Arc Flash Risks in New Zealand- Causes and Preventive Measures

Introduction

According to Worksafe, New Zealand data, two to four arc flash incidents occur annually in the country. Although electrocution tops the list of electrical hazards in the workplace, arc flashes can reap heavy damages and even fatalities. 

At Care Labs, we help industries across New Zealand understand and adopt proactive safety measures to protect their facility and workers.

WorkSafe, New Zealand’s workplace health and safety regulator has articulated AS/NZS 4836:2023 standard which details the PPE that needs to be worn while working on or near energized equipment in industries.

An arc flash happens when an electric current takes a detour from its original path and flows through the air between two conductors. In industries, this is associated with the release of large amounts of energy, with temperatures soaring close to 20000 °C. This, accompanied by explosions, flying debris, hot gases, vaporized metal, etc can potentially devastate anything in its vicinity. Any industry be it manufacturing, data center, or renewable energy facilities with critical electric power systems, has arc flash risks that need to be diagnosed regularly.

What Causes an Arc Flash?

Here are the top causes of arc flash incidents in New Zealand:

• Human Error

Among the many causes of arc flash incidents, human error accounts for a significant percentage of these hazards. Performing maintenance without de-energizing the system, not wearing proper PPE, misoperation of equipment, failing to follow the LOTO procedures, etc are the main contributing factors to human errors. As an example, an electrical worker not following a LOTO procedure can face serious injuries due to electric shocks, and arc flash incidents.

• Equipment Failure

Critical industrial equipment like switchgear, circuit breakers, transformers, etc. when ages can potentially increase arc flash risk probabilities. Over time, high fault currents, lack of preventive maintenance, and insulation breakdown due to environmental conditions can lead to the degradation of these devices. For example, during peak load conditions, an outdated switchgear can cause an arc flash incident to happen. 

• Malfunctioning Protective Device Coordination

Protective devices like relays, if not coordinated properly can result in cascading faults that escalate to arc flash incidents and costly disruptions in the system. One of the main parameters checked during arc flash analysis in New Zealand is the relay coordination details. As an example, when integrating renewable energy, improper relay coordination can result in arc flash hazards.

•  Improper Installation or System Design

Improperly installed systems, such as loose connections or poorly designed switchgear, can create conditions for arc flash. Design flaws may include inadequate fault current calculations or insufficient clearances between energized components. For example, A commercial building in Auckland with inadequate separation between live parts in the main switchboard increases the risk of an arc flash during maintenance.

• Overloaded devices

If the operating conditions exceed the equipment rating, it can cause overheating, insulation breakage, and increased arc flash risk hazards. This happens typically during facility expansion and insufficient planning. For example, a data center in Wellington adding new servers to the system must analyze the electrical power system for potential arc flash hazard risks.

• Dust, Moisture, and Corrosion

Environmental factors like dust, moisture, and corrosion can significantly increase the chances of arc flash incidents for facilities in New Zealand. However, regular maintenance and arc flash hazard assessment for industries in New Zealand can identify these high-risk areas and necessary actions taken. For example, dust accumulation in MCCs can lead to arc flash incidents while restarting.

By understanding each of these causes, a facility manager can adopt the best practices like preventive maintenance, visual inspection, regular power system study, and analysis. 

Care Labs’ arc flash analysis for New Zealand industries helps them to reduce and mitigate the associated risks significantly. Our arc flash analysis solutions adhere to regulatory frameworks by OSHA, IEEE 1584, NFPA 70E, and AS/NZS 4836.

Preventive Measures for Arc Flash Risks

Understanding arc flashes can help reduce the impact of these electrical hazards by a great deal. However, it is the responsibility of concerned authorities like facility managers, business owners, etc to implement the preventive measures and conduct electrical system analysis from time to time. This can help protect the equipment, system, and workers. Furthermore, it helps prevent unnecessary outages and legal liabilities.

Here are the common practices that can reduce arc flash risks in New Zealand:

• Conduct arc flash risk assessments- We at Care Labs, encourage a culture of proactive safety and recommend arc flash analysis every 3 to 5 years. Advanced technologies like ETAP help us detect the risks and create the best solutions that go by industry and compliance standards.

• Embrace the best practices like arc flash labels for panels and equipment, arc flash boundary marketing, and using the appropriate arc flash PPE by compliance standards like NFPA 70 E, IEEE 1584, and AS/NZS 4836 can mitigate risks.

• Replace the defective equipment to meet the safety standards. For example, arc-rated switchgears are essential to minimize the risks of arc flashes.

• Ensure protective device coordination to avoid cascading faults.

• Train electrical workers and other personnel working near energized equipment to adopt the PPE, understand the arc flash labels, and so on.

Summary

Arc flash hazards pose a significant threat to complex electrical networks. Industries in New Zealand must understand the causes and safety measures to safeguard their facilities from these hidden threats. An Arc Flash analysis from Care Labs can help maintain safety, compliance, operational reliability, and efficiency in a system, by and large. 

For more information on Care Labs’ arc flash analysis in New Zealand Contact us today!

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Electrical Engineer, Care Labs