Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Utility organizations must recognize suicide as a grave personal injury, equipping the workforce with adequate mental health training and tools.
Lineworkers confront daily risks many can’t imagine – arc flashes, falls, electrocutions and more. Yet there’s a silent, insidious threat currently claiming more lives in the electric utility industry than any physical injury. We’re talking about suicide. Safety professionals dedicate their careers to mitigating risk and preventing harm, understanding that serious injuries and fatalities devastate […]
When the System Isn’t Enough: How to Create Personal Motivation That Saves Lives
Used in combination, the Total Worker Health framework and motivational interviewing offer a proven way to foster lasting behavioral change.
Author’s Note: In this article – the first in a five-part series – we explore the notion of accepting 100% accountability for our safety at work, just as we do at home. This is an act of self-preservation. The hope is that management’s safety focus will overlap with our own preparation. We want as much […]
Forecasting the Future of Utility Safety: 10 Predictions for 2026 and Beyond
Technology will become increasingly vital to industry safety and sustainability efforts over the next decade.
As we stand on the precipice of a new era in the utility sector, it is clear the future holds transformative potential driven by relentless technological progress. We are already seeing not just small changes but a complete overhaul. The horizon is replete with innovations aimed at redefining safety protocols and operational efficiency. Predicted advancements […]
Safety By Design: Evaluation and Effective Action
Use leading indicators, meaningful audits and structured corrective actions to strengthen safety management systems.
The previous articles in this series outlined the essential components of a strong safety management system (SMS). To achieve safety success, electric power organizations must ensure those components align with and support one another. This article – the last in the series – addresses two final topics of importance: assessing an organization’s SMS performance and […]
2025 Update: Ferroresonance Explained
Ferroresonance is a complicated issue, one that industry workers must be educated about. That’s because as the number of URD system installations grows and systems age, instances of ferroresonance increase – as do threats to worker and customer safety, equipment and service reliability. I first became acquainted with ferroresonance in the 1980s while troubleshooting a […]
Don’t Cross That Line
In this installment of “Voice of Experience,” I am going to share a safety perspective that struck a real chord with me when someone offered it during a recent meeting. My goal in passing it along during this season of reflection is to prompt readers to contemplate and continue refining their safe work practices. From […]
December 2025 Q&A
Q: Can I ground through a wave trap? A: General discussion about wave or line traps centers on their function. At operating frequency, they have extremely low impedance to any voltage at 60 Hz. Some would say that for the sake of convenience, it’s OK to ground at a switch even where there is a […]
Be the Light
Here’s how you can become a brightly shining safety light in your organization.
“This little light of mine, I’m gonna let it shine, let it shine, let it shine, let it shine.” Light. We literally cannot live without it. In addition to sustaining life, light can be used in various other ways, including helping us to see clearly and sanitizing unsafe conditions. That sounds a lot like what […]
Dangers & Safety in Overhead Utility Work Training Safer Operators Through Simulation
SPONSORED BY CM LABS
JANUARY 21ST, 2026 @ 1PM ET
Dangers & Safety in Overhead Utility Work Training Safer Operators Through Simulation
Which will include:
- The key industry challenges, including workforce shortages, experience gaps, and persistent incident and fatality risks.
- Why traditional training methods alone can’t fully prepare linemen for high-risk situations.
- How simulation enables a more data-driven approach to workforce development .
- How simulation helps reduce incidents, accelerate onboarding, and lower training costs .
Voice of Experience – Storage Safety Hazards, Response, and the Evolution of the Grid with Josh Dinaburg, CSA Group
As the grid transitions to green energy, battery energy storage systems (BESS) are popping up everywhere—from utility substations to residential neighborhoods. But what happens when lithium-ion technology fails? In this episode of The Voice of Experience, host Danny Raines and Fire Test Specialist Josh Dinaburg from the CSA Group dive deep into the reality of […]
Utility organizations must recognize suicide as a grave personal injury, equipping the workforce with adequate mental health training and tools.
Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Lineworkers confront daily risks many can’t imagine – arc flashes, falls, electrocutions and more. Yet there’s a silent, insidious threat currently claiming more lives in the electric utility industry than any physical injury.
We’re talking about suicide.
Safety professionals dedicate their c…
In the News
Used in combination, the Total Worker Health framework and motivational interviewing offer a proven way to foster lasting behavioral change.
When the System Isn’t Enough: How to Create Personal Motivation That Saves Lives
Author’s Note: In this article – the first in a five-part series – we explore the notion of accepting 100% accountability for our safety at work, just as we do at home. This is an act of self-preservation. The hope is that management’s safety focus will overlap with our own preparation. We want as much overlap as possible.
