Arc flash incidents: Unintended costs

February 22nd, 2010

We’ve alluded to the fact that assessing the costs of an arc flash at your facility cannot begin and end with a likely OSHA citation. While electrical accidents may be small in terms of a percentage of all workplace accidents, the severity of the injury incurred and the fatality rate are much higher. Therefore, the impact can be much longer-lasting and much more costly.

If one of your electricians suffers a severe burn from an arc flash event, the cost of that accident to the organization over the next five or ten years could be in the tens of millions of dollars. First, OSHA will likely issue a citation for failing to protect your employee. But that will be insignificant “chump change” compared to the other costs to come. These costs include equipment damage, lost product, downtime, medical bills, insurance premium increases, workers’ compensation, attorney’s fees, accident investigation costs, law suits, retraining, the list goes on. Indirect costs, such as OSHA’s news release announcing your company’s accident and citation, can be even more costly. The news release will explain to the world, mentioning your company by name, that the accident could have been avoided by following recognized safe practices for working around electrical hazards. Instantly, safety newsletters and blogs will pick up the story and in minutes the news is spread around the world.

It’s hard to associate an exact dollar figure with these costs, but experience has shown us, without question, it is far more expensive to allow one of these preventable accidents to occur than it is to avoid it.

You can’t afford not to implement an electrical safety program

January 27th, 2010

One of the messages we’ve tried to communicate to decision makers is that there is a strong business case to be made for electrical safety. It has at times been a tough sell during these tough economic times.

Unfortunately, there is a story out of Texas that demonstrates the point in the extreme. A chemical company was fined a total of nearly $1.5 million (yes, that figure is correct) after an OSHA investigation into an explosion that killed an employee. The explosion was apparently sparked by unsafe electrical equipment operation.

We can only guess what this specific company’s future will be after such a fine. But we know for certain that in this down economy, such a fine – or, more specifically, such an incident – would be a near-back breaker for many companies. Aside from the fine, there will be replacement of equipment, downtime, likely a lawsuit or some kind of punitive damages, training of a new employee, and countless other expenses rolled into the incident.

We also know that Labor Secretary Solis has signaled OSHA will be ramping up enforcement efforts in this new administration, if her address to attendees ASSE’s Safety 2009 is any indication. http://ehstoday.com/standards/osha/solis-texas-contruction-safety-initiative-asse-2320/. Yet some employers balk at investing in arc flash analyses of their facilities and electrical safety training because, as they put it, it is “cost-prohibitive.” Let this story remind us all that the impact of an electrical accident on your business could be “existence-prohibitive.”

Now, this Texas company was cited for multiple other alleged violations, so it is difficult to say a solid electrical safety program would have made the difference in the company’s future viability. But it could have made all the difference in the world for that worker and his family. And as we’ve seen, protecting your employees from electrical hazards is as important to the bottom line as it is to your most valuable asset, your employees.

Lewellyn Technology makes donation to American Red Cross

January 14th, 2010

Lewellyn Technology is doing its part to aid those affected by the devastating earthquake that rocked the Caribbean country of Haiti on Tuesday. Lewellyn Technology, Inc., an electrical safety training company based out of Linton, Indiana, will be making a donation to the American Red Cross relief efforts in Haiti. In addition, the company will also match donations made by its employees. According to Darla Harmon, Vice President of Operations, “The quick response to the matching donation has been very generous.”

As of Thursday, the American Red Cross had released over $10 million towards a campaign to help some 3 million Haitian earthquake victims.

You can donate to the American Red Cross online at the following link – http://bit.ly/8nUgBT

The calendar changes; electrical safety practices do not

December 31st, 2009

Happy New Year from Lewellyn Technology! Every organization establishes goals when the calendar turns over a new year. We feel it is important to remind you that keeping your employees safe from electrical hazards should continue to be a top priority in 2010. OSHA requires employers to afford this protection and the excuses for failing to do so become fewer with each passing year.

Likewise, electrical work does not become any safer with the passing of a day, a month, or a year. Our ability to predict and protect against its dangers has increased over the last several decades, however, most notably because of advancements by companies producing personal protective equipment and in technology and procedures to conduct arc flash hazard analyses.

So let this serve as reminder: The year has changed, but your responsibilities to protect your employees from the dangers of electrical work have not. Contact Lewellyn to begin to make 2010 the year you advance your company’s electrical safety program.

