The Role of Substation Safety Equipment in Arc Flash Safety

Why Is Safety Important in Electrical Substations?

Safety is important in electrical substations because workers are routinely exposed to high-voltage equipment that can cause severe injury, fatalities, and costly outages if hazards are not properly controlled. Electrical substations contain energized components capable of producing arc flashes, electrical explosions, and thermal burns within seconds. Without proper substation safety equipment, clear procedures, and controlled access, even routine maintenance tasks can lead to serious incidents.

Effective substation safety reduces the risk of a high voltage substation arc flash accident by controlling exposure to live equipment, limiting access to qualified personnel, and clearly communicating hazards. Safety measures also help prevent equipment damage, unplanned downtime, and regulatory violations. By prioritizing safety from the start, substations protect workers, maintain system reliability, and support uninterrupted power delivery.

Why is Arc Flash Safety Critical for Electrical Substations?

Electrical substations truly have the power. In the wrong hands, that power is dangerous. That’s why it’s important to ensure arc flash safety and physical security inside buildings as well as outside on the grounds using proper substation safety equipment. Experts share their insights on effective management and electrical hazard prevention to support long-term substation safety.

It takes a lot of work to keep the lights on. Growing electricity demands are creating a need for more electrical substations. Cities throughout the world are upgrading infrastructures and adding more substations to serve rapidly developing areas. While these substations help secure reliable electricity to prevent power outages and support booming large-scale industrial facilities, airports, and the like, they require security and safety themselves. Using a Toro Max industrial labeler to clearly mark boundaries is a key step in this process.

It's important to mitigate hazards in the electric power substations to keep the workers who maintain them safe from electrical hazards like an arc flash or electrical explosion, including the risk of a high voltage substation arc flash accident. Using the right substation safety equipment plays a key role in reducing these risks.

Substation Safety and Security to Reduce Arc Flash

Substations can have distribution voltages of up to 33kV and 69kV, which can seriously damage a person or kill them if an arc flash occurs. Proper GHS compliance labeling on nearby maintenance chemicals and clear hazard signs are vital for worker protection. A high voltage substation arc flash accident can result in severe injuries, equipment damage, and costly downtime. In 2019, there were 39 deaths in the utility industry, a category that includes substations, according to the Bureau of Labor Statistics. 

Market projections for medium-level (33 kV and 69 kV) global substations show an increase of 5.6% by 2026 as part of integrations of sustainable energy infrastructure alone. With the addition of substations, it's important to make sure they are safe, compliant, and efficient from the start by implementing professional substation labeling systems to further prevent arc flash incidents and support overall substation safety. Electrical safety requirements are part of OSHA 29 CFR 1910, but there are a lot of other safety elements that go beyond compliance, including clear identification and reliable substation safety equipment. 

One of the top tasks electrical substation workers handle is keeping unqualified personnel out of the substation, which is a foundational aspect of substation safety.

"Over the years, we have had numerous trips/upsets from individuals accidentally tripping breakers/equipment," said Richard Todd, an electrical engineer in Baton Rouge, Louisiana. "The area should be locked, and only qualified personnel should have access." 

People are not the only invaders of substation spaces. That's why pest control can sometimes be another mindful activity. Birds, insects, and other small creatures can cause big problems around substations, increasing the potential for a high voltage substation arc flash accident if equipment is compromised.

Best Practices and Substation Safety Equipment for Arc Flash Safety

Checking the perimeter of the substation is a crucial step before any maintenance is done, said Aaron LeBlanc, a longtime lineman and vlogger of Bob's Decline on YouTube. He says there are three important steps: 

1. Notify your company's dispatcher, if you have one, that you are at the substation. Inform what you'll be working on. "A lot of substations are remotely operated," he said. This extends communication for safety. Once you're finished, he said, let them know you're leaving and give them the "all clear."
2. Conduct a perimeter check to make sure the grounds are not damaged, debris is clear from walking and working paths, and observe and report anything else that might need repair to maintain substation safety.
   
3. Perform a general inspection of equipment such as cables, transformers, the sub yard, and other critical substation safety equipment.

Other important steps in ensuring substation safety, efficiency, and compliance are to check the substation's information and organization. The substation should have warning signs that meet arc flash label requirements. Cleanliness keeps other hazards from rearing. Clean up clutter, keep out combustibles, and do not use substation houses for storage. Personal protective equipment should have its place for proper storage, along with tools and materials that support substation safety equipment programs.

Make Logical Marks to Prevent a High Voltage Substation Arc Flash Accident

Substation communication is essential for a responsible electrical safety program. That's why it's important to use critical thinking and evaluate where to place electrical safety signs, labels, and even floor marking that adheres to arc flash label requirements and helps prevent a high voltage substation arc flash accident. They are cost-effective and easy to install on demand. Post signs that alert people to access points, voltage information, emergency information, and more. Labels identify electrical motor controls, cables, wires, panel information, and switches as part of a complete substation safety equipment strategy.

"The shutdown units should be well-identified, like with flags, plastic warning ribbons," said Alain Mosian, an electrical safety expert in Quebec. This goes along with lockout/tagout safety programs.

Additionally, electrical safety signs can communicate safe distances and reinforce proper security and barriers. Accidents and injuries from a high voltage substation arc flash accident can be devastating to personnel and hurt a company's productivity and bottom line. Workplaces should include safety procedures and checklists for all workers. Include them along with frequent training and toolbox talks. Following safety standards and using well-planned substation safety equipment can help reduce the likelihood of dangerous events at substations.

Arc Flash and Substation Safety Equipment Solutions from DuraLabel

Easily design and print arc flash labels and electrical safety signs any time you need them, onsite or in the field with the versatile DuraLabel^® Kodiak^® Max Industrial Sign and Label System. This printer also serves as an effective substation safety equipment solution for facilities that need durable, compliant safety communication.

Get help crafting a system that will provide the safety communication you need. Call 1-888-820-4631 and one of our experts will guide you through the process. 

Learn more about arc flash labeling with the DuraLabel Arc Flash Labeling Quick Start Guide. This guide will improve safety on your site, as well as walk you through how to create effective arc flash labels for your entire site. Download our free guide on Arc Flash Labeling below. 

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