Tutorial B:

Conducting an Arc Flash Hazard Analysis

to Determine the Maximum Likely Incident
Energy in Plant Electrical Arcs; and
Methods to Manage the Hazard
H Landis Floyd
Daniel R Doan
Craig M Wellman
Arc Flash Hazards Analysis

H. Landis Floyd

2
 Tutorial Agenda

• History, Research, Regulations -

Lanny Floyd
• Incident Energy Assessment,
Spreadsheet Use - Dan Doan
• Engineering and Administrative
Controls, PPE - Craig Wellman

3
Managing Arc Flash Hazards

• How we got to where we are

• Impact of 2000 revision to NFPA70E
• Implementation tools

4
 DuPont
Arc Flash Injury Performance
1992 - 1999

• 148 Arc Flash Incidents

• 21 Injuries

• 1999
– 14 Incidents
– 4 Injuries

5
 Arc Flash Timeline
1968 Dow implements arc flash PPE program

1980 Published article on use of arc flash PPE

1981 Ralph Lee publishes theory for hazard

calculations

1986 DuPont implements arc flash PPE

program

1990 OSHA subpart S does not address arc

flash details
6
 Arc Flash Timeline
1994 OSHA 1910.269 addresses clothing hazards

1995 DuPont undertakes arc flash R&D

1995 ASTM Arc Test Method development

1995 NFPA70E defines arc flash boundary

1996 DuPont arc flash research published

7
 Arc Flash Timeline
1997 DuPont protective clothing research
published

1998 ASTM standards for PPE testing

1999 Arc Flash rated PPE appears

2000 NFPA70E expands arc flash

requirements
2002 NEC requires arc flash hazard warning

8
 Bad things can happen.
An electric arc fault is a bad thing.

9
10
11
12
 Why is Burn Injury
a Major Concern?
• The most severe burns are caused by
ignited clothing, not by the original
flash fire or electric arc exposure.
• Clothed areas can be burned more
severely than exposed skin.

13
 Clothed areas can
be burned more
severely than
exposed skin

14
 Injury Consequences

• Burn injuries can be fatal

• Survival depends on age, health,
exposure intensity and time, area of
the body burned
• Treatment of second degree burns
requires weeks, for third degree
burns it can be years
15
Treating Burn Injury Is Very
Expensive
• The cost of treatment can exceed
USD1,000,000 for a single case.
• Treatment can require years of
skin grafting and rehabilitation.
• The victim may never be able to
return to work.
16
The Personal Cost Is Devastating
• Due to disfigurement and intense pain
the victim will often not want to live,
depression is common.
• Children will likely not be able
recognize the burn victim after the
accident.
• The victim’s spouse will be
traumatized, divorce is common.

17
The Past:

• No standard methods to
determine incident energy of
a potential arc hazard

• No standard methods to rate

PPE performance
18
Today:

Technology exists to determine

incident energy and establish
PPE ratings.

19
 Standards
• ASTM F1958-99 Standard Test Method for Determining the
Ignitability of Non-flame-Resistance Materials for Clothing
by Electric Arc Exposure Method Using Mannequins
• ASTM F1959-99 Standard Test Method for Determining the
Arc Thermal Performance Value of Materials for Clothing
• ASTM F1506-01 Standard Performance Specification for
Flame Resistant Textile Materials for Wearing Apparel for
Use by Electrical Workers Exposed to Momentary Electric
Arc and Related Thermal Hazards
• ASTM F1891-00a Standard Specification for Arc and Flame
Resistant Rainwear
• NFPA70E-2000 Standard for Electrical Safety Requirements
in Employee Workplaces 20
 Incident Energy

• Energy Per Unit of Area Received On A

Surface Located A Specific Distance Away
From The Electric Arc, Both Radiant And
Convective, in Units of cal/cm2.

21
 Cal/cm2
• 1.2 cal/cm2 - Second Degree Burn
• 3 cal/cm2 - 1% probability ignition
of light weight cotton shirt.
• 6 cal/cm2 - Arc Rating of 1 layer 6
oz/yd2 aramid.
• 32 cal/cm2 - Arc Rating of one layer
6 oz/yd2 plus 4.5 oz/yd2 aramid
over a cotton T-shirt.
22
 Highlights of
changes impacting
arc flash hazards
PPE in the 2000
edition of NFPA70E

23
 NFPA70E - 2000

Where it has been determined that work will be

performed within the flash protection boundary,
the flash hazard analysis shall determine, and
the employer shall document, the incident
energy exposure of the worker

24
This incident energy exposure level shall be
based on the working distance of the
employee’s face and chest areas from a
prospective arc source for the specific task to
be performed.