To underscore the point, here is our usual roundup of a few recent cases of electrical accidents in the news:

‘Electrical arc’ blamed in TVA power plant fire
(Kingsport, TN Times News, Dec. 31)

Worker injured in…electrical explosion
(CP24, Toronto, Canada, Dec. 31)

(W)orker injured in Sunday accident
(Roanoke, VA Times, Dec. 21)

Failure to protect employees from electrical hazards contributes to company’s fine
(OSHA News Release, Dec. 18)

Again, we bring these stories to your attention not to sensationalize the subject or as a sort of scare tactic. Rather, we feel it is important that personnel charged with working on or near energized electrical equipment have every reason to approach their jobs with humility, and with a safety-first mindset. Providing evidence of the danger is not a scare tactic; it is a way to empower electricians with more knowledge of their profession.

Electrical Safety: The glue of your 70E program (Part II)

December 17th, 2009

This is part 2 in a 2-part series on electrical safety training. Find part 1 here.

The instructor in an NFPA 70E electrical safety training course must present the material with passion. This means they possess the ability to convince personnel of the importance and necessity of the need for the change in safety culture 70E requires, but also they mus possess the ability to convert a resistant trainee.

Implementing NFPA 70E will mean presenting to electrical trades and maintenance personnel new procedures and PPE standards that will change the way these people have worked for years. It’s more than the tangible differences in workplace protocol; it is a change in a company’s culture. That’s huge, and breeds a predictable resistance among some, particularly the more experienced. The instructor must have the ability to recognize when this is happening, know how to handle the situation, and have the passion to confront the individuals and the experience to back it up.

The instructor must be credible: He or she must have at some point worn a tool belt, been in the field, or been in maintenance or in the electrical trades. It really helps if they have some scars from that experience.

The difficulty of achieving culture change is never overstated. The effort involves approaching a group of people who are already the highest-paid hourly employees at your facility, and telling them they need additional training. It won’t always be an easy sell. They’ve worked long and hard to learn this trade. You can’t just send them a memo saying things are different now and they have to change the way they’ve been working for years.

Some electricians have gone so far as to take a stand against 70E. You may have witnessed them sticking out their chest with macho bravado saying something like, “I’ve been doing electrical work for 25 years and I’m not dead yet,” or, “Any good electrician with enough experience knows how to stay out of it and not get hurt.”

This kind of person is not just naive, they’re dangerous. They are a member of a demographic most likely to be killed by an electrical hazard. Again, it takes a passionate instructor to lead a class with this type of individual present.

It takes experience to know just what should be included in the training as well. The topics on which qualified personnel are to be trained are listed in 70E and in the OSHA regulations. However, simply using these as “check-off” lists will leave your training incomplete. For example, one of the requirements is that the qualified person be able to determine nominal voltage. Fifteen minutes of instruction on reading a volt meter is a far cry from what is needed in this case.

There are many diverse electrical distribution systems in industry and your staff needs trained on the specific system or systems employed at your facility. They need to know what the voltage should be phase to phase and phase to ground and where and how to measure it. They need to know that your facility may have many different types of systems. They need to know how to determine which equipment is more likely to be interlocked with other equipment and how to properly verify voltage for lockout tagout purposes and how to isolate it. It’s much more in-depth than learning to read your meter.

That type of thorough instruction is only delivered by instructors who are passionate about the subject matter. A passion for training yields attentive trainees, which yields safer personnel, which yields a more productive workforce.

Electrical safety: “Experienced” doesn’t mean “invincible”

December 14th, 2009

Our last post explained the importance of 70E training in making your electrical safety program stick. Attempting to change a culture of safety through training can be a difficult task, especially if your employees have many years of experience. Often times, these electricians who have survived decades on the job believe that if they haven’t been injured by an arc flash or other accident yet, they likely never will be.

They’re absolutely wrong, and a story out of Florida this weeks adds to the mountain of evidence to prove this.

Take a look at this story, “Two electrical workers injured in explosion…” (Gainesville Sun, December 11). Pay attention to a couple of key phrases. First, the men are described as doing “routine maintenance” on the system. Then in the second to last paragraph, one electrician is described as working in the profession for 20 years.

And yet, while performing a routine job with the benefit of his wealth of experience, he was injured in an electrical accident.

The fact is, working with electricity is a dangerous job whether you’ve been at it 20 years or 20 weeks. The veterans and rookies alike need to have a thorough understanding of the standard for best practices for electrical safety in the workplace, NFPA 70E. Experience does not instill invincibility.

There were a couple other electrical accidents in the news this week; use these examples as you see fit to improve workplace safety and performance at your facility:

Generator malfunction injures employee…” (KY3, Springfield, MO Dec 7)

(E)mployee killed in boiler explosion” (MySanAntonio.com, Dec. 6)

And as always, contact Lewellyn to get started on an arc flash analysis of your facility.

