CHAPTER 7-ARC-FLASH ANALYSIS

7.1 Introduction
The primary objective of an arc flash study is to determine
the amount incident energy based on the available perspective
three phase arc fault current, clearing time of the protective device
during an arc fault, gap between live parts and the working
distance.

The calculated incident energies will either be used to

verify that the existing arc flash rating of the PPE is sufficient
or to specify the arc rating of new PPE. Another objective of an arcflash study is to calculate and define arc-flash boundary or the flash
protection boundary. This boundary is the distance from the arc
source in which the heat energy experienced by the skin is about
1.2 cal/cm2 which is the minimum heat energy required to incur a
curable second degree burn.

According to PEC 2009 article

1.10.1.16 1.10.1.16 Flash Protection. Switchboards, panel boards,

industrial control panels, meter socket enclosures, and motor
control centers that are in other than dwelling occupancies and are
likely to require examination, adjustment, servicing, or maintenance
while energized shall be field marked to warn licensed electrical
practitioner

or

non-licensed

electrical

practitioner

under

the

supervision of a licensed electrical practitioner of potential electric

arc flash hazards. The marking shall be located so as to be clearly
visible to licensed electrical practitioner or non-licensed electrical
practitioner

under

practitioner

before

the

supervision

examination,

of

licensed

adjustment,

electrical

servicing,

or

maintenance of the equipment. The markings must contain

information such as calculated incident energy at a given working
distance, PPE arc-flash rating required, and the flash protection
boundary.

Chapter 1-Introduction

Page 361

This analysis will evaluate 11 medium-voltage arc-flash

points and 10 low-voltage switchgear and low voltage panels arcing
energy or incident energy, hazard level and will specify the level of
PPE required as well as the flash protection boundaries.
The analysis will be based on IEEE 1584-2004 Guide for
Performing

Arc-Flash

Hazard

Calculations.

According

to

this

standard, the arcing fault current can be calculated using equation

7.1 for low-voltage systems and equation 7.2 for medium-voltage
system.
For Low-Voltage

Log(I ARC ) K 0.662 log(ISC ) 0.0966V 0.000562G

0.5588V log(ISC ) 0.0034G log(ISC )
I ARC 10Log(IARC)

Equation 7.1

For Medium-Voltage
Log(I ARC ) 0.00402 0.983 log(ISC )
Log(IARC)

I ARC 10

Equation 7.2

Where IARC is the arcing current in kA

K is -0.153 for open air and -0.097 for arcing in a box
ISC is bolted three-phase short circuit current (symmetrical
RMS)
V is the system voltage in kV
G is the conductor gap in mm
The normalized incident (Ein) energy for 0.2 seconds clearing time
and 610mm working distance is give as
Log(Ein)=k1 +k2 + 1.081log(IARC) +0.0011G
Ein=10Log(Ein)
Chapter 1-Introduction

Equation 7.3
Page 362

The incident energy at a specific location (Ei) is calculated as

Ei=4.184 Cf Ein (t/0.2) (610/D)x

Equation 7.4

Where k1 is the open air or box factor (-0.792 for Open and 0.555 for boxed)
k2 is the ungrounded/grounded factor (0 for ungrounded and
-0.113 for grounded system)
Cf is the calculation factor (1.5 for LV and 1.0 for MV)
D is working distance
X is the distance factor 2.0 for LV & MV open air, 0.973 for MV
switchgear, 1.473 for LV switchgear, 1.641 for MCC and panel
Another objective of arc-flash study is to determine the arcflash boundary which is defined by IEEE 1584 as approach limit at
a distance from exposed live parts within which a person could
receive a second degree burn if an electrical arc flash were to
occur. The incident energy at that boundary that can incur such
injury is about 5 Joule/cm2. The arc flash boundary (DB) is
calculated as
DB=[4.184 Cf Ein (t/0.2) (610x/EB)]1/x

Equation 7.5

Where DB is the distance from arc in mm

EB = incident energy at the arc flash boundary, typically
1.2 cal/cm2 or 5 Joules/cm2
Ein = incident energy normalized
Cf = calculation factor
t = arcing time in seconds from overcurrent device time
current curve
X = distance exponent

