Video summary

I got arc flashed.

Main summary

Key takeaways

News and Commentary

Overview

Derek (“solarboi”) describes surviving an arc flash incident at a solar installation. He uses the experience to argue for stricter electrical safety practices—especially verifying that equipment is actually de-energized and never relying on assumptions.

What an Arc Flash Is (Context)

  • Derek explains that an arc flash is an extremely powerful electrical arc through air, producing a flash/fireball-like event—sometimes described like an explosion.
  • He references industry safety guidance (notably NFPA 70E and OSHA concepts) to explain why companies require:
    • procedures, and
    • protective work practices to prevent or mitigate hazards when working near live electrical parts.

What Derek Was Doing Before the Incident

  • He was dispatched solo to troubleshoot a new uncommissioned solar installation:
    • 3.4 MW DC / 2.4 MW AC
  • The main issue was that low-voltage power wasn’t showing up as expected.
    • Neutral-to-ground was reading nominally 277V.
  • He eventually located auxiliary transformers in the switchgear by working on the load side of a main breaker.
    • He believed this approach allowed him to work without being exposed to energized busbars.

The Key Mistake Leading to the Incident

  • He discovered wiring/connection issues—specifically, a coil of zip-tied wires that were likely missing a required connection during installation.
  • While reaching in to move/cut the zip ties, he made a crucial safety assumption about busbar positioning:
    • He assumed the bus arrangement followed the pattern he was used to (line at top of breaker, load at bottom).
    • In this gear layout, that assumption was wrong.
    • The buses he believed were de-energized were actually on the energized (line) side.
  • He also questioned why he didn’t wear arc flash PPE/calorie suit:
    • He explained he believed the work was not live based on his testing plus the incorrect bus layout assumption.

What Happened During the Arc Flash (Best Current Reconstruction)

  • He believes his pliers contacted—or effectively bridged/grounded—a phase bus (Phase C or Phase A), causing a massive fault.
  • Co-workers later found his pliers fused, indicating extremely high current through the tool.
  • He describes a flash/fireball-like event that rapidly caused phases to arc to each other, with an estimated short-circuit current around 26,000 amps at 480V.
  • He notes factors that likely limited injury severity:
    • The arc didn’t have direct access to most of his body.
    • He wasn’t shocked through his body (the current path involved the pliers).
    • Upstream utility protection (“viper”) tripped quickly, limiting arc duration.

Immediate Aftermath and Medical Course

  • During the flash, he quickly realized what was happening, experienced intense fear, and then collapsed/run to the grass.
  • He suffered severe burns:
    • skin peeling and bleeding,
    • significant pain,
    • strong odor/smoke exposure sensation.
  • He struggled to call 911 due to panic and fingertip burn damage (touchscreen not registering).
  • EMS arrived after about 15 minutes; he was transferred and treated at a hospital/ER, then helicoptered to a burn center.
  • Reported outcomes:
    • Burns to about 19.5% of his body (face, arms, hands)
    • A ventilator for a couple of days
    • A skin graft on his left hand
    • Approximately 7–8 weeks later, he is working on recovery—stretching and re-strengthening—and expects near-full recovery

Main Safety Takeaways (His Conclusions)

  • Do not assume the path or status of conductors based on typical layouts or design familiarity.
  • Emphasize visually confirming the entire conductor path after any exposed/cabinet boundary or design change—especially where bus transitions between sections could invalidate earlier assumptions.
  • Frame the incident as evidence that even experienced electricians can make fatal assumption errors, and that testing/procedures exist to prevent exactly that kind of mistake.

Presenters / Contributors

  • Derek (“solarboi”) — primary presenter/author of the account
  • Jason Brozen (Tyndale) — referenced contributor consulted for corrections about cotton vs. polyester clothing and arc flash clothing myths
  • Derek (“editorboi”) — editor/voice making a specific correction within the narrative

Original video