Arc Flash Protection for Electrical Safety Professionals

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Presents

Arc Flash Protection

for Electrical Safety Professionals

Revision 3

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IDC Technologies Pty Ltd PO Box 1093, West Perth, Western Australia 6872 Offices in Australia, New Zealand, Singapore, United Kingdom, Ireland, Malaysia, Poland, United States of America, Canada, South Africa and India Copyright IDC Technologies 2010. All rights reserved. First published 2010

ISBN: 978-1-921007-64-4
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Table of Contents
1
1.1 1.2 1.3 1.4 1.5

An Overview of Electrical Hazards

Overview General hazards in industry Electrical hazards Electrical Hazards and Safety Measures Summary

1
1 1 2 5 5

2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Arc Flash and its Effects

Introduction What is an arc Important definitions related to arc flash Common reasons for arc flash Arc Flash mechanism Effects of Arc Flash Incident energy of arc and arc flash hazards Location affects the hazard Consequences of an arc flash incident

7
7 7 8 9 9 10 11 14 15

3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Fundamentals of Power Systems

Introduction Common distribution options Main components of an industrial distribution system Voltage classification Multiple voltage levels in power distribution Types of distribution arrangements and redundancy Faults in electrical systems Short circuit currents Bolted Vs Arc Fault currents Earthing and its influence on Arc Faults System Earthing Influence of Earthing on Arc Faults

17
17 17 19 20 20 25 30 33 34 34 35 38

4
4.1 4.2 4.3

Fault Current Calculations

Approach What is impedance Impedance of alternators

39
40 40 42

4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12

Typical fault currents in various voltage levels Typical electrical networks Electrical networks represented by equivalent diagram Representing multiple sources in the equivalent diagram Reduction of impedance diagram Concept of base MVA for equivalent circuits Typical per unit impedance of transformers Fault contribution by motors Typical calculations using numerical examples

44 44 45 46 47 50 51 51 52

5
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10

Protection of Electrical Power Systems

Need for protective apparatus Basic requirements of protection Basic components of a protection system Protection of power distribution systems Detection of fault currents Fuses for protection Protective relays Electomechanical protection relay Electronic protection relays Coordination of protection

57
57 58 59 59 60 60 62 63 67 69

6
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

Arc Flash Studies - Codes and Standards

Introduction Safety Standards for Arc Flash hazards Research in Arc Flash hazards Basic requirements stipulated in standards for operator safety National fire protection hazards (NFPA) NFPA 70B 2002 OSHA standards 29-CFR, Part 1910 The institute of electronics and electrical engineers (IEEE standard 1584) Guide for Arc Flash hazard analysis Limitations Difference between NFPA 70E and IEEE 1584 Summary

73
73 74 74 75 76 80 80 82 83 83 84 84

7
7.1 7.2

Arc Flash Study - Detailed Procedure

Flash protection approach boundary Detailed Arc Flash Study

85
85 89

7.3 7.4 7.5 7.6 7.7 7.8

NFPAQ 7OE - May 2003 ROP Incident energy calculations Methods of applying the model Warning labels Personal Protective Equipment (PPE) Summary

91 92 99 99 102 103

8
8.1 8.2 8.3 8.4

Data Collection and System Modeling

Data collection Determine system modes of operation Lower short circuit conditions with long tripping times Summary

105
105 117 120 121

9
9.1 9.2 9.3 9.4 9.5 9.6

Determining Arc Flash hazard risk category

Flash hazard analysis Hazard risk category / PPE matrix table approach Hazard risk category for metal clad switchgear 1kV and above Simplified table approach Comparison of flash hazard analysis methods Summary

123
123 124 128 130 132 136

10
10.1 10.2 10.3 10.4

Controlling Arc Flash Hazards

Introduction Eliminating Arc Flash events Avoiding Arc Flash risks Mitigating arc effects

137
137 137 148 150

11
11.1 11.2 11.3 11.4 11.5 11.6 11.7

Personal Protective Equipment

Evolution of flame resistant fabrics ASTM Fire resistant clothing Other PPE FR Fabrics and the effect of undergarments Disadvantage of FR fabrics Summary