25
Working Distance
480V
MCC

26
Flame Resistant Clothing and Personal
Protective Equipment shall be used by the
employee based upon the incident energy
exposure associated with the specific task.

27
 Chapter 3
Protective Equipment
3-1 General.
Employees working in areas where there are
electrical hazards shall be provided with, and
shall use, protective equipment that is
designed and constructed for the specific part
of the body to be protected and for the work
to be performed.

28
 3-3 Personal Protection
Equipment.

3-3.1 General.
When an employee is working within the
flash protection boundary, he/she shall wear
clothing and other protective equipment in
accordance with 2-[Link] of Part II.

29
3-3.2 Movement and Visibility

When flame resistant (or fire retardant treated)

clothing is worn to protect an employee, it
shall cover all ignitable clothing and shall
allow for movement and visibility.

30
 3-3.5 Body Protection

Employees shall wear clothing resistant to

flash flame wherever there is possible
exposure to an electric arc flash.

31
Such clothing can be provided as shirt and
trousers, or as coveralls, or as a combination
of jacket and trousers, or, for maximum
protection, as coveralls and jacket. The
higher degree of protection is provided by
heavier fabrics or by layering combinations
of natural fiber clothing resistant to electric
arc flash (under layers of fire resistant
clothing.)

32
Personal Protective Equipment
Flash Burn Protection

33
 3-[Link] Outer Layers

Garments worn as outer layers over FR

clothing, such as jackets or rainwear, shall also
be made from FR material

34
 3-[Link] Underlayers

Meltable synthetic fibers shall be avoided in

fabric underlayers next to the skin. Garments
worn as underlayers (underwear) that neither
ignite nor melt and drip in the course of an
exposure to the electric arc and related
thermal hazard may provide additional
thermal protection.

35
 3-[Link] Coverage

Clothing shall cover potentially exposed areas

as completely as possible.

36
3-3.9.4 Factors in Selection of
Protective Clothing
Protective clothing includes shirts, pants,
coveralls, jackets, and parkas worn
routinely by workers who, under normal
working conditions, are exposed to
momentary electric arc and related thermal
hazards. Arc and flame resistant rainwear
worn in inclement weather are included in
this category of clothing.
37
Clothing and equipment that maximize worker
protection shall be utilized. Clothing and
equipment required by the degree of exposure
shall be permitted to be worn alone or be
integrated with normal apparel. It shall cover
associated parts of the body and all normal
apparel that is not flame-flash resistant, while
allowing movement and visibility.

38
All personal protective equipment shall be
maintained in a sanitary and reliable condition.
Individual protection items will normally be
used in conjunction with one another as a
system to provide appropriate protection.

39
 3-[Link] Layering

FR and natural fiber garments shall be

permitted to be used for a layered system for
added protection. A typical layering system
may include an undershirt, a shirt and trouser
and coverall. Specific tasks may call for
specific protection systems.

40
41
The 2002 Edition of the National Electrical Code
will have this new requirement in Article 110.16

110.16 Flash Protection. Switchboards, panelboards, and motor

control centers in other than dwelling occupancies, that are likely to
require examination, adjustment, servicing, or maintenance while
energized, shall be field marked to warn qualified persons of
potential electric arc flash hazards. The marking shall be located so
as to be clearly visible to qualified persons before examination,
adjustment, servicing, or maintenance of the equipment.
FPN No. 1: NFPA 70E-2000, Electrical Safety Requirements for Employee
Workplaces, provides assistance in determining severity of potential exposure,
planning safe work practices, and selecting personal protective equipment.
FPN No. 2: ANSI Z535.4-1998, Product Safety Signs and Labels, provides guidelines
for the design of safety signs and labels for application to products.