Electrical safety training: The glue of your 70E program

December 10th, 2009

This is the first in a 2-part series on the importance of training to your overall electrical safety program.

You committed to implementing NFPA 70E. You had an arc flash analysis conducted on your facility, removed the hazards where possible, labeled each piece of equipment to show its Hazard Risk Category, purchased insulated tools and voltage-rated gloves, and established your PPE program. You spent a great deal of time and money and devoted precious resources to achieving this level of electrical safety for your employees.

And without one crucial component, all your efforts will amount to precisely nothing.

No matter how large or small your facility, training to bring about a change in safety culture is the glue that holds together your electrical safety program. Without effective training for the people exposed to electrical hazards such as arc flash, all of the resources devoted to 70E implementation will be wasted.

Training is usually the least expensive part of a 70E rollout, but it is the most likely to be mishandled. Many companies offer NFPA 70E training services, and your selection of a provider can literally make or break the entire program. A positive, effective training experience is often decided by the presence of a single characteristic in the training instructor: passion.

Passionate people are persuasive people. It is crucial to have everyone on the same page when the subject matter is new procedures and practices related to electrical safety in the workplace. People in general are resistant to change, especially if that change is a departure from long-standing operational procedures. An instructor must present the contents of an electrical safety course with the passion of a preacher at a tent revival meeting.

That means having a strong belief in the material they’re presenting, and it also means the ability to carry out another often-needed activity related to training. In an installment next week, we’ll discuss what that is.

Contact Lewellyn Technology for information on our training services.

Electrical Safety: Lessons from the News

December 7th, 2009

A couple items in the news this week underscore a couple important truths about electrical work.

In one story out of Phoenix (”Electric Shock Sends Man to Hospital,” KHPO, Dec. 1), we learn of a 54-year-old man who was shocked on the job and went into cardiac arrest. We don’t know much about the man, but it’s safe to say that at age 54, he has been doing electrical work for a while.

Important lesson #1: Even experienced electricians can have an accident. Electrical work is as dangerous a profession today as it was when this man likely started working. No one is immune from the hazards of electricity.

Another story tells of a man still recovering from injuries sustained in an electrical accident 15 months ago. (”Worker still recovering after electric shock,” ABC4 Salt Lake City, UT, Dec. 4)

Important lesson #2: The effects of an electrical accident on both the employee and employer are long-lasting. As our President, Daryn Lewellyn, outlines in this article, there is a strong business case for implementing a comprehensive electrical safety program at your facility. We see in this Salt Lake City incident just two of the potential costs of failure to do so: the ongoing medical bills of a disabled worker, and costs related to a lawsuit. Yet those effects pale in comparison to the impact of the death of the other worker mentioned in the article.

Also making the news are two OSHA citations related to electrical hazards, linked here and here. Electrical hazards rank ninth in OSHA’s top ten most-cited violations for 2009, with 2,556 violations to date. That’s an average of about seven per day.

Lewellyn believes electrical safety is not just about avoiding citations and lawsuits. Our arc flash and electrical safety training services are foremost about preventing injuries. Don’t hesitate to contact us if we can help you improve workplace safety and performance.

Electrical Safety: News week in review

November 30th, 2009

Here are a few news articles we found in the past week about workplace electrical accidents:

Worker suffers shock, fall
(Fort Myers, FL News-Press, Nov 28)

One killed, one injured repairing main break
(Washington Times, Nov 26)

Maintenance worker in serious condition after shock
(WPVI, Philadelphia, Nov 24)

Tree trimmer suffers severe electrical burns
(Modesto, CA Bee, Nov 24)

Lewellyn seeks to provide safety and maintenance professionals not only with information about the dangers of their profession, but also with articles, videos, and sessions to provide information on solutions for the hazards they face. The best solutions of course, are to make sure your people are thoroughly trained and that you have completed an arc flash hazard analysis of your facility.

NFPA 70E: Where do I start?

November 24th, 2009

For some safety professionals, deciding whether to implement NFPA 70E is not the question. They understand what OSHA has to say about the topic, and are ready to proceed.

At this point, many safety professionals hit a wall. Understanding the importance of 70E is a great start, but understanding where to begin implementing the standard is much more complicated.

In this video, Lewellyn Technology President Daryn Lewellyn explains where to begin in 70E implementation:

Learn more about arc flash and how we conduct arc flash analyses.