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depend on the relay scheme utilized, but makes it clear system
changes require a recheck of prior analysis to confirm desired
results.
B. Increase the Working Distance
Working distance is the distance from the possible arc point
to the head and body of the worker positioned in place to
perform the assigned task. Increasing this distance moves the
worker farther from harms way. There are a number of ways
to increase the working distance, directly and indirectly.
1) De-energizing Equipment
De-energizing equipment always provides the safest work
situation for the electrical worker. This option moves the
possible arc point behind the interrupting device. However, de-
energizing equipment is often not an option in todays tight
production workplace; andsince restarting an industrial
process is often fraught with riskit can just shift risk to other
workers in a facility, such as process operators.
2) Use technology to work away from energized equipment
Mechanical and electronic options exist to allow workers to
complete their work farther from the arc point. The most
common is remote racking breakers using an umbilical-cable-
connected control box. Infrared inspection and video
surveillance might also be included here.
3) Install warning labels (consider painting floor)
Once an arc flash hazard analysis is completed, equipment
must be labeled with warnings reflecting the results. The
authors have observed, however, that these labels are often
fixed to the equipment and require incursion into unsafe areas
just to read the warning. A related option, that is easier to
follow and enforce, is to paint the floor in front of equipment
in different colors reflecting the PPE required.
4) Ensure PPE Appropriate for the Hazard Level
Whether by calculation or use of a table, once an arc flash
hazard analysis is completed, workers must wear PPE
appropriate to the analysis results.
C. Decrease the Fault Clearing Time
Fault clearing time is the duration from fault inception to
fault extinguishment. Decreasing the fault clearing time will
decrease the incident energy and minimize the damage to
people or equipment. There are different options, either alone
or combined, to decrease fault clearing time.
1) Increase fault current
As noted above, there can be a counterintuitive incident
energy calculation response due to the overcurrent protective
devices reaction to the fault current. In some cases it may
make sense to actually increase the fault current to lower the
incident energy.
2) Install faster (3-cycle or 5-cycle) breakers
Protection engineers might design a relay scheme that is
quite fast, but if that relay scheme sends a trip signal to a slow
circuit breaker (e.g., a 12-cycle breaker), the benefits of the
fast relay scheme are undermined. New breakers should have a
3- or 5-cycle rating. With such breakers a fault clearing time of
less than 100ms (6 cycles) is possible. And once installed,
breakers must be maintained in good operating condition to
continue to operate within design parameters.
3) Consider or reconsider relay scheme
a) Recheck coordination focused on arc flash mitigation
Once an arc flash analysis is completed, it is often valuable
to recheck the relay coordination study specific for arc flash
mitigation. Relay engineers are typically conservative. This is
exhibited two ways: 1) The use of bolted fault currents as a
basis for coordination studies and 2) The typical use of 0.3-
second coordination interval between the inverse time current
curves of overcurrent devices. These are good practices, but
may exacerbate the arc flash characteristics of a system.
Using an arcing fault current basis and setting overcurrent
devices accordingly can provide a more realistic picture of the
fault clearing time.
In addition, with arc flash mitigation in mind, the security
provided by the 0.3-second coordination interval may not be as
important as ensuring the fastest fault clearing time possible.
The advantage of this recheck is it requires no new
equipment. The disadvantages are the cost of the coordination
study recheck, the potential insecurity reduced coordination
intervals may create (although newer technologies, such as
IEC61850, may make it possible to reduce coordination
intervals more than possible in the past), and the trip times are
still relatively slow.
b) Zone interlocking
A zone interlocking scheme uses blocking signals to
respond differently depending on the location (or zone) of the
fault. As such, this provides an ability to supervise fault
response and provide a faster tripping option for zones where
an arc flash is more likely or where personnel are more likely
to work.
The advantage of this scheme is it can use existing
equipment and is typically faster than simpler time overcurrent
schemes. The disadvantages are the cost of a new coordination
study and additional complexity.
c) Bus differential
A bus differential scheme is based on Kirchoffs Current
Law. During normal operation the sum of all currents entering
and exiting a node must add to zero. However during an
abnormal event within the protected node, or zone of
protection, this sum is not zero and the node is isolated to clear
the fault.
This scheme, whether a high-impedance or low-impedance
type, is fast and secure but can be relatively costly because it
can require dedicated CTs, complex settings, additional
wiring, and extra testing.
