How to Improve Arc Flash Protection in the Oil & Gas Industry

By Safeopedia Staff
Last updated: March 29, 2024
Key Takeaways

Addressing common PPE pain points will improve compliance and ensure that workers are protected from the arc flash hazards in their work environment.

Arc flash incidents are a serious concern in the oil and gas industry. These electrical explosions can result in severe injuries, extensive equipment damage, and costly downtime.


It is essential for safety managers to understand the risks associated with arc flashes and implement an effective personal protective equipment (PPE) program to protect workers and maintain a safe work environment. This article will provide an overview of arc flashes, discuss strategies for protecting against them, address common PPE pain points, and offer tips for building an effective arc flash PPE program.

Understanding Arc Flashes

An arc flash occurs when an electrical current leaves its intended path and travels through the air, creating a powerful explosion. This can be caused by various factors, including equipment failure, human error, or environmental conditions.


The consequences of an arc flash can be devastating. With temperatures reaching up to 35,000°F, it is capable of causing severe burns, fires, and damage to equipment. The blast can also produce intense pressure waves, shrapnel, and toxic gases, all of which pose additional risks to workers and equipment.

Given the hazardous nature of arc flashes, it is crucial to protect workers and maintain a safe work environment. According to the National Fire Protection Association (NFPA), electrical-related injuries account for a significant percentage of workplace fatalities and injuries in the United States. Implementing an effective Arc Flash PPE program not only safeguards employees but also helps companies comply with federal and state regulations, such as OSHA standards, and industry guidelines, like the NFPA 70E.

(Learn more in Electrical Safety Basics: A Guide to NFPA 70E)

Protecting Against Arc Flash Hazards

1. Hazard Assessment and Risk Mitigation

The first step in protecting workers from arc flashes is to conduct a thorough hazard assessment. This includes identifying potential sources of electrical hazards, evaluating equipment condition and maintenance practices, and determining the appropriate risk mitigation strategies.

Some of these strategies include:

  • De-energizing equipment whenever possible
  • Implementing lockout/tagout procedures
  • Using arc-resistant equipment and enclosures
  • Regularly maintaining and inspecting electrical systems
  • Providing training on electrical safety and arc flash awareness

2. Personal Protective Equipment

When engineering and administrative controls cannot entirely eliminate the risk of an arc flash, PPE is necessary to protect workers from potential injuries. Arc flash PPE typically consists of flame-resistant (FR) clothing, arc-rated face shields, insulated gloves, and other protective gear designed to minimize injury in the event of an arc flash.

(Learn about 4 Problems with Traditional Arc Flash Head Protection)

Addressing Common PPE Pain Points

While PPE plays a critical role in protecting workers, it can also create discomfort and impede productivity. Addressing these pain points is essential for ensuring workers comply with PPE requirements and maintain a safe work environment.

Here are some common PPE pain points and their corresponding solutions.

1. Heat and Discomfort

  • Select lightweight, breathable flame-resistant fabrics that offer both protection and comfort
  • Opt for moisture-wicking materials to help regulate body temperature and reduce sweating
  • Encourage workers to take regular breaks in cool areas to prevent heat stress

2. Limited Mobility

  • Choose PPE designed with ergonomics in mind, such as gear with stretch panels or adjustable straps
  • Ensure workers are wearing the correct size PPE for optimal fit and mobility
  • Periodically re-evaluate PPE designs and seek worker feedback for continued improvement

3. Visual and Auditory Obstructions

  • Select arc-rated face shields with anti-fog coatings to maintain clear vision
  • Consider integrated safety glasses and face shields to reduce bulk and improve comfort
  • Use hearing protection with communication capabilities to facilitate clear communication while maintaining safety

(Find out How to Protect Your Hands from Arc Flashes)

Building an Effective Arc Flash PPE Program

An effective arc flash PPE program involves more than providing workers with the appropriate gear. It’s a comprehensive approach that considers hazard assessments, risk mitigation, worker comfort, and ongoing training.

To build an effective program, follow these steps.

1. Develop a Comprehensive Electrical Safety Program

An electrical safety program should provide guidelines for identifying and mitigating electrical hazards, as well as procedures for the safe use of electrical equipment. It should include:

  • An arc flash hazard analysis, which identifies potential sources of arc flash hazards and determines incident energy levels
  • Equipment labeling, indicating arc flash boundaries and the required PPE for each task
  • Clear procedures for working on or near energized electrical equipment, including lockout/tagout, testing, and grounding

2. Select the Appropriate PPE for the Hazard

After conducting a thorough hazard assessment, select PPE that meets the necessary arc rating and protection levels for each task. This may include:

  • FR clothing, such as shirts, pants, coveralls, and jackets
  • Arc-rated face shields and hoods
  • Insulated gloves and other hand protection
  • Head, foot, and hearing protection designed for electrical work

3. Provide Ongoing Training and Education

Regular training ensures that workers understand the risks associated with arc flashes and the importance of wearing PPE. Your training program should cover electrical safety, arc flash hazards, and the proper use and care of PPE. It should also include:

  • Initial orientation and training for new hires
  • Refresher training for experienced workers
  • Any changes to equipment, procedures, or PPE requirements
  • Opportunities for hands-on practice with PPE and safety equipment

4. Monitor and Enforce PPE Compliance

Regularly inspect workers’ PPE for signs of wear or damage, and replace it as needed to maintain effective protection. Additionally, enforce PPE compliance by:

  • Conducting periodic audits and observations of work practices
  • Providing positive reinforcement for workers who consistently wear and care for their PPE
  • Addressing instances of non-compliance promptly and consistently

5. Seek Continuous Improvement

An effective arc flash PPE program should adapt to changing conditions, equipment, and worker needs. To ensure your program does, regularly review it and solicit feedback from workers to identify areas for improvement. This may include:

  • Updating hazard assessments as new equipment is installed or procedures change
  • Evaluating new PPE technologies and designs to address comfort and productivity concerns
  • Identifying and addressing any emerging trends or issues in worker compliance or arc flash incidents


Arc flash incidents pose a significant risk to workers in the oil and gas industry. It is crucial for safety managers to understand the dangers associated with arc flashes and implement a comprehensive PPE program to protect workers. By addressing common PPE pain points, you can create a program that not only safeguards your workforce but also enhances productivity and overall safety performance.

Ready to learn more? Check out our free webinar on How to Build an Arc Flash PPE Program Your Workers Will Embrace!

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Written by Safeopedia Staff

Safeopedia Staff

At Safeopedia, we think safety professionals are unsung superheroes in many workplaces. We aim to support and celebrate these professionals and the work they do by providing easy access to occupational health and safety information, and by reinforcing safe work practices.

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