Chapter 1-Introduction

Page 363

7.2 Arc-Flash Calculation for Medium-Voltage System

13.8kV Power Plant

Switchgear
52

AFP-1

AFP-2
6.9kV
Switchgear

52

AFP-3

52

52

AFP-4

52

AFP-5

52

52

AFP-7

AFP-6

AFP-8

TRL3A
M

KM5806

YM7601

KM8639

52

52

AFP-9

AFP11

AFP-10

TRL3B

KM8601
To
MCC8

To
MCC9

Figure 7.1 Arc-Flash Location Diagram for Medium-Voltage

System

Chapter 1-Introduction

Page 364

Load Side of 52TRM1P

Calculation of Arcing Fault Current
From the result of three phase short circuit analysis in chapter 4,
ISC= 23.25kA. Both the 100% and 80% of arcing fault are
calculated using the equation 7.2,

Log(IARC ) 0.00402 0.983 log(ISC )

IARC 10Log(IARC)
Log(I ARC ) 0.00402 0.983 log(23.24) 1.347
I ARC 101.3476 22.239kA
I85%ARC 18.9kA
Using this calculated arcing current, the normalized incident energy
is calculated as
k1=-0.555, k2=-0.113, G=153mm
Log(Ein)=k1 +k2 + 1.081log(IARC) +0.0011G
Ein=10Log(Ein)
Log(Ein)=-0.555-0.113+1.081log(22.239) + 0.0011(153)
Log(Ein)=0.956
Ein=100.956=9.047 joule/cm2
Calculating the incident energy at 85% arcing fault current
Log(Ein)=-0.555-0.113+1.081log(18.9) + 0.0011(153)
Log(Ein)=0.88
Ein=100.88=7.59 joule/cm2

Chapter 1-Introduction

Page 365

Using this normalized incident energies and equation 7.3, the

specific incident energy for a working distance (D) of 457mm is
calculated as
Ei=4.184 Cf Ein (t/0.2) (610/D)x
Cf=1.0 (for MV System), x=0.973 for MV switchgear
D=700mm
Clearing time of Relay Primary protective device of TRM1 51PTRM1P
at 100% arcing fault is

3.922
t
0.0982 2.98 0.37 second
19.302 2

1.84

And the clearing time of the same relay at 85% arcing fault is

3.922

t
0.0982 2.98 0.4 second
18.9 2

1.84

Incident energy at 100% arcing fault current is

Ei= 4.184 (1.0) (9.047) (0.37/0.2) (610/700)0.973
Ei=61.79 joule/cm2 or
Ei=61.79 x (1.2/5) cal/cm2 = 14.83 cal/cm2

Chapter 1-Introduction

Page 366

Incident energy at 85% arcing fault current is

Ei= 4.184 (1.0) (7.59) (0.4/0.2) (610/700)0.973
Ei=56.168 joule/cm2 or
Ei=56.168 x (1.2/5) cal/cm2 = 13.48 cal/cm2
As per IEEE 1584, both 100% and 85% incident energies
correspond to a hazard level 3 and would require a PPE rating of 25
cal/cm2.
Arc-Flash Boundary Calculation
Using the equation 7.5, the arc-flash boundary is calculated as
DB=[4.184 Cf Ein (t/0.2) (610x/EB)]1/x
At 100% arcing current:
DB=[4.184 (1) (9.05) (0.37/0.2) (6100.973/5)]1/0.973
DB=8409mm
At 85% arcing current:
DB=[4.184 (1) (7.59) (0.4/0.2) (6100.973/5)]1/0.973
DB=9274mm
This result implies that if there is an operational need to
open

the

13.8kV

load

side

switchgear

at

power

plant

for

maintenance or inspection while energized, a safety barrier of 9.3

meters from the circuit breaker cubicle should be maintained and
only personnel with a 25cal/cm2 arc-flash suit should be allowed to
enter the said barrier.

