Donnie Johnson: The Story of

an Arc Flash Survivor

Twelve years ago, August 12 started just like any other morning for electrical
contractor Donnie Johnson. Except for one thing: Tampa, Florida, the city where
he lived and worked, was bracing for Hurricane Charlie, and his job was to
connect a large electrical generator to a giant frozen foods warehouse facility in
preparation for it. An electrician for almost two decades, he had told his wife just
before they married, "As long I have these (hands), we will always have money."
All of this came to an abrupt halt when Donnie, husband and father of two,
suffered third-degree burns down to the muscle on both arms and hands and
second-degree burns to his face, head, and neck due to an arc flash explosion.
He acknowledges that his severe injuries were preventable had he been
following the safety procedures and wearing PPE. The heat of the arc blast
seared through him in a split second at a temperature the burn unit doctors told
him was seven times as hot as the sun's surface. When his wife came to the
accident scene, she could only identify him by recognizing his boots sitting near
his stretcher in the ambulance.
It's important to note that while Donnie miraculously survived, he has devoted a
big part of his life to telling his story. Why? In his own words, "I'm not offering
'arc flash' education or providing safety rules or guidelines, I am simply telling
what could happen if you don't follow your safety procedures," he writes on his
website, Donnie's Accident. "This is about my personal experiences before,
during, and since the accident. Also how it affects you and those who care about
and depend on you.... All of this happened to me because I wasn't wearing my
safety gear."
In an email conversation with Donnie, he relayed this: "If I can make one guy
use his PPE, then I've done something! Jobs are dangerous enough out there
without adding to it by not following safety procedures or wearing PPE!"
Reading Labels, Wearing PPE May Have Prevented This Accident
As a service electrician, Donnie was wiring a large, semi-trailer mounted
generator to an electrical system. He had the wiring in place and terminated. It
was at this point, Donnie said, where he should have reached into his fully
stocked PPE bag. Instead, he thought, "What could possibly happen as long as I
am careful?" and "All that gear is so hot and bulky."
The meter he had been using for several months to check rotation was not a
phase rotation meter, but a motor rotation meter. He neglected to read the
warning label, stating it was not to be used on live circuits. He checked the
electrical rotation on the 480 volt generator, fully energized to get an accurate
reading. He opened the electrical cabinet panel, connected the first two clips,
but as he attempted to clip the third, the meter failed and blew a puff of carbon
into the electrical gear.
"This is the equivalent of throwing a cup of water into the electrically energized
gear," Donnie explained. "The carbon set off a carbon arc between the three
phases in the switch gear, shorting all three phases together and causing an
explosion with an arc flash or blast. All of this happened in a split second. As I
was being blown to the ground, I actually saw a two- to three-foot ball of white
light, or basically a ball of lightning."
The loud explosion from the erupting heat can cause heat or metals to be
inhaled into the lungs and solidify. He could only hear a sizzling noise. The only
other workers had escaped the scene when the explosion happened, so he was
alone. In shock, he pulled himself out of the darkened building, with his first
thought being how he was going to get the power back on. As people ran toward
him, he was starting to realize just how badly he had been injured by their
reactions. Although he was conscious, with burns as severe as his were, the
explosion damaged his small nerve endings, causing him not feel the pain yet.
He asked a worker to call his wife and tell them he'd be transported to Tampa
General Hospital because he couldn't put his hands in his pockets to retrieve his
phone. Paramedics arrived and cut his clothing away from his body. At the
hospital, doctors inserted a breathing tube because the swelling from the burns
was making his windpipe swell shut. Doctors then made incisions the entire
length of each arm in order to relieve the swelling.
Over the next few weeks, surgeons grafted skin to his arm. He developed an E.
Coli infection in his lungs, the first of many infections. With skin being the main
protector from infection, the burns brought Donnie's healing process to a virtual
standstill. He developed pneumonia and blood infections. A surgeon removed
about a one-inch section of his trachea. He developed an infection and it
ruptured the stitches that held the re-section together. He had a tracheotomy,
with a tube inserted to bypass the surgical site to allow it to heal. Then, two
months later, another surgery was performed to close the tracheotomy opening.
He had surgery on his hand to relieve scar bands and almost lost his thumb. His
windpipe was also collapsing from scar tissue caused by the breathing tube
being in for so long. They found he was allergic to one of the medicines, which
was causing complete organ failure. His only source of nourishment was an IV
drip.
One Split-Second Arc Flash Explosion Brought Almost Two Years of
Rehabilitation
Rehabilitation to build the atrophied muscles would take more than a year and a
half of therapy. Donnie weighed 165 pounds upon entering the hospital. His
severe pancreatitis and fear of how his digestive system would react to food
made eating impossible, and after a month and a half in a coma, he dropped 50
pounds. His arms and legs were the same size as his 9-year-old son's, including
the thick bandaging. The pain from the actual burns subsided, but the graft sites
on his legs still caused intense pain.
All the while, the east coast of Florida was being ravaged by hurricanes Francis
and Jeanie. Donnie's surgeries and recovery lasted almost two years, and as he
points out repeatedly on his website, all because he didn't take less than a
minute to put on his arc flash PPE.
Life After Donnie's Arc Flash Explosion Accident
Donnie started back to work in the office at the beginning of 2006. Today, he is
closing in on his 22nd year with the same electrical contractor, Borrell Electric
Company, where he was recently promoted to Service Department manager. He
and his wife also present workplace safety around the United States. Since
releasing the Donnie's Accident video, he has received emails from more than
150 countries and 150,000 unique visitors. How does this celebrity status feel?
In an email exchange, Donnie said, "I'm very proud that safety managers around
the world are using my video as part of their employee training. Even with full
safety training, it is hard to fight complacency.... I hope I can make a difference
and with all good intentions, open some eyes. Accidents will happen, but if I had
been wearing my PPE I would have probably only gone to the hospital for a
checkup and minor injuries. I'm no safety expert, but I try to provide an example
of what could happen if you don't follow your safety procedures, and I was lucky!
"When someone complains about the safety gear being hot, uncomfortable, or
too bulky, I pull up my sleeves and tell them, 'It's a hell of a lot more
comfortable than living with this for the rest of your life.... If you make it.'"
Sally Murdoch is the Content Manager & Public Relations Specialist at Graphic
Products, Inc., which is located at 9825 SW Sunshine Court, Beaverton, OR
97005, 888-326-9244. Although Donnie's injuries were electrical in nature, many
professions rely on visual communication to warn of arc flash or LO/TO danger,
whether you're a plumber, a carpenter, or a mason. Graphic Products specializes
in both premade and custom arc flash labeling, best done with a thermal
transfer systems, such as the DuraLabel Toro. As well as an arc flash guide
developed by Graphic Product partner EasyPower, we have a guide specifically
on arc flash labeling.
Posted on Aug 23, 2016