42
 Summary so far...
• Arc Flash Hazard just recognized
in last decades of the 20th century.
• Regulations and standards
developed in the last decade.
• We have the tools to assess the
hazard.
Questions?
43
Arc Flash Hazard Analysis

Daniel R. Doan
44
 Methods of Analysis

• 70E equations
• Arc Pro
• Use of C. L. Fuses to
Reduce Arc Flash Energy
• Worksheet
• All rigorous methods require the
same steps
45
 Arc Flash Hazard Analysis

• Review the steps for analysis

• Example
• Document Control

46
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault currents in protection
Step 4 Find arc clearing times
Step 5 Determine working distance
Step 6 Calculate the incident energy

47
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions

48
Step 1. Determine plant conditions
- Review system single line and operation.
- List conditions, such as:
Normal operation
Loops closed
Transformers in parallel
Dual Feeds
- Do analysis for each condition that applies

49
Example
System

50
Step 1 - Example conditions

• Two main transformers, Loop open

(Normal condition)
• Two main transformers, Loop closed
• One main transformer, Loop open
• One main transformer, Loop closed

51
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find bolted short circuit fault values

52
Step 2. Find Short Circuit Values
- If available, look at previous studies or
design calculations
- Use a vendor’s on-line program
- Use a short circuit study program for large
or complicated systems

53
Step 2. Find Short Circuit Values

- Determine symmetrical three phase fault

values for the 1.5 to 4 cycle case.
- Don’t add a safety factor. Higher current
can give shorter arc fault duration and the
wrong energy value.
- Example of a system entered into a
commercial program

54
55
 Example
• Create Single Line - layout, bus names
• Enter details on transformers, buses,
substations, and feeders
• Enter large motors
• At MCC Level, enter single motors if
above 100 HP

56
57
 Example
Bolted
Fault
Bus Name Voltage kA
Switch Center 1 12kV 9
Substation Bus 480V 52
MCC 480V 41

58
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault current in protection

59
 Step 3. Find Arcing Current

- Arcing fault current is less than bolted fault

(systems no higher than 690 Volts) .

-- Arcing Fault Current is the same as the

bolted fault current in systems over 690 V.

60
 600V, 3-Phase Arc Current As A
Function Of Bolted Fault Current
50
45
40
Arc Current, kA 35
30
25
20
15
10
5
0
0 10 20 30 40 50 60 70 80 90 100 110
Bolted Fault Current, kA

61
Find arcing fault current using equations

For < 1 kV,

FA = - 0.003 FB 2 + 0.734 FB + 1.356
where:
FA = Arcing fault current in kA
FB = Bolted fault current in kA (5-106 kA)

For > 1 kV,

FA = FB

62
 Step 3. Find Arcing Current in
Protection
• Arcing current divides between multiple
sources

• Motor contribution from the faulted bus

doesn’t go through the fuse or breaker.

• Study report will show contributions from

motors and different buses
63
64
 Step 3. Find Arcing Current in
Protection
Bolted Arcing
Total 52,000 100.0% 31,400
From:
Bus A 26,000 50.0% 15,700
Bus B 24,000 46.2% 14,492
Motors 2,000 3.8% 1,208

65
 Example
Bolted Arcing
Fault Fault
Bus Name Voltage kA kA
Switch Center 1 12kV 9 8.7
Substation Bus 480V 52 30.5
MCC 480V 41 25.6

66
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault currents in protection
Step 4 Find arc clearing times

67
 Step 4. Arc Clearing Times
• Get system coordination drawings.
• Update as required.
• Get protective device Time-Current Curves for
simple case
• Use arcing fault current in protective device.
• Arc clearing time = Trip time + Operating time
= Melting time + Arcing time
68
 Current in Amperes: x 100 at 0.48 kV and x 4.000 at 12 kV.
1000
XFMR FLA
9-Fuse
S&C SM4,5 STD 25KV
100E A
12 kV
12-Relay GE IAC-77
8-Transformer TapRange:[0.25 / 12.0] Tap:5.00 TD: 4
Z=5.86 % Pick Up:1200 A 12 kV
P=1000 kVA CT: 1200:5
0.48 kV
FLA=1202.81 A