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d) Enable instantaneous overcurrent protection during
maintenance
Perhaps the most popularly discussed relay scheme for arc
flash hazard mitigation is to use instantaneous protection
during maintenance activities. In this option the maintenance
workers use a switch or pushbutton to enable instantaneous
overcurrent protection while working in the area. There has
also been some discussion of an automatic switchover option
whereby a motion detector could be used to invoke a change in
relay settings (e.g., enabling an alternate settings group).
The advantages of this scheme are that the critical
equipment should already be in place, and only simple changes
(adding a control switch or pushbutton, adding some control
wiring, and updating the relay settings slightly) are required to
implement the scheme. The disadvantage of this scheme is it
depends on actions by maintenance workers that may become
casual with the procedures over time. There is also the small
riskbecoming a large risk if normal settings are not restored
at the conclusion of the maintenance activitiesof
overtripping during these maintenance activities, a trade-off
for the increased safety.
e) Optical sensors
Since arc flash faults emit such a high intensity light, one
option that is growing in popularity is the use of optical
sensors. These schemes typically use fiber opticseither a
non-jacketed sensor fiber that detects light along its entire
length or a lens fiber that detects light only at its terminal
endto detect the arc flash.
To ensure security of detection, optical sensor relays also
have a current input to supervise the light detection. As such,
the trip signal is only sent to the connected breakers when an
overcurrent condition also exists when the arc flash is
detected.
The advantages of an optical scheme are: Speed (2.5 ms trip
signal). Its independence from other relay schemesit does
not need to be coordinated with other deployed schemes. Its
trip time is independent from fault current magnitude. And
finally, it is not dependent on work procedures. That is, it
operates whether the worker remembers to follow all the
required work procedure steps or not. The disadvantages of
this scheme are the inconvenience and cost to retrofit on
existing switchgear installations and it does not provide any
help in outdoor, open air systems. However, such outdoor
systems generally have lower incident energies than switchgear
installations.
VI. APPLICATION EXAMPLE 1 (CITY OF RICHLAND).
A. Arc flash hazard assessment conclusion
8 cal/cm
2
PPE provides sufficient mitigation.
B. Overview
Application Example 1 involves a typical distribution
substation transformer and metalclad switchgear. (The One-
line diagram is shown in Figure 2.) The utilitys work and
exposure is typically on the low side of the transformer. As
such, the discussion and review will focus on that aspect. For
simplicity in this example, the comparison and calculations
will exclude arc in a box situations.
C. Design Assumptions
For reference, the 15MVA substation power transformer
high side is 115kV grounded wye with a 12.47kV grounded
wye secondary and an impedance of 7.8%.
Given and assumed parameters:
9kA maximum fault calculated from transformer
impedance only.
24 distance between employee and fault based upon
minimum approach distance (22 per NESC Table
441-1).
Boundary energy of 2 cal/cm
2
as cotton clothing wont
provide enough protection over that value (OSHA
1910.269 Appendix F(II)(A)).
D. Mitigation
This information, as well as the clearing times from the time
coordination curves, was input into the IEEE 1584 spreadsheet
(see Figure 3) with the results shown in Figures 4 and 5.
The results indicate the load side of the feeder breakers may
experience an arc flash incident energy of 2.0 cal/cm
2
.
Between the feeder breakers and the circuit switcher, the arc
flash incident energy may be 7.9 cal/cm
2
.
Since most utility work will be on the distribution system
protected by the feeder breakers, 4 cal/cm
2
clothing will be
used. Additional protection will be necessary for protection
against arc in the box situations. Most FR (Flame-Resistant)
clothing manufacturers provide 8 cal/cm
2
clothingshirts and
pantsthat appear very similar to everyday-wear clothing.
This facilitates adoption by employees. An informal check
confirmed other utilities have similar plans to use 8 cal/cm
2
clothing.
422
Fig. 2. Application Example 1 One-line
Fig. 3. Arc Flash Input Parameters
Fig. 4. Arc Flash Calculations
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Fig. 5. Arc Flash Summary
VII. APPLICATION EXAMPLE 2 (IBERDROLA RENEWABLES).
A. Arc flash hazard assessment conclusion
Divergent concerns require a belt and suspenders
approach including a dedicated optical sensor relay scheme.