The next article will address mental preparation, which is different than mental health. It’s a targeted focus to reduce risk of serious injuries and fatalities by improving our ability to remain self-aware and vigilant. We must keep our heads in the game.
When you’ve…
Technology will become increasingly vital to industry safety and sustainability efforts over the next decade.
Forecasting the Future of Utility Safety: 10 Predictions for 2026 and Beyond
As we stand on the precipice of a new era in the utility sector, it is clear the future holds transformative potential driven by relentless technological progress.
We are already seeing not just small changes but a complete overhaul. The horizon is replete with innovations aimed at redefining sa…
Use leading indicators, meaningful audits and structured corrective actions to strengthen safety management systems.
Safety By Design: Evaluation and Effective Action
The previous articles in this series outlined the essential components of a strong safety management system (SMS). To achieve safety success, electric power organizations must ensure those components align with and support one another.
This article – the last in the series – addresses two final…
2025 Update: Ferroresonance Explained
Ferroresonance is a complicated issue, one that industry workers must be educated about. That’s because as the number of URD system installations grows and systems age, instances of ferroresonance increase – as do threats to worker and customer safety, equipment and service reliability.
I first became acquainted with ferroresonance in the 1980s while troubleshooting a pad-mounted, three-phase transformer at night. The pad fed a chemical plant, closed for the evening, in the middle of nowhere. The 480-volt, 2000-amp main was single-phasing, so plant electricians had dropped all the 480-volt…
Don’t Cross That Line
In this installment of “Voice of Experience,” I am going to share a safety perspective that struck a real chord with me when someone offered it during a recent meeting. My goal in passing it along during this season of reflection is to prompt readers to contemplate and continue refining their safe…
December 2025 Q&A
Q: Can I ground through a wave trap?
A: General discussion about wave or line traps centers on their function. At operating frequency, they have extremely low impedance to any voltage at 60 Hz. Some would say that for the sake of convenience, it’s OK to ground at a switch even where there is a l…
Here’s how you can become a brightly shining safety light in your organization.
Be the Light
“This little light of mine, I’m gonna let it shine, let it shine, let it shine, let it shine.”
Light. We literally cannot live without it.
In addition to sustaining life, light can be used in various other ways, including helping us to see clearly and sanitizing unsafe conditions. That sounds…
Dangers & Safety in Overhead Utility Work Training Safer Operators Through Simulation
SPONSORED BY CM LABS JANUARY 21ST, 2026 @ 1PM ET
Dangers & Safety in Overhead Utility Work Training Safer Operators Through Simulation
Which will include:
The key industry challenges, including workforce shortages, experience gaps, and persistent incident and fatality risks.
Why tra…
Opinion
Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Tom Murphy and Brian McKeon
When the System Isn’t Enough: How to Create Personal Motivation That Saves Lives
Tom Cohenno, Ed.D., CSP, CUSP, HWC
Forecasting the Future of Utility Safety: 10 Predictions for 2026 and Beyond
Shawn M. Galloway
Safety By Design: Evaluation and Effective Action
Pam Tompkins, CSP, CUSP
Video
Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Lineworkers confront daily risks many can’t imagine – arc flashes, falls, electrocutions and more. Yet there’s a silent, insidious threat currently claiming more lives in the electric utility industry than any physical injury. We’re talking about suicide. Safety professionals dedicate their careers…
Featured Topics
Utility organizations must recognize suicide as a grave personal injury, equipping the workforce with adequate mental health training and tools.
Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Lineworkers confront daily risks many can’t imagine – arc flashes, falls, electrocutions and more. Yet there’s a silent, insidious threat currently claiming more lives in the electric utility industry than any physical injury.
We’re talking about suicide.
Safety professionals dedicate their c…
Used in combination, the Total Worker Health framework and motivational interviewing offer a proven way to foster lasting behavioral change.
When the System Isn’t Enough: How to Create Personal Motivation That Saves Lives
Author’s Note: In this article – the first in a five-part series – we explore the notion of accepting 100% accountability for our safety at work, just as we do at home. This is an act of self-preservation. The hope is that management’s safety focus will overlap with our own preparation. We want as…
Technology will become increasingly vital to industry safety and sustainability efforts over the next decade.
Forecasting the Future of Utility Safety: 10 Predictions for 2026 and Beyond
As we stand on the precipice of a new era in the utility sector, it is clear the future holds transformative potential driven by relentless technological progress.