Chapter 1-Introduction

Page 367

Calculation results by repeating the same procedure for the rest of

the medium-voltage switchgears are presented in table 7.1, 7.2 and
7.3.
Table 7.1 Calculation results for normalized incident energy
ARCFLASH
POINT
1
2
3
4
5
6
7
8
9
10
11

Location

Isc
(kA)

Iarc
(kA)
22.24
19.30
19.30

En
(j/cm2)
100%
9.05
7.76
7.76

En
(j/cm2)
85%
7.59
6.51
6.51

Load Side of 52TRM1P

Line Side of 52TRM1S
Load Side of 52TRM1S
and 6.9kV Bus
Line/Load Side of
52KM5806
Line/Load Side of
52YM7601
Line/Load Side of
52KM8639
Line/Load Side of
52KM8601
Line/Load Side of TRL3A
Primary Feeder
Line/Load Side of PC001
Feeder
Line/Load Side of TRL3B
Primary Feeder
Line side of PC001 panel

23.25
20.13
20.13
20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

20.13

19.30

7.76

6.51

19.78

18.98

7.62

6.39

Note: k1=-0.555, k2=-0.113, G=153mm

Chapter 1-Introduction

Page 368

Table 7.2 Calculation results for incident energy at 100%

arcing fault current level
ARCFLASH
POINT
1
2
3

4
5
6
7
8

9
10

11

Location
Load Side of
52TRM1P
Line Side of
52TRM1S
Load Side of
52TRM1S and 6.9kV
Bus
Line/Load Side of
52KM5806
Line/Load Side of
52YM7601
Line/Load Side of
52KM8639
Line/Load Side of
52KM8601
Line/Load Side of
TRL3A Primary
Feeder
Line/Load Side of
PC001 Feeder
Line/Load Side of
TRL3B Primary
Feeder
Line side of PC001
panel

t
(s)

E
(J/cm2)

E
(cal/cm2)

Hazard
Level

0.37

71.78

17.23

0.73

121.05

29.05

0.57

94.00

22.56

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.25

1.98

0.05

8.10

1.94

Note: Cf=1, D=600mm, x=0.973

Chapter 1-Introduction

Page 369

Table 7.3 Calculation results for incident energy at 85%

arcing fault current level
ARCFLASH
POINT
1
2
3
4
5
6
7
8
9
10
11

t
(s)

E
(J/cm2)

E
(cal/cm2)

Hazard
Level

0.40
0.91
0.71

65.26
126.23
98.02

15.66
30.30
23.52

3
4
3

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.92

1.66

0.05

6.80

1.63

Location
Load Side of 52TRM1P
Line Side of 52TRM1S
Load Side of 52TRM1S
and 6.9kV Bus
Line/Load Side of
52KM5806
Line/Load Side of
52YM7601
Line/Load Side of
52KM8639
Line/Load Side of
52KM8601
Line/Load Side of
TRL3A Primary Feeder
Line/Load Side of
PC001 Feeder
Line/Load Side of
TRL3B Primary Feeder
Line side of PC001
panel

Note: Cf=1, D=600mm, x=0.973

Table 7.4 Calculation results for Arc-Flash Boundary (AFB)
for Medium-Voltage Loads
ARC-FLASH
POINT
1
2
3
4
5
6
7
8
9
10
11

Location
Load Side of 52TRM1P
Line Side of 52TRM1S
Load Side of 52TRM1S and
6.9kV Bus
Line/Load Side of 52KM5806
Line/Load Side of 52YM7601
Line/Load Side of 52KM8639
Line/Load Side of 52KM8601
Line/Load Side of TRL3A
Primary Feeder
Line/Load Side of PC001
Feeder
Line/Load Side of TRL3B
Primary Feeder
Line side of PC001 panel