6-Fuse
GE CLF-CLASS L
100 1200 A
0.48 kV
5-LVCB GE SST
Sen:600 LTM:1.000 LTB:3
INST: 8.000

2-Fuse
BUSS LPS-RK-1
400A
0.48 kV Cold Stall Time
Hot Stall Time

10 4-Cable
350 KCMIL (CU)
E.P.R.
(1/phase) 0.48kV

1-Motor Starting
Full Load:360.0 A
Locked Rotor:2160.0 A
Acc. time:2.00 sec

1
Time in Seconds

XFMR INRUSH
.1

5 2
V C B 1 2 0 0 A

1 2 5 1

1 2 0 0 :5

1 2 0 0 0 v o lts

9
F:21000A
8 1 0 0 0
k V A

M A IN B U S 4 8 0 V ,1 0 0 0 A
6

1 2 0 0 A C L F
F 2 1 0 0 0 A mp s
5

A K U 2
- 5 6 0 0 A F /6 0 0 A S

C A B L E 2 3
- /C 3 5 0 M C M

D IS C 6 0 0 A
2

L P S R
- K 4 0 0 A

1 M 3 0 0
h p

.01
.5 1 10 100 1000 10000

TIME CURRENT CHARACTERISTIC CURVES

Substation 80J - N. AIR COMPRESSOR GE SST Trip Unit - Existing Settings
NO: TCC-1A
CURVES ARE PLOTTED TO 0.48 kV DATE: 1-26-1999

69
Step 4. Arc Clearing Times - CLF
Use maximum melting time from fuse
curve if fault current is not in limiting
range
Limit point is the 0.01 sec point on the
fuse curve.
For 1-2 times limit point in amps, use
0.008 seconds (1/2 cycle)
Over 2 times limit point, use 0.004
seconds (1/4 cycle)
70
Step 4. Arc Clearing - Relays, Bkrs

•Get relay trip times from curves

Instantaneous: use 0.01 sec
•Use typical breaker operating times
LV Power Breakers .05 sec
MV Breakers .08 sec
HV Breakers .13 sec
•Clearing Time = Trip time + Operating Time
71
 Example

Bus Name Trip Operating Clearing

Time Time Time
Switch Center 1 0 0.4 0.4
Substation Bus 0.15 0.05 0.20
MCC 0.25 0.05 0.30

72
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault currents in protection
Step 4 Find arc clearing times
Step 5 Determine working distance

73
 Step 5. Working Distance
- Depends on task and equipment
- Small distance increase makes a big
difference in incident energy
- General work: 18 inches (50 cm)
- MV: consider tasks with 36 inches
(100 cm) distance
- HV: may be remote air switches, use
larger distances like 72 inches (2 meters)
74
 Example

Bus Name Working Distance (in)

Switch Center 1 36
Substation Bus 18
MCC 18

75
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault currents in protection
Step 4 Find arc clearing times
Step 5 Determine working distance
Step 6 Calculate the incident energy and arc
flash boundary
76
Step 6. Calculate Incident Energy
- Now you have all the data you need
- Insert data in Worksheet
- Use equations
- Example

77
 380-1000V, 3-Phase "Arc-In-Box"
Maximum Incident Energy Algorithm

EMB = 1038.7 D -1.474 t [.0093FB2 - 0.3453 FB +5.9675]

where:
EMB = Maximum Box Incident Energy, cal/cm2
D = Distance From Electrodes, inches (DB>18)
FB = Bolted Fault Current, kA (16-52 kA Range)
t = Duration of Arc, seconds

78
 380-1000V, 3-Phase
“Arc-In-Box” Algorithm Solved For
Boundary Distance
D = [ (t/EMB) (9.66 FB2 - 358.7 F + 6198) ] 0.6785
Equation can define boundary distance
For specific incident energy levels such as:
• 2nd Degree Burn Boundary of Bare Skin
• FR Clothing Protection Boundary

79
 > 1 KV, 3-Phase, Incident Energy
Algorithm - Lee Theory

EMB = 793 FB V t / D 2
where:
EMB = Maximum Box Incident Energy, cal/cm2
D = Distance From Electrodes, inches (DB>18)
FB = Bolted Fault Current, kA
V = System Ph-Ph Voltage, kV
t = Duration of Arc, seconds

80
 Example

Bus Name Incident Energy(cal/cm2)

Switch Center 1 22.1
Substation Bus 28.2
MCC 30.0

81
 Final Results

• Run calculations for all conditions

• Put together in summary
• Group by voltages or by area

82
 Equation Limitations

• LV Equations per current published research are

limited to Bolted Fault currents between 16 kA
and 52 kA.
• Theoretical equations have no limit, but are
incorrect when compared to actual tests.
• Developed a method to use theoretical equations
to extend the range of useful equations...