We are already seeing not just small changes but a complete overhaul. The horizon is replete with innovations aimed at redefining sa…
Use leading indicators, meaningful audits and structured corrective actions to strengthen safety management systems.
Safety By Design: Evaluation and Effective Action
The previous articles in this series outlined the essential components of a strong safety management system (SMS). To achieve safety success, electric power organizations must ensure those components align with and support one another.
This article – the last in the series – addresses two final…
2025 Update: Ferroresonance Explained
Ferroresonance is a complicated issue, one that industry workers must be educated about. That’s because as the number of URD system installations grows and systems age, instances of ferroresonance increase – as do threats to worker and customer safety, equipment and service reliability.
I first…
Don’t Cross That Line
In this installment of “Voice of Experience,” I am going to share a safety perspective that struck a real chord with me when someone offered it during a recent meeting. My goal in passing it along during this season of reflection is to prompt readers to contemplate and continue refining their safe…
Utility organizations must recognize suicide as a grave personal injury, equipping the workforce with adequate mental health training and tools.
Inspecting the Fifth Wire: Winning the War on Lineworker Suicide
Lineworkers confront daily risks many can’t imagine – arc flashes, falls, electrocutions and more. Yet there’s a silent, insidious threat currently claiming more lives in the electric utility industry than any physical injury.
We’re talking about suicide.
Safety professionals dedicate their careers to mitigating risk and preventing harm, understanding that serious injuries and fatalities devastate lives and ripple through the workforce. But what if the most devastating injury of all is one largely overlooked in traditional safety programs?
Industry employers already deliver traditional safety training to employees and outfit them with personal protective equipment as their last line of defense against harm. These companies aren’t waiting for a physical injury to occur before providing the necessary tools and training.
It makes sense to ask, then, what’s stopping utility organizations from providing workers with tools and training to prevent self-harm?
Because suicide is arguably the greatest of all personal injuries, it demands levels of training and attention that match or exceed those invested in preventing other types of physical injuries. Fortunately, we don’t need to reinvent the wheel. We simply need to extend the logic of our existing safety principles.
Consider this: We wouldn’t dream of sending a brand-new apprentice up a pole with only a brief classroom explanation about how to climb it, plus a phone number to call or an app to download for climbing instructions. Yet this is often the industry’s approach to mental health. We direct employees to resources, but are we also actively training them to recognize warning signs in themselves and their peers? When is the last time we practiced our intervention skills or worked to destigmatize the act of seeking help?
Just as we train utility crews to inspect every visible wire on a pole, we are also morally obligated to teach them to inspect the invisible one – what we refer to as the “fifth wire” – that connects them as human beings.
Stark Stats
The 2023 national suicide rate among the general population was 14.1 per 100,000, according to the U.S. Centers for Disease Control and Prevention (see www.cdc.gov/suicide/facts/data.html). Per the 2023 Annual Report on Suicide in the Military, the rate per 100,000 active service members was 35.9 for the Marine Corps, 34.8 for the Army, 22.5 for the Air Force and 21 for the Navy (see www.dspo.mil/Portals/113/2024/documents/annual_report/ARSM_CY23_final_508c.pdf).
The data is even starker for those serving our industry. Among construction workers in 2022, there were over five times more suicide deaths than fatal work injuries (see www.cpwr.com/wp-content/uploads/DataBulletin-September2024.pdf); CDC data from 2021 paints an equally disturbing picture (see https://cdc.gov/mmwr/volumes/72/wr/mm7250a2.htm).
These statistics are a clarion call demanding that we stop overlooking the invisible fifth wire that connects the human crews who keep our lights on. But recognizing that call alone isn’t enough. Utility safety and operations leaders must actively promote a community of belonging within their organizations, equipping the workforce with simple, practical, effective tools – just as they do for physical safety purposes.
A sense of belonging is a critical driver of safety and performance in high-stakes environments like line work. According to a 2019 Harvard Business Review article, “When people feel like they belong at work, they are more productive, motivated, engaged and 3.5 times more likely to contribute to their fullest potential …” (see https://hbr.org/2019/02/the-surprising-power-of-simply-asking-coworkers-how-theyre-doing).
Put simply, maintaining cohesive peer networks is a fundamental need and strategy in the war on lineworker suicide.
Battle Formation: Shield, Sword and Armor
Winning the war requires each of us to employ three critical items to protect ourselves from making destructive choices: the shield of vulnerability, the sword of stigma obliteration and the armor of peer networks.
