Powering protection

ABB is a global technology leader in electrification and automation, delivering cutting-edge solutions across a diverse array of industries. With more than 270 factories worldwide and thousands of employees working daily in high-risk electrical environments, ABB operates in settings where safety is critical. It is not just a priority, but a core value embedded into every aspect of its operations. From advanced robotics to electrical distribution networks, ABB’s commitment to safety ensures that innovation is pursued with human wellbeing at the forefront.

One of the most compelling examples of this commitment comes from a rare and life-threatening arc flash incident that occurred at an ABB site. This event shows the vital importance of personal protective equipment (PPE) and demonstrates how it can make the difference between life and death. In this instance, Tranemo, known for its inherent flame retardant and arc flash protective clothing, played a critical role in protecting an employee from potentially catastrophic injuries. This story highlights the critical role of PPE, but also the strong culture of safety shared by ABB and its partners. Together ABB and Tranemo work to protect people operating in challenging electrical environments worldwide.

At ABB, safety is more than a regulatory requirement, it is a core operational principle. Christopher Smith, HSE audit & assurance manager at ABB, explains, “Health and safety at ABB is referred to as our license to operate. We need this to perform safely, and it is critical to our operations. ABB focuses on creating its own systems, rules, and processes to protect our contractors and colleagues when they are working in high-risk environments.” These systems are not merely administrative; they are practical frameworks designed to ensure that every individual can work with confidence and return home safely each day.

Prioritising safety together

Electrical hazards are an everyday risk for many ABB employees, and mitigating these risks requires more than caution and experience, it demands the right protective clothing for the task at hand. Tranemo Advanced Workwear has developed a long-standing partnership with ABB to support their safety needs. Through this collaboration, ABB teams receive expert guidance to ensure the clothing they wear is appropriate for their specific tasks and risk exposure.

Safety should never be optional. Christopher emphasises that those working in electrical environments should be wearing arc flash protective clothing as a standard uniform. This approach reflects a simple but powerful principle: safety should never be optional. In environments where routine tasks can escalate into hazardous situations, protective clothing is not just an accessory, it is essential. 

The arc flash incident

The incident occurred at a low-voltage site during what should have been a routine task. A field engineer was performing maintenance work that, under normal circumstances, posed minimal risk. Unfortunately, this was no ordinary day. During routine repair work in a low voltage area, the engineer was unexpectedly exposed to a severe arc flash. An arc flash is a sudden release of electrical energy through the air causing a powerful electrical discharge with extreme heat. They can cause devastating burns, permanent injury, blindness, or even fatality to those in close proximity.

What made this event more dangerous than your average arc flash incident was its duration. While arc flashes typically last only a fraction of a second, this incident lasted between two and three seconds. Even a brief arc flash carries enormous potential for harm, but one that persists for several seconds can be catastrophic. In this case, the exposure was extreme, creating a scenario where the outcome could easily have been fatal.

Last line of defence

PPE serves as the last line of defence. For the field engineer, this truly was the case, and it is likely that the PPE saved their life. At the time of the incident, the engineer was wearing a Tranemo two-layer protective system, a long-sleeved base layer (ELIM 4.6 cal/cm²), with a long-sleeved sweatshirt (ELIM 8.6 cal/cm²) worn over the top. 

During the arc flash, the outer layer was severely damaged, showing visible signs of the incident. Crucially, however, the inner protective layer remained intact, shielding the employee’s torso and preventing life-altering injuries. The engineer sustained first, second, and third-degree burns to the face and hands, which were not fully covered by the protective clothing. Yet, the most critical areas – the torso and vital organs – remained completely unharmed, with no burns or redness on the skin at all.

Christopher Smith gave emphasis to the gravity of the situation: “The severity of the burns would have caused serious, life-threatening injuries. The potential outcome is unthinkable.” This incident demonstrates that while PPE may not prevent all injuries, it can certainly mitigate the risk of catastrophic harm. In other words, protective clothing doesn’t just reduce the severity of incidents – it can save lives.

Protective clothing worn

The protective clothing system worn during the incident highlights the importance of selecting garments appropriate to both the environment and the task. The garments worn were a flame retardant sweatshirt (5085 89) with an ELIM rating of 8.6 cal/cm² and a long-sleeve flame retardant t-shirt (6315 90) with an ELIM rating of 4.6 cal/cm². The combination of these layers provided a higher ELIM rating than the sum of their individual parts, demonstrating the practical benefits of a multi-layer PPE system.

Together, ABB and Tranemo ensure that PPE is not only compliant with standards but is also right for each individual wearer, and to protect the people who rely on it daily. Every layer, fabric, and design element is selected with the goal of providing maximum safety without compromising comfort or usability.

Lessons learned

The arc flash incident serves as a stark reminder of the hazards in electrical work and the indispensable role of protective clothing. Personal protective equipment can mean the difference between minor injuries and life altering outcomes. 

Christopher Smith reflects, “The most important lesson from this incident is simple but powerful. Arc flash protective clothing saves lives. Too often in the electrical industry, high-risk activities are still carried out without the right protection.” This statement is a call to action for all companies operating in electrical environments. Never underestimate the value of properly selected and correctly worn PPE.

Even seemingly routine tasks carry risks, and everyday jobs can quickly become dangerous. ABB and Tranemo work together to ensure employees wear the right PPE for their specific roles, helping to minimise the impact if an incident occurs. Tranemo has a simple vision that no one should be seriously injured in an accident where the correct work clothing could have prevented the accident or helped to reduce the consequences of it. A vision that ABB fully shares.  

Christopher reflects and shares his advice to all of those who work within the electrical industry: “Put your people in arc flash protective clothing as a standard uniform.” This straightforward recommendation is simple, yet vital and this case study echoes its importance. 

Fully protected

At ABB, worker protection is regarded as deeply personal. PPE is the last line of defence, but for it to serve its purpose effectively, it must meet three critical criteria. It must provide reliable protection, fit correctly, and be comfortable enough for continuous use.

Tranemo works hard to produce ergonomic designs, source breathable fabrics, and produce flexible garments to ensure that employees can perform their duties effectively and comfortably while remaining fully protected.

This focus on innovation, safety, and inclusivity strengthens the partnership between ABB and Tranemo, reinforcing a shared commitment: keeping people safe in the most challenging working environments. Every design decision, safety protocol, and training initiative is aimed at reducing risk and ensuring that employees can rely on their protective clothing. 

A commitment to safety 

The story of the arc flash incident at ABB is more than a cautionary tale – it is a testament to the life-saving capability of properly selected and correctly used PPE. Protective clothing is not optional, it is essential. 

This incident demonstrates an important truth. In high-risk environments, PPE can and does save lives. The collaboration between ABB and Tranemo illustrates how a shared dedication to safety can protect people, reduce risks, and foster a workplace culture where employees are empowered to perform their roles safely and securely.

The message is clear: prioritising safety, investing in the right protective clothing, and embedding a culture of vigilance are not optional – they are essential. Companies can then ensure that even when the unexpected occurs, their staff are protected. PPE is the last line of defence, but when chosen and used correctly, it can be the difference between a life forever changed and a life saved. Ultimately, this is a story not just about PPE, it is a story about valuing human life above all else.

For more information, visit www.tranemoworkwear.co.uk