83
 Compare Equations
At 480V, Fault of 16kA, and Distance of 36 inches,
Equation 1 (Research) returns 7.5 cal/cm2
Equation 2 (Theoretical) returns 4.7 cal/cm2
Scale factor k = 7.5 / 4.7 = 1.61
Now use Equation 2 multiplied by k when Fault is
less than 16 kA.
Similar method applied for over 52 kA

84
 50.00
45.00
40.00
35.00
30.00
Energy

Uncorrected
25.00
Corrected
20.00
15.00
10.00
5.00
0.00
0.00 10.00 20.00 30.00 40.00 50.00
Bolted Fault, kA

85
 Common Mistakes
1. Use the wrong current.
Remedy: The arcing fault current should be used to
determine TA. The bolted fault current should
be used in the incident energy equation.

2. Forget to consider multiple sources of fault

current.
Remedy: In loop systems the fault current will
probably be divided between two protective
devices - making the arcing time much longer.

86
 Learnings
1. Found MCCs and buses with much
higher energy levels than expected

2. Current Limiting fuses don’t always keep

the energy below 1.2 cal/cm2.

3. Non-fused LV Breakers can give very

high energy levels, depending on
settings.

87
 Spreadsheet available at
PCIC Website

At the Safety Subcommittee web page,

[Link]

88
 Arc Flash Hazard Analysis
Step 1 Determine plant conditions
Step 2 Find short circuit fault values
Step 3 Find arcing fault currents in protection
Step 4 Find arc clearing times
Step 5 Determine working distance
Step 6 Calculate the incident energy
Final Results and Document Control
Questions?
89
 Arc Flash Hazard
Managing the Hazard

Craig M. Wellman

90
 Managing the Hazard
• PPE Program
– Apply PPE to protect people
• Administrative controls
– Operate/maintain so as to minimize the hazard
• Engineering controls
– Design to minimize the hazard

91
 PPE program

• Assess functional needs

• Plan for garment management
• Train users
• Institutionalize program

92
 PPE program

• Assess functional needs

– Determine incident energy (E) levels for
equipment
– Determine tasks in equipment requiring PPE
– Job factors - duration, weather, dexterity,
vision

93
 Classes of equipment
Panelboards, drives, starters, controllers, transformers, 240V to 690V,
fed by breaker
600 V class motor control center (MCCs) fed by fused switch or breaker
with limiter
600 V class MCCs and plug- in- bus duct fed by breaker without limiter
600 V/ 1000 V class switchgear
Other 600 V/ 1000 V class equipment
Fused contactor type motor starters, 1kV to 5kV
Metal- clad switchgear, 1 kV to 5 kV
Metal- enclosed switchgear, 1 kV to 5 kV
Metal- clad switchgear, > 5 kV
Metal- enclosed switchgear, > 5 kV

94
 Example site task list
Reading a panel meter while operating a meter switch
CB or fused switch operation with enclosure doors closed
CB or fused switch operation with enclosure doors open
Work on energized parts, including voltage testing
Work on control circuits with energized parts I20 V or below exposed
Work on control circuits with energized parts >120 V exposed
Insertion / removal / racking / of CBs / units from cubicles, doors open
Insertion / removal / racking of CBs / units from cubicles, doors closed
Application of safety grounds, after voltage test
Removal of bolted covers (to expose bare, energized parts)
Opening hinged covers (to expose bare, energized parts)
Opening voltage transformer or control power transformer compartments
95
 Task list guidance
• One level of PPE per class of equipment may not
be reasonable
• One or two feeds
• Doors
• Medium voltage applications where resistance
grounding is used, in either modern metal clad
switchgear (includes sleeves over stabs) or
shielded cable

96
 PPE Program
• Garment management plan
– Assignment plan - People/group/location?
Number?
– Maintenance plan - Contract vs. individual
– Select PPE for E levels, tasks, job conditions,
• Everyday wear

97
 FR garments rated by
fabric weight
• Men’s and women’s lines
– Shirts 4.5 oz and 6 oz
– Lab coats 6 oz
– Pants 6 oz, 7.5 oz, 8.5 oz
– Bib overalls 6 oz
– Coveralls 4.5 oz, 6 oz, and 7.5 oz
– Knit shirts 6.5 oz and 9.5 oz
– Hooded sweatshirts 9.5 oz
– Switching coats 7.5 oz, 10 oz
98
Flame resistant shirt

(Pants also needed) 99

Face shield
• Green face shield with
extenders provides 8 cal/cm2
protection to front