The Shield of Vulnerability
Lineworkers make electrical connections every day. As leaders, we must help them connect with each other. This is the basis of the Sweethearts & Heroes Fifth Wire Program, which was founded on one simple, field-tested process built for life’s realities: Circle. One of the world’s oldest human connection practices, stretching back 400,000 years, the Circle process fosters a sense of belonging and purpose among group members, establishes positive social norms, builds networks of support, and develops critical skills for personal and collective well-being.
Vulnerability is encouraged in Circle, nurturing an environment in which individuals are more likely to reach out for help before they reach a crisis point. The act of being vulnerable also provides opportunities for us to share the hope we all carry with everyone else in the group.
Circle is designed to build upon a group’s strengths. Sadly, however, vulnerability is often associated with weakness – and fear of appearing weak can paralyze us. Still, we overcome our struggles and build the strength we seek by finding the courage to talk about difficult topics. Winning the war on lineworker suicide requires us to acknowledge our shared humanity, to create psychologically safe environments in which it’s OK for anyone to say, “I’m not OK” – knowing their admission will be met with support, not judgment. By leading with personal stories of overcoming adversity, we inspire hope in others that they can successfully conquer their own challenges.
The Sword of Stigma Obliteration
Stigma isolates people in their pain. Many communities perpetuate a pervasive stigma around suicide, often reinforcing silence through cultural norms and misconceptions about weakness and resilience.
Under pressure to appear “fine” or maintain a facade of strength, individuals can suffer in secrecy, fearing judgment, alienation or punishment. Modern society’s reluctance to openly address suicide not only deepens the isolation of those struggling but deprives communities of the awareness and empathy needed to foster true healing and prevention.
The sword of stigma obliteration is our tool for tackling this formidable opponent, cutting through the silence and shame that allow hopelessness to fester. Engaging in open, honest conversations is the most potent way to wield it because discussion of complex subjects – especially tough ones like loss and grief – has an inoculating effect on us. When we candidly speak about an immense personal struggle, that act typically helps us and our listeners, piercing through isolation and offering a path forward.
We must actively create platforms and opportunities for these conversations among utility crews with the goal of making them routine and accepted – just like any other safety briefing.
The Armor of Peer Networks
Finally, we must equip ourselves with the armor of peer networks and foster a culture of mutual support and shared responsibility.
One crucial aspect of this is staying “left of bang,” a concept developed by Patrick Van Horne that emphasizes proactive intervention based on behavioral cues. Behavior is communication. When someone begins isolating themselves at lunchtime, giving away their tools or exhibiting sudden changes in mood – even nearly imperceptible shifts – these are warning signs. We must train the workforce to recognize and respond to these signs before “the bang” happens. Fortunately, each of us possesses a profound intuitive capacity in our connections with others, a powerful resource rooted in the subconscious mind that can be intentionally honed into a finely tuned superpower.
For instance, an auxiliary nurse working in a psychiatric facility may be more adept at predicting a patient’s suicidal ideations than a skilled clinician armed with standard evaluation tools. This predictive ability is not mystical; it is developed by consistently observing an individual. Through their interactions, the nurse establishes a baseline of the patient’s nonverbal cues and mannerisms, creating a deep-seated intuitive connection – one that makes subtle, critical shifts in behavior immediately apparent.
During his work with the U.S. Air Force on the Wingman-Connect suicide prevention program, Peter A. Wyman, Ph.D., director of the Network Health and Prevention Program at the University of Rochester, found that peers set the adaptive, healthy social norms for each other. That means whether it’s in the electric utility industry, among our children or in the Marine Corps, people look up to those with prestige and influence within their peer groups. Thus, we must empower these informal leaders – particularly those who have weathered their own storms – to champion mental well-being, model help-seeking behavior and actively support their colleagues.
Much like Wingman-Connect, the Fifth Wire Program has repeatedly demonstrated that strong social bonds within a cohesive group mitigate suicidal ideation and depression symptoms. Circle offers a simple, action-based, lifesaving practice for crew-level check-ins, providing crew members with time and space to inspect and maintain the invisible wire that connects them.
Conclusion
Line work is hazardous in more ways than most people realize. Today, we are losing far too many of our brothers and sisters in the trade by their own hands.
But while the challenge before us is immense, it’s not insurmountable. We can begin to turn the tide in the war on lineworker suicide by recognizing it as a grave personal injury and equipping the workforce with the mental health tools and training they need.
About the Authors: Tom Murphy is founder, CEO and resident superhero of the Vermont-based Sweethearts & Heroes. Reach him at tom@sweetheartsandheroes.com or 802-309-9539.
