In 2001, with the merger of Commonwealth Edison (ComEd; Chicago, Illinois, U.S.) and PECO Energy (Philadelphia, Pennsylvania, U.S.) in progress, Exelon Energy’s Director of Supply Management, Dave Frank, put together a cross-functional flame-retardant (FR) clothing committee to evaluate the extensive research that currently involved both companies.

Both PECO and ComEd were already in FR clothing programs that were having a significant impact on reducing the number and severity of burn injuries. With their current clothing contracts expiring, the new committee was charged with securing a supplier that could provide the industry’s best products without compromising safety performance, while gaining improved worker acceptance, and achieving supply and cost improvements.

Lab Trips Verify Performance
Prior to the Exelon merger, as part of a “Safety Culture Change Initiative,” PECO supervision, safety professionals and line worker team safety representatives were sent to investigate best safety practices and safety developments at other companies, utilities, safety conferences, and flash-fire and arc testing laboratories. These lab visits allowed personnel to observe first-hand the performance testing of FR clothing. Representatives were able to gain considerable information and knowledge by observing arc flash testing at the Kinetrics High Current Lab (Ontario, Canada) and at the KEMA High-Voltage Lab (Chalfont, Pennsylvania). Flash-fire exposures were witnessed at the Textile Analysis Laboratory of the University of Alberta (Edmonton, Canada) and at DuPont’s Thermo-Man Facility (Wilmington, Delaware, U.S.).

Consolidated Edison of New York invited Exelon team members to join them in witnessing tests performed at the KEMA facility. During the testing, FR clothing was exposed to arcs flashes in both overhead and underground environments. Energized tests using instrumented manikins situated in everyday work positions simulated dangers around conductors, splices and line equipment. KEMA tests were designed to precisely replicate real-world conditions, so that data was easier to interpret. Results were obtained on non-FR garments, a variety of FR fabrics, arc-suppression blankets and face shields. The data showed that workers are exposed to a significant increase in arc flash energy when faults occur in contained equipment or in confined spaces. KEMA tests also verified that layering clothing provides a critical safety improvement when arcs occur in underground or confined space environment.

Worker Acceptance
From past experiences and recent developments in FR clothing technology, Exelon realized the importance of worker acceptance of FR clothing. As one employee put it, “Sure the leadership of any company can find ways to get its workers to comply with safety rules using incentives or discipline, but with the new FR clothing designs, which are more comfortable and durable, that part of the supervisor’s job just got easier.”

With the ComEd side of Exelon Energy Delivery already involved in a choice program with more garment options, a wear test program was conducted at PECO Energy in the East. Bulwark Protective Apparel and Tyndale FR clothing companies provided 25 line workers from the electric aerial, underground, substation, emergency and gas operations departments with new lighter-weight blends and natural-fiber FR garment samples. User polls found that many had a preference for the Indura UltraSoft garments, a more comfortable, natural-fiber-based clothing now offered in FR garments. Committee members took this information into account when they made clothing recommendations that were ultimately adopted by management.

Competent Technical Supplier
Exelon’s broader knowledge of FR garments gained from the extensive research resulted in a stricter criterion for uncompromising protective clothing and higher standards for the potential suppliers. Vendors were required to demonstration technical expertise in protective clothing and submit flame and arc test data on all garments to meet American Society for Testing & Materials (ASTM) F1506-00 industry standards or better. All garments were to include custom labeling indicating lab test compliance data and the fabrics actual arc rating or Arc Thermal Protection Value (ATPV) on the label of each garment.

Suppliers had to be able to offer garments from multiple manufacturers in the industry making it possible for Exelon to have the widest possible selection available to the workforce. Exelon could also benefit from having access to the latest developments in FR clothing without being tied to only one manufacturer. Availability of contemporary styles and comfort were important criteria as long as each product met Exelon’s protective requirements and enhanced the professional corporate image.

Training is Critical
This thorough industry research has equipped Exelon staff to more effectively train its employees on the purposes and proper choice of FR clothing selection. Through safety bulletins and classroom training, Exelon staff is able to share the logic behind the requirement, for example, that all employees wear 100% cotton undergarments beneath their FR clothing. Arc testing demonstrated that a 7 oz. INDURA Ultra Soft shirt, when worn alone, provides 8.2 calories of protection from an electric arc. Layering will significantly increase this protection. If a 100% cotton T-shirt is added underneath, or even better, an FR coverall is worn overtop, ATPVs increase dramatically. While testing showed that additional protection varies from fabric to fabric, wearing additional layers always increases protection. Training presentations using data from the labs and manufacturers on garment material performance, videos on flash-fire testing and photographs of actual arc tests witnessed by Exelon employees, enabled users to see when tests validated manufacturer’s performance claims.

