Four Ways to Strengthen Electrical Safety in Industrial Facilities

From arc flash risk assessments to preventive maintenance and worker training, facilities can reduce electrical hazards and improve reliability by treating electrical safety as an ongoing program, not a one-time project.

• By Shawn Gregg
• Aug 06, 2026

In industrial environments, electrical infrastructure directly impacts uptime, equipment reliability and the strength of an organization’s overall safety culture. Safety officers play a critical role in ensuring that power distribution and control systems are safe to operate, maintain and expand. And the stakes are incredibly high.

According to OSHA, arc flash incidents remain among the most serious electrical hazards in industrial settings. Electrical hazards are consistently cited in OSHA’s top workplace violations, and arc flash events can reach temperatures of up to 35,000°F (hotter than the surface of the sun) resulting in severe burns and injuries – even death. Structured safety programs, timely assessments and strategic maintenance practices can help mitigate these risks across the plant floor.

Here are four best practices to help facilities protect personnel, safeguard power and control systems, and maintain reliable operations.

1. Start at the Beginning: Conduct an Arc Flash Risk Assessment

To improve electrical safety you must first understand the risks. An arc flash audit or assessment provides the foundation for safe work practices, personal protective equipment (PPE) requirements and proper labeling across power and control systems. Without current analysis, facilities may be relying on outdated assumptions about available fault current, clearing times or protective device coordination.

Standards such as NFPA 70E require that arc flash risk assessments be reviewed at least every 5 years—or sooner if significant system changes occur. That includes adding new production lines, expanding facilities, upgrading switchgear or modifying electrical distribution. Any change that affects available fault current or protective device settings can alter arc flash incident energy levels.

A comprehensive assessment should lead to:

• Updated arc flash and shock hazard labels on panels, switchgear, MCCs and control systems
• Defined PPE requirements for each piece of equipment
• Documented approach boundaries and safe work distances
• Coordination with lockout/tagout procedures
• Updated single-line diagrams and system documentation

One area that often flies under the radar is proper labeling. When equipment lacks voltage markings, energy data or PPE guidance, electricians are forced to make assumptions and that introduces unnecessary risk. Clear labeling ensures technicians can quickly identify hazards before opening enclosures or performing maintenance.

2. Establish a Regular Electrical Maintenance Program

Once the arc flash audit is completed, staying on top of ongoing maintenance is critical to ensure systems operate as intended and protective devices perform properly during any adverse event. Industry standard NFPA 70B emphasizes the need for a documented electrical maintenance program, shifting organizations from reactive response and repair to proactive risk reduction.

An electrical maintenance program should include a clear schedule and incorporate things like routine inspection of switchgear, panels and control systems; verification of cable integrity and proper routing; and testing breakers and protective relays. It can also include more advanced options such as thermographic analysis to identify overheating connections or ultrasonic inspection of high-voltage equipment to flag insulation breakdown or loose connections.

Like any component in an industrial setting, electrical equipment has a shelf life. As elements age, insulation degrades, connections loosen and protective devices may no longer operate as intended. These conditions increase the likelihood of arc flash events and unplanned downtime. Routine inspection helps to avoid that scenario and can also help identify overheating conductors, improper cable routing or incorrect medium-voltage wiring which can compromise both safety and reliability.

3. Maintain Inspection Timelines to Reduce Risk

PPE and insulated tools are the last line of defense for workers interacting with energized equipment. Ensuring they are evaluated on required inspection cycles is essential. For example, rubber gloves must be regularly tested for pinholes, tears or insulation breakdown. Even small defects can render gloves ineffective against electrical contact. Hot sticks or insulated rescue hooks are another equally critical component. These tools allow responders to safely pull or push a worker away from energized equipment in an emergency. Without proper testing and inspection, their insulating properties cannot be assured.

Our recommended inspection timeline follows industry standards:

• Rubber insulating gloves: test every six months
• Hot sticks: inspect and test every two years
• Arc flash risk assessment review: at least every five years
• Arc flash training: every three years

4. Don’t Neglect Training and Safe Work Practices

Even the best equipment and PPE are ineffective without training. Workers must understand how to properly use protective equipment and identify hazards to truly minimize safety risks. And it’s especially important that training is provided to both qualified electrical workers as well as those who may work near energized equipment.

Topics can include arc flash and shock hazard awareness, interpreting equipment labels, inspecting and using PPE, and the emergency response and rescue procedures for your specific facility.  If system modifications are made or new equipment is brought online, training should be amended to include those new elements.

It’s also worth noting that lockout/tagout remains one of the most effective methods for preventing electrical injuries. Ensuring equipment is properly isolated, tagged and verified as de-energized before work begins significantly reduces exposure to arc flash and shock hazards.

Electrical safety is not a one-time initiative. It is an ongoing process that includes assessment, maintenance, and training. When facilities focus on protecting people and reinforcing safe work practices, the result is improved reliability, reduced downtime and a stronger safety culture.

This article originally appeared in the July/August 2026 issue of Occupational Health & Safety.