Brian McKeon is a content writer for Sweethearts & Heroes.
Editor’s Note: For more on this topic, listen to a recent interview with Tom Murphy on the Utility Safety Podcast, available at https://utilitysafety.podbean.com/e/what-is-the-fifth-wire-building-a-human-safety-net-in-the-utility-sector-with-tom-murphy/.
Used in combination, the Total Worker Health framework and motivational interviewing offer a proven way to foster lasting behavioral change.
When the System Isn’t Enough: How to Create Personal Motivation That Saves Lives
Author’s Note: In this article – the first in a five-part series – we explore the notion of accepting 100% accountability for our safety at work, just as we do at home. This is an act of self-preservation. The hope is that management’s safety focus will overlap with our own preparation. We want as much overlap as possible.
The next article will address mental preparation, which is different than mental health. It’s a targeted focus to reduce risk of serious injuries and fatalities by improving our ability to remain self-aware and vigilant. We must keep our heads in the game.
When you’ve experienced as much loss as I have, safety becomes more than policy – it becomes a personal mission.
During the 31 years I worked for a large utility, I witnessed more tragedy than anyone should in a lifetime. Forty-four employees died on the job, part of 87 total fatalities at the company since 1965. Those individuals were my coworkers and friends, not just statistics.
Among the accidents that took their lives were vehicle crashes, falls from height, helicopter disasters over land and sea, and countless electrocutions. A major steam leak killed my entire shift and carpool partners. Some incidents are simply too painful to talk about. Most involve a person doing something that, if they could, they would choose to take back.
Each loss I’ve experienced has deepened my resolve to pursue what I call “the holy grail” of safety: a way we can end preventable worksite tragedies once and for all.
Serious injuries and fatalities still occur far too often despite decades of systemic improvements and process upgrades within utility organizations. As part of my ongoing journey to help the industry find a solution, I’ve closely examined Total Worker Health (TWH) – a National Institute for Occupational Safety and Health framework that integrates safety, health and wellness – and motivational interviewing (MI), a proven method of fostering lasting behavioral change.
Together, these two approaches offer what traditional safety systems alone do not: a shift from compliance to personal commitment. Real change begins when people choose to work safely because they want to – not because they’re told to.
Who is Responsible for Safety?
Management and frontline workers share safety responsibilities. And while the “don’t blame the worker, fix the system” mindset has value, the reality is that the moment we get into our car or set foot on a jobsite, we accept the risks inherent to that system.
Now, none of us would knowingly walk into certain death, which tells us we have agency. That’s important; each day, we make choices about which risks we’re willing to accept.
For example, most of us trust the rules of the road yet still drive defensively because we know others can make mistakes. The same applies at work. Although management has the obligation to eliminate or mitigate hazards and design systems to fail safely, even the best systems have their limits – which is why workers must take safety ownership, too.
Much as with driving, each of us must work defensively, developing awareness, discipline and personal safety rules that go beyond company policy. Frontline workers need their own safety margins and ways to stay alert because in the end, they are the ones who pay the ultimate price, not management.
Keep in mind, however, that safety isn’t just about you or me; it’s also about those around us. Consider how carefully you drive with a friend’s child in the car. You naturally step up your focus. The same mindset can work on the job, and it doesn’t have to be exhausting.
When my kids were little, they once stepped into a crosswalk simply because the light read “Walk.” I pulled them back, explaining, “Just because it’s legal doesn’t mean it’s safe. Always look both ways.” Over time, that next-level awareness became second nature to them. Ideally, we want to make our safety habits at work second nature, too, because minimal compliance may be insufficient for adequate protection.
Closing the Gap Between Knowing and Doing
Do your personal safety rules exceed your employer’s minimum standards? The truth is that many of us don’t really know how well we follow the rules. We complete our required training and annual refreshers, but we still have blind spots, gaps between where we are and where we need to be to work as safely as possible. Closing those gaps takes effort, which means many of us stop actively improving as soon as we can. Sometimes, deep down, we think safety is mostly a matter of luck.
That attitude changes when the stakes are obvious and high. A World Series outfielder, a U.S. Navy SEAL or a heart surgeon doesn’t slack off – because they can’t afford to. For each of them, being focused is nonnegotiable. For us, the stakes may not look as dramatic, but the consequences can be just as final, as with the coworkers I lost.
Total Worker Health: A More Complete Approach
We must begin approaching our jobs with the same preparation, mindset and sense of personal responsibility that the outfielder, Navy SEAL and surgeon do. That’s where NIOSH’s TWH comes in, expanding safety beyond accident prevention. It combines safety, health and wellness into one holistic framework designed to help people thrive, not merely survive.
