The Quest for Personal Protective Equipment Arc Rating: Implications for Electrical Workers' Safety and Health

Authors: Marcio Bottaro, Luis Eduardo Caires, Thais Ohara de Carvalho, Paulo Futoshi Obase, Hedio Tatizawa

Abstract:

Since the primary numerical metric used to evaluate Personal Protective Equipment – PPE, including protective clothing or other equipment designs, is typically derived from a single arc rating report, researchers and occupational safety professionals have raised significant concerns regarding the reliability of assigning a safety rating based on a single thermal performance test. Moreover, questions arise about the adequacy of determining PPE conformity solely from a single arc flash test. Although it is well known that the arc rated PPE work and show unquestionable evolution in workers’ safety, a tendency to pursue every higher arc rating value is evidenced in the marketing, and in Brazil, it has been a special concern on the reliability of such practice of “select” a more convenient arc rating report to use as base parameter on final PPE test and subsequently certification process. In fact, this procedure is not forbidden and it ends up being supported and encouraged due to the way such tests are conducted according to international standards. Although commonly practiced, variations in test laboratory procedures, as well as inherent variations in materials such as textiles, introduce significant concerns regarding the reliability of higher reference values across batches of final products. This study highlights the discrepancies between claimed arc rating values and those obtained through laboratory testing over time for various textile materials. The findings reveal that focusing on the upper margins of thermal characterization can lead to adverse effects on the final versions of PPE, which are ostensibly ready for worker use. Deterministic failures such as charring, dripping, and breakopen in proof undergarments were observed, with a notable increase in the frequency of these failures in 2024 tests in Brazilian arc flash laboratory. These results underscore the urgent need for advancements in standardization processes to ensure the reliability of PPE and safety of workers.

Keywords: arc rating, arc flash protection, arc flash risk, PPE certification, PPE open arc test