Protecting Workers from Arc Flash: A Hierarchy of Controls Approach

Electrical maintenance is one of the most hazardous jobs in any facility. Arc flash incidents can reach temperatures hotter than the surface of the sun, releasing massive energy bursts, blinding light, deafening sound waves, and shrapnel-like molten metal. It’s a serious risk that demands a serious safety strategy —a comprehensive Arc Flash Safety Solution.

Many companies think de-energizing electrical equipment is the ultimate safety solution—and in some ways, it is. But in reality, it presents two major problems:

1. You can’t perform inspections under load. Many failures only appear when the system is energized, meaning de-energization makes proactive maintenance impossible.
2. Shutting down equipment causes expensive downtime. Power interruptions result in lost production, customer disruptions, and major scheduling challenges.

The NFPA 70E Hierarchy of Controls provides a structured approach to minimizing arc flash risks. The best approach isn’t just about shielding workers—it’s about eliminating risk wherever possible while maintaining operational efficiency.

1. Elimination: Theoretical Perfection, Practical Nightmare

The safest way to prevent arc flash injuries is to remove the hazard entirely by de-energizing equipment before inspections or maintenance. This eliminates direct exposure to live electrical components and ensures the lowest possible risk.

Why De-Energization Falls Short

Electrical systems need to be inspected under load. Many faults, including loose connections and thermal anomalies, are only detectable when equipment is energized.

Downtime is expensive. Shutting down equipment just to perform inspections results in lost revenue, decreased productivity, and potential service disruptions.

Restarting systems can introduce risks. Cold starts put stress on electrical components, increasing the likelihood of unexpected failures.

The Real Solution: IR Inspection Windows as Elimination

Infrared (IR) and ultrasound inspection windows allow workers to conduct closed-panel inspections, meaning they can monitor electrical equipment without exposure to live components.

• No need to open energized panels – No direct arc flash exposure.
• Inspections can be done under full load – No costly shutdowns.
• Reduces PPE reliance – Less protective gear required, improving efficiency.

Because inspection windows eliminate direct worker interaction with live electrical systems, they can be considered an Elimination control under NFPA 70E.

2. Substitution: Making Open-Panel Inspections Obsolete

If full elimination isn’t possible, the next best option is substituting hazardous inspection methods with safer alternatives.

Why Open-Panel Inspections Are a Bad Idea

• Exposes workers to arc flash hazards
• Requires extensive arc-rated PPE
• Takes more time and labor to complete inspections

How IR & Ultrasound Windows Provide a Safer Alternative

• Infrared Windows – Enable thermal imaging without opening panels.
• Ultrasound Ports – Allow partial discharge detection for insulation faults.
• Customizable Inspection Solutions – Designed for all panel types, improving efficiency and safety.

By replacing open-panel inspections with closed-panel infrared and ultrasound inspections, facilities dramatically reduce risk while maintaining compliance with NFPA 70E.

3. Engineering Controls: Minimizing Arc Flash Severity

When arc flash cannot be eliminated, the next step is using engineering controls to contain and reduce the impact of an incident.

Recommended Engineering Controls

• Arc-Resistant Switchgear – Designed to direct arc energy away from personnel.
• Remote Racking & Switching Systems – Reduce the need for direct worker interaction with energized components.
• Current Limiting Devices – Lower fault current levels, reducing arc flash intensity.

4. Administrative Controls: Training & Procedures

Proper training and procedural controls help ensure electrical safety in the workplace.

Key Administrative Controls

• Electrical Maintenance Training – Ensures workers understand NFPA 70E & NFPA 70B compliance requirements.
• Arc Flash Risk Assessments – Identify high-risk areas and help implement safer work practices.
• Job Safety Planning – Work permits and pre-job briefings ensure hazards are properly assessed.

5. PPE: The Last Resort

If elimination, substitution, and engineering controls cannot fully mitigate risk, Personal Protective Equipment (PPE) serves as the final layer of defense.

Essential Arc Flash PPE

• Arc Flash Suits – Flame-resistant suits rated for incident energy exposure.
• Insulated Gloves – Voltage-rated and tested for shock protection.
• Face Shields & Hoods – Arc-rated visors and full-coverage hoods prevent facial burns.
• Dielectric Boots – Provide insulation to prevent step potential shocks.

Choosing the Right Arc Flash Suit

While PPE is essential for certain high-risk tasks, it should never be the first choice for arc flash. The goal should always be to eliminate or reduce exposure before relying on protective clothing.

The Final Verdict: The Best Arc Flash Safety Solution

De-energizing is ideal, but impractical – It prevents under-load inspections and results in costly downtime.

IR Inspection Windows provide true Elimination – They remove the need for live work altogether.

Substituting open-panel inspections with closed-panel solutions is the smartest move – Minimizing exposure is the key to workplace electrical safety.

Engineering controls & training help, but PPE should be the last resort.

By following NFPA 70E and NFPA 70B compliance standards, facilities can significantly improve workplace electrical safety while reducing reliance on PPE.

Upgrade your facility’s arc flash safety protection today. IRISS inspection windows are the best investment for NFPA 70E compliance, workplace electrical safety, and electrical fire prevention—without the need for expensive PPE for every inspection.

Ready to Implement Your Arc Flash Safety Solution?

Ensure your workplace is protected from arc flash hazards with our Arc Flash Safety Solution. Contact us today to discuss your safety needs with our experts.