153
153 157 160 163 165 166 166

Appendix A

167

Preface Arc flash safety-An introduction

Arc flashes in electrical equipment are now considered to be one of the major causes of electrical accidents, even surpassing the well known hazard of electric shock. Avoiding arc flash incidents and the resulting injuries is one of major challenges facing electrical workers today and requires adequate attention in the stages of system planning, design, installation, operation and maintenance. This course aims to put the subject of arc flash hazard and protection in proper perspective so that the hazards and their underlying reasons are properly understood. The introductory chapter covers the topic of electrical safety and describes various hazards to electrical workers. This is followed through in the next chapter by a detailed discussion of arc flash incidents, their most common causes and the effects of exposure to arc flash. Arc flash hazards mainly arise from the energy of the flash which then causes burns on the exposed skin depending on the amount of incident thermal energy and the duration of such exposure. These in turn depend upon the short circuit level at the point of arcing and the speed with which protective devices act to disconnect the fault from supply sources. The short circuit level depends on the system parameters and configuration and these are explained in the next two chapters; chapter 3 which deals with the fundamentals of power distribution systems and chapter 4 which covers the method of calculating short circuit currents with a few numerical examples. The basics of protection equipment and their role in limiting the hazards of arc flash exposure are discussed in chapter 5. This is followed by a more in-depth discussion in chapter 6 on the various studies conducted on arc flash incidents which paved the way for several standards dealing with arc flash safety. The actual calculations that need to be done to determine the arc flash incident energy in relation to the distance from the arc source and the flash protection approach boundary are covered in chapter 7. The next chapter discusses the methodologies recommended in IEEE 1584 for data collection and modeling. Based on the calculations described in these chapters the hazard-risk matrix needs to be worked out. Chapter 9 discusses this topic and compares the recommendations of different standards dealing with arc flash safety as regards use of appropriate personal protective equipment (PPE) and warning notices required to be put on electrical switchboards to inform operating personnel of the hazards and protective equipment category required. It must be understood that arc flash events are not inevitable but can be prevented with proper design of equipment and protection systems, by monitoring the equipment in the course of their operation and by paying attention to preventive maintenance. These aspects are touched upon in chapter 10. The final chapter of the course discusses fire resistant clothing materials used for the PPE for arc flash hazard protection, their testing as per ASTM F1506 standard and the selection and care of FR PPE clothing.

1 An Overview of Electrical Hazards

This chapter lists the typical personnel safety hazards in industry and more specifically the types of electrical safety hazards. It illustrates the types of electrical accidents that generally take place in an industry and explains the normal preventive measures.

Learning Objectives
Course overview General hazards in industry Electrical hazards Electrical accidents and safety measures

1.1

Overview
It is often remarked that electricity is a good slave but a bad master. Improper use of electricity or careless handling of electrical equipment leads to a number of avoidable accidents (many of which can be fatal) every year, resulting in huge loss. Out of the various hazards present in any work place, the most important are the electric shock hazard and the arc flash hazard. This course is about the latter and will discuss the underlying reasons for arc flash incidents and the steps necessary to mitigate the effects of such incidents. .

1.2

General hazards in industry

In any industrial facility several types of hazards exist. The hazards may be due to any of the following: Electrical equipment Mechanical equipment Fire or flames Hazardous/toxic materials Hot liquids/gases Cold liquids Explosive gases Corrosive liquids We are mainly concerned with electrical hazards and will briefly discuss the various types of electrical hazards below.

2 Arc Flash Protection

1.3

Electrical hazards
Hazards from electrical equipment can be any of the following: Electric shock and associated effects such as: Internal organ damage due to passage of electricity through body Burns on skin at point of contact Injuries by electric shock combined with fall Arc flash causing external burns and injuries by explosive expansion of air due to the arc. Fall from heights Corrosive liquids used in electrical equipment Hazards resulting from explosive atmosphere Hazards due to high temperature Electric shock The main hazard from electrical equipment is, naturally, the danger from electric shock. Electric shock can be a result of contact with live parts such as electrical conductors or with parts of equipment which are not normally live (such as enclosures) but become life due to failure of electrical insulation. Electric shock is thus a result of the following conditions. Exposure to live parts (Direct contact) Exposure to parts that accidentally become live (Indirect contact) Potential difference between different points in the earth under certain conditions The last named is similar to indirect contact except that it does not involve contact with any electrical equipment (either a live part or enclosure). Electric shock or electrocution can cause many problems in a human body. Electric current flowing through body results in muscular contraction. If the current flows through heart muscles it can cause stoppage of heart by a condition called fibrillation. Even if an electric shock is not fatal, it can cause other problems such as internal organ damage due to excessive heating of body tissues, burns at the point of contact of the skin with live conductors, loss of consciousness or loss of balance resulting in fall while working at a height. In some instances an electric shock may not by itself cause an injury, but a resulting fall from a height can as described in a subsequent paragraph. Arc Flash Apart from electric shocks caused by contact with parts that are (or become) live, another major danger for those who work on electrical equipment is the hazard due to arc faults. Such faults are often caused by the affected workers themselves, when they work on or in the vicinity of live equipment and cause a short circuit fault inadvertently. In fact, arc faults in equipment and their potential dangers are subjects of extensive study and have given rise to standards such as IEEE 1584 (Guide for Performing Arc-Flash Hazard Calculations). This is the principal subject matter of this course and will be discussed in detail later. Arc flash can also result when safe clearances between a live part and earth are compromised during work. This can result in the intervening air space breaking down and initiating an arc. This is particularly true of exposed overhead equipment such as switchyards. The most serious hazard of an arc flash is burn injuries resulting from the arc with the seriousness of injury dependent on the following factors: Fault energy as given by the fault level of the system (VA) Time of fault clearance

