By Judy Ruddy
Managing Editor of Safety at BLR

One person is electrocuted in the workplace every day, says Ken Mastrullo, safety and health manager for Region 1 OSHA, who spoke at a recent professional development conference sponsored by the Nutmeg Chapter of the American Society of Safety Engineers (ASSE).

Some 4,000 workers suffer non-disabling electrical injuries every year, 3,600 workers suffer disabling electrical injuries every year, and 2,000 workers are sent to burn units every year with electrical injuries, he says. Before coming to OSHA, Mastrullo was associated with the National Fire Protection Association (NFPA). He was the lead author of The Electrical Safety Program Book and co-author of the NFPA 70E Handbook, the standard for electrical safety in the workplace.

Electrical hazards include:

• Shock
• Arc flash
• Arc blast
• Other hazards

Shock injuries typically occur to the hands. Workers should not rely solely on V-rated tools to protect their hands, but need personal protective equipment as well.

Arc flash accidents are life-altering events because they can cause horrendous second- and third-degree burns as well as other injuries. An arc flash can ignite or melt clothing, resulting in further burns. Victims sometimes require skin grafts or amputations.

A high-amperage arc can produce a pressure wave blast with a force of up to 1,000 pounds, strong enough to throw a victim and result in injuries from falling or colliding with nearby objects. Hearing loss may also occur.

Consequences Are Severe

The consequences of arc flash burns are severe. Victims may suffer from pain and scarring and may have difficulty re-integrating into the community. They may experience anxiety, depression, or other psychological symptoms. The social and economic costs may also be high. Some workers may not be able to return to their pre-injury jobs. Workers' compensation pays only a portion of lost wages.

Employers also bear increased costs, including lost productivity, possible OSHA fines, possible lawsuits, low employee morale, damaged equipment, and higher insurance premiums.

An Effective Electrical Safety Program Is Key

  An effective electrical safety program is the key to preventing electrical accidents. Mastrullo says that to prevent electrical injuries, employers should:

• Identify and recognize hazards,
• De-energize equipment before electrical work,
• Identify affected parties,
• Provide awareness training for unqualified workers,
• Provide protective schemes and training for qualified workers, and
• Document procedures in writing.

According to J. Michael Callahan, PE, and Robert Levandoski, CSP, CIH, of Fuss & O'Neill Inc., who also presented at the ASSE Nutmeg conference, an electrical safety program should address the needs of all employees as well as contractors and visitors to a facility. Everyone should be aware that the program exists and should be familiar with the parts that pertain to his or her own job. The program should address policy, requirements, responsibilities, and guidance in general terms. Specifics and details could be placed in other subdocuments, such as procedures, to which the program can simply refer.

The program should contain the following elements:

• Stakeholder commitment (senior management, EHS, facilities, and production)
• Good documentation of electrical distribution system
• Comprehensive safety program
• Clear, well-organized written electrical safety procedures
• Ongoing safety training program
• Lockout/tagout procedures
• Emergency procedures
• Outside contractor procedures
• Auditing and recordkeeping procedures
• Clear and unambiguous labeling program
• Working live procedures
• Personnel protective equipment procedures

OSHA regulations should be considered when establishing an electrical safety program. The program should:

• Make personnel aware of electrical safety rules, responsibilities, and procedures.
• Demonstrate the employer's intention to fully comply with the law.
• Document general requirements and guidelines for providing a safe workplace.
• Document general requirements and guidelines that direct the activities of personnel exposed to electrical hazards.
• Encourage and make it easier for each employee to be responsible for his or her own electrical safety.