Chapter 1-Introduction

AFB (mm)
100%
9275
15869
12237

AFB (mm)
85%
8410
16568
12775

1004
1004
1004
1004
1004

838
838
838
838
838

1004

838

1004

838

985

823

Page 370

Based on the results of medium-voltage system arc-flash

calculation, the maximum incident energy will be generated by an
arc-flash event at the line side of 52TRM1S with a calculated energy
at 100% arcing current of 29.05 cal/cm2 and at 85% arcing current
of 30.30 cal/cm2. At that point, the normalized incident energy at
100% arcing current is higher than the 85% arcing current and this
is attributed to the increase in protective relays clearing time from
0.73 second to 0.91 second. For both situation the hazard level is 4
and requires PPE rating of 40cal/cm2. The calculations also suggest
that the arc-flash boundaries are 16.6m and 12.8m for line side and
load side respectively. These distances from the breaker cubicle
must be maintained in case there is a need to perform live
inspection and maintenance and that these boundaries should only
be accessed by personnel with appropriate training and equipped
with arc-flash suit rated at 40cal/cm2. For the rest of the arc-flash
points, a boundary of approximately 1meter (0.838m) should be
maintained and only personnel with appropriate training and
equipped with an arc-flash suit rated at 5 cal/cm2 should be allowed
to enter the boundary to perform live inspection and maintenance.

Chapter 1-Introduction

Page 371

7.3 Arc-Flash Calculation for Low-Voltage System

AFP-12
52

AFP-13

AFP-14

AFP-15

AFP-16
M
TYPICAL
LV
MOTOR

EMDB/MNDB
PANEL

Figure 7.2 Arc-Flash Location Diagram for Low-Voltage

System MCC8

Chapter 1-Introduction

Page 372

AFP-17
52

AFP-18

AFP-19

AFP-20

AFP-21
M
TYPICAL
LV
MOTOR

YM7607 VFD
PANEL

Figure 7.3 Arc-Flash Location Diagram for Low-Voltage

System MCC9
Line side of secondary breaker of TRL3A
Calculation of Arcing Fault Current
From the result of three phase short circuit analysis in chapter 4,
ISC= 46kA. Both the 100% and 80% of arcing fault are calculated
using the equation 7.1,

Log(I ARC ) K 0.662 log(ISC ) 0.0966V 0.000562G

0.5588V log(ISC ) 0.0034G log(ISC )
I ARC 10Log(IARC)

Log(I ARC ) 0.097 0.662 log(46) 0.0966(0.48) 0.000562(32)

0.5588V log(46) 0.0034G log(46)
I ARC 10Log(1.351) 22.45kA
Chapter 1-Introduction

Page 373

Using this calculated arcing current, the normalized incident energy

is calculated as
k1=-0.555, k2=-0.113, G=32mm
Log(Ein)=k1 +k2 + 1.081log(IARC) +0.0011G
Ein=10Log(Ein)
Log(Ein)=-0.555-0.113+1.081log(22.45) + 0.0011(32)
Log(Ein)=0.8278
Ein=100.8278=6.727 joule/cm2
Calculating the incident energy at 85% arcing fault current
Log(Ein)=-0.555-0.113+1.081log(19.081) + 0.0011(32)
Log(Ein)=0.7515
Ein=100.7515=5.643 joule/cm2
Using this normalized incident energies and equation 7.3, the
specific incident energy for a working distance (D) of 457mm is
calculated as
Ei=4.184 Cf Ein (t/0.2) (610/D)x
Cf=1.0 (for MV System), x=0.973 for MV switchgear
D=700mm
Clearing

time

of

Relay

Primary

protective

device

of

TRL3A

51PTRL3AP at 100% arcing fault is

3.922
t
0.0982 2.891 0.633 second
22.45(0.48 / 6.9) 2

0.27

Chapter 1-Introduction

Page 374

And the clearing time of the same relay at 85% arcing fault is

3.922
t
0.0982 2.891 0.773 second
0.85(22.45)(0.48 / 6.9) 2

0.27

Incident energy at 100% arcing fault current is

Ei= 4.184 (1.5) (6.727) (0.633/0.2) (610/600)1.641
Ei=137.36 joule/cm2 or
Ei=137.36 x (1.2/5) cal/cm2 = 32.97 cal/cm2
Incident energy at 80% arcing fault current is
Ei= 4.184 (1.5) (7.59) (0.773/0.2) (610/600)1.641
Ei=140.7 joule/cm2 or
Ei=140.7 x (1.2/5) cal/cm2 = 33.76 cal/cm2
As per IEEE 1584, both 100% and 85% incident energies
correspond to a hazard level 3 and would require a PPE rating of 40
cal/cm2.
Arc-Flash Boundary Calculation
Using the equation 7.5, the arc-flash boundary is calculated as
DB=[4.184 Cf Ein (t/0.2) (610x/EB)]1/x
At 100% arcing current:
DB=[4.184 (1.5) (6.727) (0.633/0.2) (6101.641/5)]1/1.641
DB=4518mm

