An arc flash incident occurred during electrical maintenance activities on a 480V motor control center (MCC) aboard a fixed offshore facility in the Gulf of America on March 21, 2025. Two contractor technicians were troubleshooting a tripped MCC bucket Figure 2) when an arc flash occurred. One technician, despite wearing Category 2 arc-rated Personal Protective Equipment (PPE), sustained first- and second-degree burns to the hands, arms, and face (Figure 1). The second technician was not injured. Although the MCC had reportedly been de-energized and locked out, the investigation revealed that voltage verification at the load-side terminals was not performed. A source of induced or backfed voltage remained present. When the technician attempted to withdraw the MCC bucket, this unidentified voltage source caused an arc flash and the release of stored electrical energy. This incident underscores the critical importance of verifying zero energy at the exact point of work, regardless of Lockout/Tagout (LOTO) status, and highlights the need for strict adherence to electrical safety protocols in offshore environments.
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