What is a Calorie?

If you take a disposable lighter and put your palm in the hottest part of the

flame for one second, you will receive about 1.2

calories per cm2 — the onset of a second degree

burn (blister burn)

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Arc Rating Standard ASTM F1959IEC 61482-1-1 Method A

How Do You Get an Arc Rating?

How Do You Get an Arc Rating?

Color & Arc Ratings

From Chapter 20, “Flame resistant textiles for electric arc flash hazards”, Hugh Hoagland, ArcWear, USA in Handbook of Fire Resistant Textiles, 1st Edition, Woodhead Publishing, UKEdited by F. Selcen Kilinc Ph.D. (NIOSH, USA)http://store.elsevier.com/Handbook-Of-Fire-Resistant-Textiles/isbn-9780857091239/

ASTM F2178Eye, Face & Head Test Method (IEC in process)

~100 cal/cm2 arc at facial plane. Faceshield closer to arc.

No second degree burn predicted by calorimeters on eyes, mouth and under chin

Glove Arc Ratings

45 cal/cm²

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Hard Hats and Safety Glasses Arc Tested

~80 cal/cm2 100% Cotton Ignition (07-2901)

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• Flame resistance in underlayers pays off in extreme incidents.

• FR uniforms that are ALWAYS on have the most impact.

~80 cal/cm2 Exposure FR Jean (07-2902)

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• Assures compliance with NFPA 70E – Closure requirement (arc tests ability to remove)

– Reflective Trim requirement (helps assure trim is not contributory)

– Design Requirements (assures zippers and other components are matched to rating of the design)

• Some open zippers fail when exposed to the AR of the fabric

• Good Marketing Video

ASTM F2621 Garment Evaluation

High Visibility + Arc-RatingThese may look the same

ANSI 107 & F1506 vs. ANSI 107 “FR”

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• NFPA 701 for curtains, wall coverings and furniture

• “Fabric and components comply with NFPA 2112” – NOT allowed, garment and manufacturer MUST be Third Party

Certified

• F1506-98– only required vertical flame test, predates arc ratings

• ASTM D6413 as a standalone– garments labeled as “meeting” this test method are improper

• FTMS (Federal Test Method Standard) 191A-5903.1 or 191A-5903.3 – Not published since 1980’s (expired standard)

Improperly Used Standards

Beware of:

• “FR until washed or dry cleaned”

• Melting “FR”

• “FR-treated” acrylics, polyester, nylon

Got Arc-Rating?

Because of the misuse of the term FR, in 2012,NFPA 70E removed the term favoring arc-rated

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“FR” Melted Onto the Head35

PPE Guidelines

• Non arc-rated layers add no protection, but may be allowed. – Cotton t-shirt cannot be counted as adding protection– Non arc-rated clothing may be worn IF it is non-melting (i.e.

cotton, wool, silk, leather)

• Layers of arc-rated garments may provide additional protection; only arc-rated systems can count. – 8 cal coverall + 4 cal shirt ≠ 12 cal

• Arc-rated outer layer (such as a high visibility vest) over a protective system (i.e. an 8 cal/cm² ARC 2 shirt) does not reduce the rating of the under layer.– Non arc-rated melting vests may not be worn over arc rated

layers.

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Layering Principles

NFPA 70E Annex M

• Arc Rated (AR)– ASTM F1506 (cited by NFPA 70E)

• Flash Fire Rated – NFPA 2112 for Industrial Flash Fire– Pass/Fail rating is for a standardized coverall

• Fire Fighter Rated– NFPA 1971 for Structural/Proximity Fire – NFPA 1977 for Wildland– Small scale battery of tests

Hazard and Risk Level Determines Required PPE

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Arc-Rated PPE

Categories 1 and 2: Difference in Minimum Rating and Addition of Balaclava

ARC 1 ARC 2

4 cal/cm2 Minimum Rating 8 cal/cm2

* 0.7mm min. thickness if rubber insulating gloves with leather protectors are not required for shock protection

Head

Safety glassesHearing protectionHard hat

Body

Rated shirt, long sleeveand

Rated pants

orRated coverall

Hand

s

Leather gloves*

Feet Leather work shoes

Rated face shield

or Rated

flash hood

◄ARC 1

ARC 2►

Rated face shield with balaclava

or Rated

flash hood

Natural fiber undergarments DO NOT

automatically add PPE level

(ARC 1 + cotton t-shirt≠ to ARC 2)

Table 130.7(C)(16)

Balaclava required if back of head in AFB130.7(C)(10)(b)(1)

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Categories 3 and 4: Difference is in RatingARC 3 ARC 4

25 cal/cm2 Minimum Rating 40 cal/cm2

* 0.7mm min. thickness if rubber insulating gloves with leather protectors are not required for shock protection

Head

Safety glassesHearing protectionHard hat

Rated flash hood

Body

Rated shirt, long sleeve and

Rated pants

orRated coverall

orRated arc flash

suit

Hand

s

Leather gloves*

Feet Leather work shoes

Table 130.7(C)(16)

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• Layering– Outer layers– Under-layers (arc-rated or non-melting)

• Coverage

• Fit

• Maintenance of equipment– Laundering

• Follow manufacturer’s instructions• No bleach or fabric softener

– Inspect for tears and frays

Arc Flash Protection Principles41

Always Wear Required Level of PPE

40 cal/cm² suit - no 2nd degree burns HRC 2 - received 2nd and 3rd degree burns

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• OSHA now requires FR winterwear and rainwear

• Enhanced the desire for manufacturer’s

• Allows employers to outfit workers in clothing that is appropriate for multiple hazards (arc, flash fire, high visibility, molten metal)

• New products on the market meet ANSI 107, NFPA 70E, and NFPA 2112

Multi-Hazard PPE

Inherent vs. TreatedDurability Wicking Comfort Cost

Aramids,FR Cotton with Nylon

Traditionally Cotton/Wool,Aramid/Rayon blends, manyare popular

today

Traditionally cotton, near a

tie today

Short term-FR Cotton, Long-term-typically aramid

Application LimitsAcid/Bases Molten Metal Fire Fighting

Poor Performers FR Cotton, Lyocell

Aramids (sticking)

FR Cotton (durability issues in multiple events)

Good Performers Modacrylic, PBI, Meta-aramid;

Para-aramid is sensitive to

chlorine bleach and mineral acids

Wool/RayonBlends

Vinal/Rayon blends,

Aluminized materials

Aramids

• Improve Safety

• Get industrial workers with a hazard into FR

• Support Innovation– What are we currently researching?

Why do we do this?

Costs of Cotton vs. Arc Rated: Examples: 2 Real Incidents

Before Arc Rated After Arc RatedPaid & Reserve Paid & Reserve

MedicalIndemnityVocationalExpenses

$812,677$773,613

$9,948$931

$32,707$6,035$1,903

$36Total $1,597,229 $44,682MedicalIndemnityVocationalExpenses

$309,571$49,369

$9,999$20

$9,213$1,890$1,195

$10

Total $368,992 $12,309Source: PECO Presentation by Bill Mattiford, PES-IEEE Seminar

Accident 1: 7/29/93 Accident 2: 7/12/94 Accident 3: 6/1/95 Accident 4: 6/1/95Accidents in FR were lightweight FR uniform. Actual results may vary.

2015 $ 1.57 x more

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Questions?

Phone: (502) 333-0510Email: flashcert@arcwear.com

www.arcwear.comArc Testing, Textile Testing, Accident Investigations

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