Design first: the foundation of electrical safety in industrial facilities

Electrical safety insights

• Electrical safety relies on robust maintenance practices, guided by standards like NFPA 70B, to prevent accidents, ensure reliability and protect both personnel and property.
• Proactive electrical safety measures, including well-designed maintenance plans and adherence to industry standards, are essential for minimizing risks and maintaining efficient power system operations.

In industrial and manufacturing plants, electrical safety isn’t just a set of procedures — it’s built into the fabric of the facility and its systems. Proper planning and thoughtful integration of safety measures during the building’s or system’s design phase are critical to protecting personnel and maintaining smooth operations.

A manufacturing facility’s staff can show off its adoption of NFPA 70E: Standard for Electrical Safety in the Workplace in many ways. Here are three key strategies for electrical system success:

1. Plan for both de-energized and live work

Safety-focused facility design starts with understanding operational needs and shutdown tolerances. While de-energized work is ideal, live work may sometimes be necessary to avoid service interruptions. Decisions about live work policies should influence system design, from phasing to temporary power conditions, and must be clearly documented in construction specifications.

Safe and efficient operations depend on the reliability of power systems, and maintaining that reliability starts with a robust electrical maintenance plan. NFPA 70B: Standard for Electrical Equipment Maintenance provides a systematic approach to ensure operational safety, minimize unplanned downtime and meet compliance requirements. As organizations embrace these guidelines, it’s essential to balance safety and operational needs while addressing challenges like resource allocation and system complexity.

2. Incorporate arc flash mitigation strategies

Arc flash hazards represent one of the most severe risks in electrical systems. Design engineers — specifically electrical engineering consultants — can reduce these risks by specifying advanced equipment and safety features. Technologies such as arc quenching relays, zone-selective interlocking and maintenance switches not only meet minimum requirements outlined in standards like NFPA 70: National Electrical Code but also go above and beyond to safeguard workers. Including arc flash analysis early in the project ensures the selection of devices with appropriate ratings and the identification of high-risk areas.

3. Design with maintenance and emergency preparedness in mind

Maintenance and safety overlap in facility design. Providing lockable switches, remote operation options for high-power equipment and disconnecting means in sight of critical systems ensures safe maintenance practices. Additionally, incorporating emergency lighting, accessible electrical rooms and clear labeling enhances both safety and operational efficiency during power outages or emergencies.

Electrical designers and ongoing facility personnel should have:

• Clear roles for responsible personnel.
• Detailed maintenance intervals based on equipment condition.
• Comprehensive documentation and record-keeping policies.

To elevate electrical safety, plant engineers and safety professionals must champion a design-first approach. By engaging with project stakeholders early in the design phase, referencing key standards like NFPA 70 and 70E and investing in advanced safety features, engineers can create facilities where safety is seamlessly integrated. Start by collaborating with your design team to identify areas where proactive measures can protect your workforce and streamline operations.

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