• Clear face shield provides

very limited protection

• Does not protect rear of head

as required (Knit balaclava)

• Hooded sweat shirt works

for 8 cal/cm2

100
 FR garments tested and
rated in cal/cm2 by NRTL
Levels Products
8 Face-fitting face shield
31 Bib-overalls, jacket, coat, hood
45 Insulated FR coveralls
50 Bib-overalls, coat, hood
100 Bib-overalls, coat, hood

101
Arc Flash Protection for up to 31 cal/cm2

(FR pants also needed)

102
 Protection for lower energy levels

Head
Clothing Protection Rating in cal/cm2

Street clothing Safety glasses 0

6 oz. FR shirt and

pants Same 1.2

Faceshield and
Same balaclava 6

Same + 6 oz FR Hood, 31
coveralls cal/cm2 20

103
 Protection for higher levels
FR Clothing Head protection Rating in
cal/cm2
6 oz coveralls + coat with 50 c/c hood 50
two 10 oz layers
31 c/c coat + pants 31 c/c hood 31

6 oz coveralls + 31 c/c 50 c/c hood 40

coat and pants
50 c/c coat + pants 50 c/c hood 50

100 c/c coat + pants 100 c/c hood 100

Calories/cm2 (c/c)
104
 Typical rainwear and
chemical splash products
• Raincoats
• Jackets, pants
• Arc flash hoods
• Acid gear

105
Arc rated rainwear

106
Usability Issues - Heavy PPE
• Traps body heat
• Fogs up, limited ventilation
• Visibility
• Communication
• Stiffness

107
 PPE Program
• Functional needs
• Garment plan
• Training
• Institutionalize
– Document all plans
– Post E levels
– Enforce
– Update
108
 2002 NEC has arc hazard label
requirement - Here is one solution

(FR material)

109
 Top half of label -
Printed in quantity

! WARNING
Arc Flash and Shock Hazard
Appropriate PPE Required

110
 Bottom half of label -
Custom printed
24 inch Flash Hazard Boundary
3 cal/cm2 Flash Hazard at 18 inches

480 VAC Shock Hazard when Cover is removed

36 inch Limited Approach
12 inch Restricted Approach - 500 V Class 00 Gloves
1 inch Prohibited Approach - 500 V Class 00 Gloves
Date: 6/28/2001

Bldg. ECR #1 Equipment Name: Slurry Pump Starter

111
 Managing the hazard --
Administrative controls
• Operate and maintain in a way that
minimizes the hazard
– Site team can provide
• Site procedures
• Training
• Process hazards analysis for electrical rooms
• PPE program requirements

112
 Site operating and
maintenance procedures
• Lock and tag
– General and equipment specific
• Maintenance Grounds
– How? Where? When? With what?
– How assure removal?
• Switching
– Recognize the hazard of tying two buses
together and minimize the time
113
 Transfer of Loads From Sub O To Sub P

SUB O
•Check Voltages & Loads on Subs O & P.
SUB P
•Lead & Backup Person Put on Appropriate PPE.
•Remove Locks & Close Tie Breaker.
•Open & Lock Both Sub O Primary Breakers.
•Remove Spare Breaker From Top Fdr 1 Compt
•Megger Spare Breaker & Re-Install.
•Remove Cover Plates For Fdrs 2-6 Top Compts.
2500 KVA 2500 KVA •Close Top Spare Breaker For Fdr 1.
11.4KV / 480V 11.4KV / 480V
•Open Bottom Breaker For Fdr 1.
•Move Bottom Fdr 1 Breaker to Top Fdr 2 Compt.
•Close Top Breaker for Fdr 2.
•Open Bottom Breaker For Fdr 2.
SPARE
•Move Bottom Fdr 2 Breaker to Top Fdr 3 Compt.
•Close Top Breaker for Fdr 3.
TIE
1 2 3 4 5 6 BKR
•Open Bottom Breaker For Fdr 3.
•Continue Until All Loads Are On Top Bus, Sub P.
•Open & Lock Tie Breaker.
OLD HICKORY •Replace Cover Plates For Fdrs 1-5 Bottom Compts
CRYSTAR
•Remove PPE.
114
 Restoring Subs O & P Back to Normal
SUB O SUB P •Lead & Backup Person Put on Appropriate PPE
•Remove Cover Plates For Fdrs 1-5 Bottom Compts
•Remove Locks & Close Tie Breaker.
•Close Bottom Breaker for Fdr 6.
•Open Top Breaker For Fdr 6.
•Move Top Fdr 6 Breaker to Bottom Fdr 5 Compt.