An Overview of Electrical Hazards 3

For example, the arc energy in an MV system short circuit fault is usually much higher compared to an LV mains circuit fault, which in turn has a much higher energy compared to a branch circuit fault in the same system. The longer an arc fault is allowed to persist, higher the damage. Faults, which are cleared much faster, are therefore much less dangerous from viewpoint of injury. High-energy faults will also cause melting of components such as copper/aluminum conductors or steel parts of enclosure. Copper is particularly dangerous because it can result in deposition of toxic copper salts on the skin. Internal injuries and also hearing damage can result from the blast pressure and damage to eyes can happen as a result of the bright light of the arc flash. Sometimes, the sudden expansion of air due to an arc fault within an enclosed space may dislodge mechanical parts such as terminal covers with a great force. Documented cases of such accidents causing injury or even death are on record. It is common practice in design of equipment such as HV switchgear to provide vents or flaps, which open in the event of explosive arc faults thus avoiding damage to the enclosure. They also help to direct the arc products way from an operator who may be stationed nearby. The newer versions of switchgear are built to be arc resistant in which an internal arc is unlikely to cause injuries to operating personnel in the vicinity and the energy is contained within the arc resistance enclosure. Fall from heights A lot of maintenance work is carried out on overhead lines and outdoor switchyard equipment at a height. Also maintenance work on large power transformers requires people to work on the top of the tank. Work on lighting fixtures and wiring involves working at a considerable height. A fall can badly inure the worker and can sometimes be fatal too. Often a minor electric shock can result in a fatal fall. People working at heights need to take appropriate harness and fall arrest gear in order to protect themselves from a fall. Climbing equipment used for such work including ladders, scaffolding and fixed/mobile platforms need to be maintained in good condition. Hazards from corrosive liquids Acids and alkalis are highly corrosive and can cause injuries of they come into contact with skin. In electrical installations, battery electrolyte which is an acid such as sulphuric acid or alkaline such as sodium hydroxide pose such hazards. The hazards in this case are: Burns/irritation due to contact with skin Loss of sight or serious injury of eyes Danger of ingestion causing internal injuries in food path Danger of inhalation (fumes) causing similar injury to lung tissue Hazards from explosive gases Explosion is a result of accidental ignition of explosive mixtures formed by combustible gases or fumes with oxygen in air. The source of ignition is often electrical. The effects of explosions are manifold and can include: Burns by fire accompanying explosion Injuries from flying objects following an explosion Damage to limbs/internal injuries by the pressure wave generated by an explosion Prevention of hazards due to explosions is primarily through the following approach. Prevent formation of explosive mixtures Prevent ignition of explosive mixtures if formed Limit the effect of explosion if ignition does take place. An example of such a hazard is a dc installation using lead acid batteries, particularly those of flooded type. During the process of charging these batteries hydrogen is generated (due to electrolysis of the water in the electrolyte) and can form an explosive mixture with air.