Evidence-based and built on bedrock psychological and safety science, TWH is the foundation of an important new approach to workplace safety. Here’s a simple breakdown:
- Safety is about managing hazards – the mechanical, technical and job-specific risks. If something goes wrong here, you call a safety specialist.
- Health means being free from injury or illness. If this slips, you typically call a doctor.
- Wellness is health actively achieved through exercise, nutrition and social connections. If this dips, you might turn to a trainer, therapist, chaplain or friend.
Technology will become increasingly vital to industry safety and sustainability efforts over the next decade.
Forecasting the Future of Utility Safety: 10 Predictions for 2026 and Beyond
As we stand on the precipice of a new era in the utility sector, it is clear the future holds transformative potential driven by relentless technological progress.
We are already seeing not just small changes but a complete overhaul. The horizon is replete with innovations aimed at redefining safety protocols and operational efficiency. Predicted advancements – ranging from connected monitoring systems to augmented reality (AR) training to robotics – point to a not-so-far-off future in which advanced technologies will be essential to everyday utility operations.
In the remainder of this…
Use leading indicators, meaningful audits and structured corrective actions to strengthen safety management systems.
Safety By Design: Evaluation and Effective Action
The previous articles in this series outlined the essential components of a strong safety management system (SMS). To achieve safety success, electric power organizations must ensure those components align with and support one another.
This article – the last in the series – addresses two final topics of importance: assessing an organization’s SMS performance and implementing a structured corrective action plan in response to identified performance gaps. We will use ANSI/ASSP Z10-2019, “Occupational Health and Safety Management Systems,” as a guide, focusing on performance measurements, incident analyses, audits and corrective actions.
Measuring Operational Safety Performance
To accurately measure SMS functionality and impact, organizations must take a comprehensive approach that goes beyond tracking incidents and OSHA rates. Understanding past issues can be helpful but is insufficient to assess a company’s overall safety effectiveness. As previously noted in this series, some organizations have accumulated thousands of man-hours without any OSHA recordables, yet they still exhibit poor, misaligned work practices in the field.
OSHA highlights the use of leading indicators to accurately measure safety performance; doing so helps the workforce identify and address potential risks. Organizations struggling to develop metrics for leading indicators can consult ANSI/ASSP Z16.1-2022, “Safety and Health Metrics and Performance Measures,” as well as Chapter 17 of ASSP GM-Z10.100-2024, “Guidance and Implementation Manual for ANSI/ASSP Z10-2019 Occupational Health and Safety Management Systems.”
Comprehensive metrics empower electric power organizations to gain deeper insight into their safety performance and identify areas for improvement. Leaders, armed with detailed understanding of this data, can make informed decisions that enhance workplace safety protocols. Additionally, fostering a culture that prioritizes continuous improvement encourages employees at all organizational levels to actively participate in safety initiatives.
Measuring Employee Safety Performance
Some companies have long relied on lagging indicators (e.g., vehicle accidents, personal injuries) to measure employee safety performance. However, using these indicators for performance evaluations and incentive programs can lead to serious problems, as ASSP GM-Z10.100-2024 points out.
In my consulting work, I have observed that employer incentive programs often reward employees for avoiding incidents and injuries. Some companies even tie bonus payments to an entire crew’s record of zero incidents. In rewarding employees this way, leaders risk creating an environment in which employees feel pressured to hide events that do occur. They may hesitate to report injuries, equipment failures or near misses – critical information to help prevent recurrences.
As part of ensuring a truly safe workplace, organizations must periodically reevaluate their incentive programs and performance evaluations, determining whether it is possible to adopt a more proactive approach to safety. It is also wise to promote active employee participation in safety initiatives rather than reward individuals for zero incidents. This requires working diligently to foster an environment in which open discussion of safety concerns is strongly encouraged, inviting employees to share their thoughts without fear.
Further, leaders should strongly consider using awards, public acknowledgments during meetings and even small incentives to recognize employees who report hazards. Organizations that establish comprehensive feedback systems enable employees to share their experiences and suggestions, promoting transparency and the quest for continuous improvement.
Incident Analyses
The primary objective of an incident analysis – a systematic process used to identify an event’s root causes – is to gain a thorough understanding of what happened and then identify and implement corrective measures to prevent a recurrence.
It’s important to remember that incidents often reveal underlying issues that require immediate, decisive action. While a proactive SMS aims to identify and mitigate risks before incidents occur, we must acknowledge that this is not always possible. Therefore, analyzing incidents is a crucial component of an effective SMS.