B. Overview
Application Example 2 is a typical large-scale wind
project collector substation. The switchgear is metalclad
with eight to ten 34.5kV breakers. (The typical one-line
diagramshowing a single 34.5 kV breakeris shown in
Figure 6.)
C. Design considerations and challenges
Arc flash safety must be ensured for Operations and
Maintenance personnel who are specialized in the
maintenance of wind turbine generators and have little
experience with substation equipment. Further, since
collector substations are often shared with utilities and other
developers, the arc flash mitigation measures must also
ensure safety of personnel not employed or trained by
Iberdrola Renewables. Finally, down time must be
minimized.
D. Mitigation
In a belt and suspenders approach, overlapping arc flash
mitigation options will be implemented:
The arc flash hazard area (area in front of the
switchgear) is closed off by a chain-link gate.
Signage is installed on the gate clearly describing the
safety hazards and required PPE needed within the
arc flash hazard area.
A mimic panel is used so that all controls of the
switchgear breakers and relays can be operated well
away from arc flash hazard area.
Breakers can be racked out through a remote device
so personnel do not have to stand within the hazard
area to perform this operation.
An optical sensor arc protection system is deployed
throughout all breaker cubicles within the switchgear
building. This limits the energy and duration of the
blast, thus decreasing the hazard to personnel and
limiting damage to equipment.
Optical-Sensor
Protected Zone
34.5 kV
Breaker
GSU XFMR
34.5/19.9
-0.69/0.398 kV
~6%Z
Fig. 6. Application Example 2 One-line
VIII. CONCLUSIONS
Arc flash hazards cause more injuries than shock
hazards.
The utility electrical system environment has
changed.
Standards and Regulations provide guidelines,
requirements, and inconsistencies. Exemptions
perceived as tenuous.
There are many mitigation options. Each has
advantages and disadvantages.
No cookie cutter approach to mitigation. Each utility
will be somewhat unique in approach.
REFERENCES
[1] R. H. Lee, The Other Electrical Hazard: Electric Arc Blast Burns,
IEEE Trans. Ind. Appl., vol. 18, no. 3, pp. 246-251, May/Jun 1982.
424
[2] R. A. Jones, et al., Staged Tests Increase Awareness of Arc Flash
Hazards in Electrical Equipment, IEEE Trans. Ind. Appl., vol. 36,
no. 2, pp. 659-667, Mar/Apr 2000.
[3] C. Inshaw and R. Wilson, Arc Flash Hazard Analysis and
Mitigation, presented at Western Protective Relay Conference,
Spokane, WA, October 20th, 2004.
[4] Guide to Performing Arc Flash Calculations, IEEE Standard 1584,
2002.
[5] Standard for Electrical Safety in the Workplace, NFPA Standard
70E, 2009.
[6] NESC (National Electric Safety Code), ANSI/IEEE Standard C2,
2007.
[7] IEEE Standards Association, [Online] Available:
http://standards.ieee.org/faqs/NESCFAQ.html#q7
[8] NEC (National Electric Code), NFPA Standard 70, 2008.
[9] Occupational Safety and Health Act of 1970, Public Law 91-596, 84
STAT. 1590, 91st Congress, S.2193, December 29, 1970, as
amended through January 1, 2004.
[10] J. Kumm, Five Ways to Reduce Arc Flash Hazards, System
Protection Services Newsletter, [Online] Available:
http://www.systemprotection.com/Literature/newsletter_archive/
[11] J. Buff and K. Zimmerman, Reducing Arc Flash Hazards: Applying
Existing Technologies. IEEE Ind. Appl. Mag., May/Jun 2008.
[12] K. Zimmerman, et al., Protection Considerations to Mitigate Arc
Flash Hazards IEEE PSRC WG K9, Draft Technical Report,
unpublished.
Jay Sperl is a Regional Technical Manager for ABB Inc. in Prosser, WA.
He received his BSEE degree Washington State University in 1988. He is
a Member of IEEE and a Registered Professional Engineer in California.
Clint Whitney is the Electrical Systems Supervisor for the City of
Richland in Richland, WA. He received his BSEE degree from
Washington State University in 1991. He is a Senior Member of IEEE and
a Registered Professional Engineer in Washington.
Andrew Milner is an Electrical Engineer in Wind Technical Services for
Iberdrola Renewables in Portland, OR. He received his BSEE degree from
Oregon State University in 2003. He is a Member of IEEE and a
Registered Professional Engineer in Oregon.
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