4 Arc Flash Protection

Temperature or thermal hazards Temperature hazard results from the high temperature on the surface of electrical equipment enclosures and current carrying parts. External surfaces of electrical equipment often attain elevated temperature, an example being the enclosure of bus ducts which can often attain surface temperatures of over 60 Deg C. Exposed conducting parts such as overhead line conductors can attain even higher temperatures. For example, the bus bars in switchgear often run at temperatures in excess of 100 Deg C. Electrical joints/mating surfaces can have temperatures exceeding the conductor temperature. This is because of increased localized resistance. Apart from causing less serious burn injuries (compared to arc flash), high surface temperature can cause ignition if flammable vapors are present in the environment. Fire hazards Electrical faults can also cause fire danger as discussed in an earlier section. Special care is required when the electrical equipment itself contains flammable materials, examples being oil circuit breakers and mineral oil cooled transformers. In some cases, a fire can result because of combustible materials stored in the vicinity of electrical equipment. Cables and wiring are often a cause of fires as a result of an insulation failure due to excessive loading. Cables can also catch fire due to exposure to flames (as in the case of boilers and furnaces). Mechanical hazards Mechanical hazards result from exposure to moving parts of electrical equipment such as motors, generators, circuit breaker mechanism etc. Hazards can result whenever there is some kind of stored energy involved and can include springs, compressed air and high pressure fluids. Table 1.1 below shows the safety hazards posed by electrical equipments commonly used in electrical generation and distribution systems and substations. Table 1.1 Electrical hazards in different equipment Type of equipment Generation equipment Transformers Overhead Transmission/distribution lines Cables Bus ducts Switchgear Motive equipment Heating equipment Lighting equipment Uninterrupted power supplies with battery Hazards Electric shock, arc flash, mechanical hazards Electric shock, arc flash, fire hazard, fall from heights Electric shock, arc flash, fall from heights Electric shock, arc flash, fire hazard Electric shock, arc flash, thermal hazard, fall from heights Electric shock, arc flash, thermal hazard, fire hazard, mechanical hazard Electric shock, arc flash, thermal hazard, mechanical hazards Electric shock, arc flash, thermal hazard Electric shock, arc flash, thermal hazard, fall from heights Electric shock, arc flash, hazards from corrosive liquids and explosive gases

An Overview of Electrical Hazards 5

1.4

Electrical accidents and safety measures

We will briefly discuss in this section about why electrical accidents happen and how we can avoid them. These points will be elaborated in subsequent chapters in further detail. Electrical accidents happen mostly as a result of the following: Failure to isolate or inadequate or insecure isolation of live parts Poor maintenance and faulty equipment Insufficient information about the system being worked on Carelessness and lack of safety procedures Isolating normally live equipment before starting any work on it can improve safety substantially in any system. We must however bear in mind that there are certain kinds of equipment where live work is possible and certain kinds of activities where work in the vicinity of exposed live parts is unavoidable. But such work must be carried out according to well laid safety procedures. The other major cause of accidents is faulty equipment (which can include both poorly designed or improperly operating equipment). Unless safety is built into the design of the equipment, it can result in accidents and injury. Similarly, improperly maintained equipment too can result in failures and thereby cause accidents. Insufficient knowledge of operating personnel, lack of familiarity with equipment and system etc. too can result in unsafe situations. Absence of proper operational safety procedures and violations of existing procedures can both result in accidents. The following are the general safety measures, which need to be adopted to reduce the possibility of accidents in electrical equipment. Safe design/installation of plant and equipment as per applicable codes and regulations Safe operating and maintenance practices established through documented procedures and instructions Appropriate knowledge on the part of workers by proper training and certification Posting clear warning signs at points of hazard Use of equipment/sensors to warn incipient problems with automated hazard containment measures Proper periodic inspection and prompt repairs Use of personal safety equipment mandated in safety procedures Creating an organizational safety structure to handle safety issues, lapses and accidents Create safety awareness among the workforce We will discuss these measures in detail in the ensuing chapters.

1.5

Summary
Improper use of electricity or careless handling of electrical equipment leads to a number of otherwise avoidable accidents. Electrical safety is a well-legislated subject and the various acts and regulations enacted in each industrialized country lay a lot of stress on the responsibility of both employers and employees in ensuring safe working conditions. However, it must also be understood that safety is not simply a matter of taking precautions in the workplace but has to start at the stage of equipment design. In any industrial facility, several types of hazards exist. The hazards may be due to electrical, mechanical and several other causes. Electrical hazards are mainly from electric shock, fall as a result of an electric shock, burns due to arc flash and injuries by explosive expansion of air due to the arc. High temperature on the surface of electrical equipment enclosures/exposed conductors and electrical faults resulting in fire within electrical equipment or nearby combustible materials are other safety hazards. Electrical equipment installed in explosive environment needs special attention. Failure to isolate or inadequate or insecure isolation of live parts is the major reason for of accidents. Isolating normally live equipment properly from supply mains before starting any work on it can improve safety substantially. Poor maintenance and faulty equipment,

6 Arc Flash Protection

insufficient information about the system being worked on and lack of safety procedures are the other major reasons for electrical accidents.