2500 KVA 2500 KVA •Close Bottom Breaker for Fdr 5.

11.4KV / 480V 11.4KV / 480V
•Open Top Breaker For Fdr 5.
•Move Top Fdr 5 Breaker to Bottom Fdr 4 Compt.
•Close Bottom Breaker for Feeder 4.
•Open Top Breaker for Feeder 4.
•Continue Until All Loads Are Back to Normal..
•Replace Cover Plates For Fdrs 2-6 Top Compts
TIE •Spare Breaker Will Be In Top Fdr 1 Compt.
1 2 3 4 5 6 BKR
•Remove Locks & Close Sub O Primary Breaker.
•Open & Lock Tie Breaker.
SPARE

OLD HICKORY
•Remove PPE.
CRYSTAR •Check Voltages and Loads on Both Subs O & P.
115
 Training
• What training is needed?
– OSHA
– NFPA 70E
– Company level practices
– Site specific procedures
– Equipment specific (Model 7700)
– Use and care of PPE

116
 Process hazards analysis
for ECRs, Switchyards
• Get help on running analysis
• What are the hazards?
– Shock, arc flash, fire, fall
• How can you mitigate them?
– How call for help? -- Phone and FA available
– Exit signs and lights
– PPE available
• Can you reduce the likelihood?
– How turn off power? -- Single lines posted
– Identification and warning labels
– Provision for locks where needed
– Minimize obstructions,117stored material
 Engineering Controls --
Design to minimize the hazard
• Reduce need for work on energized equipment
• Reduce probability of three phase faults
• Reduce fault current
• Reduce fault duration
• Reduce impact of arc flash on people
• Provide information on available fault energy

118
Studies reveal all electrical injuries
involve energized equipment!
• Most organizations prohibit hot work,
(except testing.)
• Why do injuries still occur?
– Testing
– Racking in breakers
– Operating switches and circuit breakers
– Equipment failures when no work underway
– Job expanded beyond original intent - #1 reason!
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Reduce need for work on or near
energized equipment
• Design to enable shutdowns
– Unitize loads - group by process function
– Provide dual feeds to critical equipment -
controls
– Money is always available for safety
• Design for easy testing and grounding
• Design for remote racking and operation
• Install warning labels
120
 Reduce probability of
three phase faults
– Metal clad vs. metal enclosed switchgear
– Insulated bus
– Resistance grounded system
• Low resistance grounded - > 1 kV
• High resistance grounded - 480 V, 400 V
– Adequate ground fault return path
– Connection points for ground jumpers

121
Maintenance grounding stud
480vac Side of 12,000 to 480 transformer

122
 Reduce fault current
• Fast current limiting fuses
– Limiter fuses on 480 V feeder breakers
• Resistance grounding
– HRG on 480 V systems
– LRG on 2.4 kV to 22 kV systems

123
 Reduce fault duration
• Use current limiting fuses
• Tighten up the coordination
• Select protective devices for people
protection as well as equipment
protection and reliable operation.
– Select relay settings for fast trips
– Select lower rated fuses
– Cut possible fault energy in half
124
 1200 A 0 .4 8 k V
0 .48 k V FL A =3 00 7 .0 3 A

1 3 -Re la y GE IA C-7 7
Ta p Ra n g e :[4 .0 / 1 6 .0 ] Ta p :4 .0 0 TD: 4
P ic k Up :2 4 0 A 1 1 .5 k V
100 In s t:3 30 0 A (p rim a ry )C T: 3 0 0 :5

2 -Fu s e
GOUL D FOR M 6 0 0 HI A M P
800 A
0 .4 8 k V

1 2-Re la y M UL TIL IN S R7 5 0 E IA C
Tap R an g e :[2 .5 / 1 0 .0 ] Ta p :3 .0 0 TD: 1 .7 0 0
P ic k Up :1 8 0 A 1 1 .5 k V
10 CT: 3 00 :5

Fa ul ts a re a t S S 4 8 0 V b u s wi th 1 o r 2 tra n s .