Both incidents and near misses provide valuable opportunities to identify and address SMS weaknesses. Near misses in particular should be viewed as valuable learning experiences, offering chances to address hazards before they escalate. Some companies mistakenly view incident analyses as opportunities to assign blame; however, their time should be spent
identifying causes and improving safety processes that support workers.
An organization’s response to an incident is revealing. Many companies have been stuck in a long process of analyzing a single incident. By the time they finish, employees often feel frustrated or have forgotten about the analysis. Leaders should act quickly and keep open communication with employees during the whole analysis process.
Audits
Audits play an important role in assessing how well an SMS works, with auditors reviewing safety processes to ensure they align with organizational goals and meet industry standards. Conducting a thorough audit enables leaders to identify opportunities for improvement, confirm regulatory compliance and foster a culture of continuous safety improvement.
When focused on the following items, an audit helps affirm and improve organizational safety performance:
- System performance verification: Audits confirm that SMS components – including hazard identification, risk assessments, training and incident investigations – are functioning as intended and achieving the desired outcomes.
- Conformance assessment: Do organizational activities align with the objectives, policies and procedures established under the SMS?
- Identification of gaps and opportunities: Well-done audits highlight deficiencies, nonconformance and areas for improvement – a solid foundation for corrective and preventive actions.
- Continuous improvement: Audit findings ideally feed into management review and corrective action processes, providing opportunities to fine-tune the SMS based on factual evidence.
- Objectivity: ANSI/ASSP Z10-2019 emphasizes that audits should be conducted by individuals who are completely uninvolved with the activities being examined.
- Documentation and follow-up: Audit results must be documented, communicated to management, and tracked until corrective actions are implemented and their effectiveness has been verified.
2025 Update: Ferroresonance Explained
Ferroresonance is a complicated issue, one that industry workers must be educated about. That’s because as the number of URD system installations grows and systems age, instances of ferroresonance increase – as do threats to worker and customer safety, equipment and service reliability.
I first became acquainted with ferroresonance in the 1980s while troubleshooting a pad-mounted, three-phase transformer at night. The pad fed a chemical plant, closed for the evening, in the middle of nowhere. The 480-volt, 2000-amp main was single-phasing, so plant electricians had dropped all the 480-volt sub-feeds except one: a single-phase, 240-volt sub-panel that fed the plant’s fire control systems plus some lighting that was barely functional (keep this information in mind – it will be important a little later).
The underground radial feed was long, and the A-phase pothead fuse had blown; my first thought was a bad cable. We pulled the radial-fed elbows at the transformer, opened the 2000-amp main and re-fused the pothead. It held – so why had the other fuse blown? Next, we checked the meter’s kilowatt demand, which was barely more than half the peak-load capacity of the 1500-kVA transformer. Then we smoke-tested the transformer, closing it in from the potheads, opening the potheads with a load-break tool, and finally closing in the elbows on the de-energized pad.
The 23-kV potheads were dead-ended on a 10-foot heavy-duty double arm. The fuse for A-phase was on the far side of the arm, on the other side of the neutral from where the bucket truck had been set up. I wasn’t going to side-sling the fuse barrel feeding a 1500-kVA pad, so I boomed over the neutral positioning for the A-phase fuse and closed it. As I was booming back over the neutral to close in B-phase and C-phase, I heard what sounded like a car crash coming from the vicinity of the pad, followed by a flash and something going to ground. The A-phase pothead fuse erupted behind me and the feeder relayed. Back at the pad, A-phase and B-phase elbows were blown off the bushings. The A-phase polymer arrester that was plugged into the feed-through bushings had split down the middle and was still smoking. Additionally, the current transformer cabinet wiring and polyphase Class 10 meter were on fire.
What Happened?
Given that the CEO of the chemical plant was on the utility company’s advisory board, some plant personnel were alerted when we blew up their transformer. Three crew members stayed at the plant to pull the bad transformer and ready a spare three-phase. An apprentice and I went to retrieve a new transformer. On our way to the yard, an engineer on-site at the plant radioed us, requesting that we bring back a 2000-kVA transformer. I asked if he thought the damaged transformer had been overloaded; he said no and told us he would explain more later.
His eventual explanation? You guessed it: ferroresonance.