Utility Practices Still Differ
Some Exelon FR practices differ from other utilities who, for example, are willing to accept earlier versions of Standard F1506, which doesn’t require garments to be arc rated. During a recent restoration effort in the Philadelphia area after Hurricane Isabel, Exelon crews were surprised and concerned to discover some utility crews believe that heavy 11-oz. 100% cotton clothing is as protective as FR garments.

The OSHA reference to the allowance of 11oz.+ of non-FR cotton is based on very low energy levels at an assumed proximity from an arc of 12 inches. This standard assumes the garment is clean and has not been washed repeatedly with fabric softeners.

The work of the ASTM F-18 committee clearly indicates that non-FR 100% cotton garments of all types have the potential to ignite readily and burn vigorously when exposed to an electric arc flash, dramatically increasing both the extent and severity of burn injuries. It is true that heavier cotton requires more energy to ignite, but it also provides more fuel and therefore increased threat of injury once ignited.

Choice Improves Compliance
Because of the hard work and years of investigation by many at Exelon, the company has maintained an excellent record of worker safety. Employees are now wearing more comfortable, safer apparel from a variety of manufacturers including Workrite, Tyndale, Carhartt and Bulwark. Old “one-size-fits-all” philosophies, which narrowed choices for both men and women employees, have been done away with. Workers are able to make proper choices about the protection they wear on the job because of garments labeling program and arc rating standards developed by the committee.

Tyndale executives responded back to us with their observation that the program Exelon adopted empowers employees to choose the products that are best suited for them. The supplier immediately noticed an interest in more personal preference, which Exelon has made available without compromising worker safety in any way.” Many Exelon employees now wear their FR clothing whenever they are on the clock.

The safety team sought input from the field at every opportunity. Comments and conversations shared convinced the team we were on the right track.

Aerial lines supervisor Dwight Herbert says, “Some of the new clothing we are wearing is softer and absorbs perspiration better. It’s hard to believe it’s FR clothing, because it feels and looks like everyday clothing.” This translates into employees being protective all the time.

A Day it All Made a Difference
“There are job conditions that challenge the use of PPE (personal protective equipment),” says Carl Johnson, electric underground splicer. “I was in a hot manhole, my safety glasses were fogging up. I admit, I was tempted to unzip my coveralls or remove my safety glasses, but Tim’s story really got to me.” Johnson is referring to a conversation earlier that morning with fellow employee and PECO Team Safety Rep Tim Houlihan who was talking passionately about the training he had received the previous day. Houlihan recounted how disturbing it was to learn of two splicers from another utility, who had needlessly lost there lives in an arc flash event after receiving fatal burns from non-FR clothing. Johnson recalls, “I thought about what Tim said, and made sure all my PPE and FR clothing was on, zipped up, and ready to protect me if I needed it.”

Later that day, Johnson did need his FR clothing when a piece of equipment, not related to the job at hand, failed in the manhole he was working in. Aerial lineman David Brewer also at the scene, explained, “We were a short distance down the street when we heard the explosion and saw a blast of fire come out of the manhole like the back end of a jet engine.

My first thought was, whoever is in there could not have survived!” As co-workers scrambled to attempt a rescue, Johnson, blinded by the smoke, followed the topside voices to the exit ladder only to be caught in a second “try-back” flash. He survived two 13,000-V flashes, about 15 seconds apart, while suffering only a small amount of first degree burns on the right side of his face, right hand, and was missing some facial hair. Johnson’s FR coveralls did not ignite, burn or cause greater harm.

That day, the FR research, safety training, concern for co-worker’s safety and the correct use of FR Clothing all came together, preventing a potential serious injury that would have affected Carl Johnson, and the people that care about him, for the rest of their lives.

Randy Wade is a senior safety professional at Exelon Energy Delivery and has worked on the PECO system since 1975. Prior to joining PECO, Wade worked at Bechtel Construction Co. He is a Certified Utility Safety Administrator and member of the American Society of Safety Engineers. As a result of his extensive research and investigation into the FR clothing industry, Wade was approved by the ASTM Executive Committee to serve as a voting member on Committee F-18.65, Electric Protective Equipment for Workers, in September of 2002. randy.wade@peco-energy.com