1
T ime in Seconds

11.5 kV
51
13 50

300:5
51
12

300:5

10
2500
kVA

SS 64E X FM R INRU S H
.1 480 volts
5

F:8 9 6 0 0 A

F:4 6 5 0 0 A
MCC
480 volts

.0 1 125
.5 1 10 100 1000 10000
 Reduce impact of arc
flash on people
• Avoid openings/vents in equipment doors
– Prefer door openings at the side of the door to
openings in the center
• Arc resistant switchgear
– Big benefit for switching
• Remote operating controls for switchgear
• Remote racking - 480 V and higher

126
 Summary
• We know a lot more about arc flash hazards
than we did a few years ago
• Regulations have new arc flash requirements
• Better PPE is available
• New application standards are available
• While progress will continue, the time for
improved protection is now.

127
When do arc flash injuries occur?
• When not expected
• When equipment is deenergized
• When at end of long feeder, where bolted
fault current is lowest

128
 Line-of-defence
• PPE for the arc flash hazard is the last line-of-defense. It is not
intended to prevent all injuries but is intended to mitigate the impact of
an arc flash should one occur.
• Per NFPA 70E, the incident energy exposure shall be based on the
working distance of the employee's face and head from a prospective
arc source for the specific task to be performed. FR clothing and PPE
shall be used.... based upon the incident energy exposure... . That
means injuries to hands and arms are expected if an arc at the level
calculated and protected against occurs.
• PPE designed to prevent all injuries would be so restrictive people
could not work and it is not available.

129
 Caution
• The equations embedded in this worksheet enable calculation of the
estimated maximum incident energy and the estimated arc flash
boundary distance.

• Users should be aware that the equations are based upon measured
incident energy under a specific set of test conditions and on
theoretical work. Real arc exposures may be more or less severe than
indicated by this worksheet. In addition, the potentially hazardous
effects of molten copper splatter, projectiles, pressure impulses, and
toxic arc byproducts have not been considered in the equations.

• Available bolted fault currents should be determined at the point of

each potential fault. Using conservatively high bolted fault currents
may give lower results in incident energy than are possible, depending
on the protective device time-current response.
130
 Disclaimer
– The information offered in this program is based on technical data
believed to be reliable. It is offered as a possible tool for conducting
an arc flash hazard analysis. It is subject to revision as additional
knowledge and experience is gained.

– THE INFORMATION IS PROVIDED WITH NO WARRANTY

OF ANY KIND, EXPRESS OR IMPLIED.

– NO USE SHOULD BE MADE OF THE INFORMATION

EXCEPT BY FULLY QUALIFIED PROFESSIONALS HAVING
FORMED THEIR OWN EVALUTION OF THE INFORMATION
FOR THEIR OWN PURPOSES AND APPLICATIONS.

131
 References
OSHA citations:
• US OSHA Cites Ford in Arc Flash Accident - March 2000
• OSHA Cites Rhode Island Electric Utility in Electric Arc Flash Injury
- March 2000

ASTM Standards
• F1506-98 Standard Performance Specification for Textile Material for
Wearing Apparel for Use by Electrical Workers Exposed to
Momentary Electric Arc and Related Thermal Hazards

• F1958/F1958M-99 Standard Test Method for Determining the

Ignitability of Non-flame-Resistant Materials for Clothing by Electric
Arc Exposure Method Using Mannequins

132
 References - PCIC Technical Papers
All on CD, some on PCIC website
• "The Other Electrical Hazard: Electric Arc Blast Burns"; Ralph H. Lee; 1982
• "Report on Enclosure Internal Arcing Tests"; Epperly, Heberlein and Higgins;
1994
• "Protective Clothing Guidelines for Electric Arc Exposure"; Neal, Doughty, and
Bingham; 1996
• "Testing Update on Protective Clothing & Equipment for Electric Arc Exposure";
Neal, Doughty, Dear, and Bingham; 1997
• "Predicting Incident Energy to Better Manage the Electric Arc Hazard on 600 V
Power Distribution Systems"; Neal, Doughty and Floyd; 1998
• Staged Tests Increase Awareness of Arc-Flash Hazards in Electrical Equipment;
Jones, Capelli-Schellpfeffer, Downey, Jamil, Liggett, Macalady, McClung,
Saporita, Saunders, and Smith; 1997
• Modeling of the Pressure Wave Associated with Arc Fault; Wactor, Miller,
Bowen, Capelli-Schellpfeffer; 2000

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