As it turned out, during our troubleshooting, we had created perfect conditions for the loud noise and fire. No one had known that the capacitive reactance of the cable on A-phase and B-phase was nearly equal to – and in series with – the inductive reactance of the 1500-kVA transformer windings. In the evenings during the off-season, the plant reduced operation and electrical loads. With the matching series reactance of the cable and transformer impedance, the lightly loaded transformer would begin to react, creating low-level ferroresonance that overheated and prematurely aged the transformer until the pothead fuse blew. When we began troubleshooting and opened the main, conditions became ideal for runaway core excitation or ferroresonance. The fact that it had taken me a couple minutes to get from the A-phase fuse to the B- and C-phase fuses – combined with the open main and no secondary load – triggered everything needed to blow up that $60,000 installation.
You may still be wondering why the engineer requested that 2000-kVA transformer. The answer: in observing damage from the incident and speaking with the crew, he recognized the problem and opted for the new transformer to raise impedance. That way, the cable capacitance and transformer inductance would no longer be almost equal.
Need-to-Know Info
Ferroresonance is a rare condition most likely to occur with three-phase, pad-mounted, delta-connected transformers. Not nearly as often, ferroresonance has been documented in wye-wye transformers as well as in aerial three-pot banks served by long-dedicated aerial circuits.
When ferroresonance occurs in a transformer, high voltages three to five times the rated primary can appear on the primary and secondary and in the core. Oil heats to temperature extremes in minutes, blowing out of vents and bubbling paint on top of the transformer. Surge arresters – not designed to clamp sustained overvoltages – can be cooked to destruction and potentially fragment during failure. The rise in primary also increases the secondary voltage, sometimes blowing up meters like bombs. Other times, purely coincidental yet ideal conditions create low-level ferroresonance that can boil the life out of a transformer with barely a whimper. I know of one case in which a 1000-kVA transformer was replaced three times in five years. Finally, the utility realized a low-level resonant circuit – yes, without an open phase – was killing the transformer every night when the commercial building load dropped to about 6% of the transformer’s rating.
URD cables are capacitors; transformer coils are magnetic inductors. To create resonant circuits, there must be capacitive reactance and inductive reactance of almost equal value in series with each other, and the inductor must have very little to no load. The most likely situation is a three-phase transformer fed by a long underground circuit. In some of the most dramatic events, a pothead fuse was opened or blew, allowing a still-energized primary cable (capacitance) to be more or less in series with a coil (inductance). If a series-connected phase-to-coil connection is allowed to remain energized, and there is low loading on the transformer’s secondary or the customer’s mains are open, no impedance exists in the primary circuit. Current is free to flow, and runaway voltage rises in the laminated core – hence the “ferro-” component of ferroresonance.
In testing, loading the secondary above 20% has proven sufficient to prevent resonance. The first indication of the condition is typically a loud rattling noise – often described as shaking a coffee can full of marbles – emanating from a transformer due to magnetostriction in the laminated core (note that normally, magnetostriction causes the 60-Hz hum in transformers). The noise is wicked enough that almost no one who hears it stands around to see what is going to happen next.
The two other ferroresonance cases I have worked on both involved amorphous-core, three-phase, pad-mounted, wye-delta transformers. One was 1,700 feet of 1/0 to a 1000-kVA; the other was 2,000 feet of 1/0 primary to a 1500-kVA pad-mount. These are not formulas for determining the potential for ferroresonance but examples of the conditions present when it has occurred.
Preventive Efforts
So, what’s the best way to avoid suspected resonant circuits? Never open three-phase transformers one phase at a time from potheads or lateral taps. Some utilities are using an air-break or AB switch to isolate the coil before switching potheads.
Other methods include shortening the primary run to change capacitance or replacing transformers to ensure different inductive impedance values. Rural electric association specs add a fourth dropout to temporarily ground the high-side floating neutral when energizing or de-energizing three-pot banks. The goal is to split the series path between the primary feed and the transformer coils, removing the series reactance, which is a prime condition necessary to create the resonant circuit.
The last preventive effort is leaving some or all of the secondary load connected. This, of course, contradicts what we have always been told (i.e., “Don’t single-phase the customer”), but not to worry. You won’t kill the three-phase customer equipment in the time it takes to close three pothead switches – and you’ll almost certainly avoid blowing up a costly transformer.
About the Author: After 25 years as a transmission-distribution lineman and foreman, Jim Vaughn, CUSP, has devoted the last 28 years to safety and training. A noted author, trainer and lecturer, he is a senior consultant for the Institute for Safety in Powerline Construction. He can be reached at jim@ispconline.com.
Editor’s Note: This is an update to Jim Vaughn’s article “Ferroresonance Explained,” first published by Incident Prevention magazine in 2012.
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