Chapter 1-Introduction

Page 375

At 85% arcing current:

DB=[4.184 (1.5) (5.643) (0.773/0.2) (6101.641/5)]1/1.641
DB=4585mm
This result implies that if there is an operational need to
open the Line side of secondary breaker of TRL3A of MCC8 for
maintenance or inspection while energized, a safety barrier of 4.6
meters from the circuit breaker cubicle should be maintained and
only personnel with a 40 cal/cm2 arc-flash suit should be allowed to
enter the said barrier.
Calculation results by repeating the same procedure for the
rest of the medium-voltage switchgears are presented in table 7.5,
7.6, 7.7 and 7.8.
Table 7.5 Calculation results for normalized incident energy
ARCFLASH
POINT

12
13
14
15
16
17
18
19
20
21

Location

Isc

Iarc

En

En

Line side of secondary

breaker of TRL3A
Load side of secondary
breaker of TRL3A
Load side of the LV
motor breakers
Load side of the LV
Panels breakers
Load side of the LV
panel
Line side of secondary
breaker of TRL3B
Load side of secondary
breaker of TRL3B
Load side of the LV
motor breakers
Load side of the LV
Panels
Load side of the LV VFD
panel

46

22.45

6.727

5.643

46

22.45

6.727

5.643

46

22.45

6.727

5.643

46

22.45

6.727

5.643

46

22.45

6.727

5.643

47

22.85

6.859

5.754

47

22.85

6.859

5.754

47

22.85

6.859

5.754

47

22.85

6.859

5.754

23.44

12.8

3.666

3.075

Chapter 1-Introduction

Page 376

Table 7.6 Calculation results for incident energy at 100%

arcing fault current level for Low-Voltages Loads
ARCFLASH
POINT

12

13

14
15
16
17

18

19
20
21

Location
Line side of
secondary breaker of
TRL3A
Load side of
secondary breaker of
TRL3A
Load side of the LV
motor breakers
Load side of the LV
Panels breakers
Load side of the LV
panel
Line side of
secondary breaker of
TRL3B
Load side of
secondary breaker of
TRL3B
Load side of the LV
motor breakers
Load side of the LV
Panels
Load side of the LV
VFD panel

Chapter 1-Introduction

E
(J/cm2)

E
(cal/cm2)

Hazard
Level

137.36

32.97

65.68

15.76

6.51

1.56

6.51

1.56

6.51

1.56

135.44

32.51

54.86

13.17

6.63

1.59

6.63

1.59

3.55

0.85

Page 377

Table 7.7 Calculation results for incident energy at 85%

arcing fault current level for Low-Voltages Loads
ARCFLASH
POINT

12

13

14

15

16
17

18

19

20
21

Location
Line side of
secondary
breaker of TRL3A
Load side of
secondary
breaker of TRL3A
Load side of the
LV motor
breakers
Load side of the
LV Panels
breakers
Load side of the
LV panel
Line side of
secondary
breaker of TRL3B
Load side of
secondary
breaker of TRL3B
Load side of the
LV motor
breakers
Load side of the
LV Panels
Load side of the
LV VFD panel

Chapter 1-Introduction

t
(s)

E
(J/cm2)

E
(cal/cm2)

Hazard
Level

0.77

140.70

33.77

0.37

67.64

16.23

0.03

5.46

1.31

0.03

5.46

1.31

0.03

5.46

1.31

0.75

138.28

33.19

0.30

56.23

13.50

0.03

5.57

1.34

0.03

5.57

1.34

0.03

2.97

0.71

Page 378

Table 7.8 Calculation results for Arc-Flash Boundary (AFB)

for Medium-Voltage Loads
ARC-FLASH
POINT

12
13
14
15
16
17
18
19
20
21

Location
Line side of secondary breaker
of TRL3A
Load side of secondary breaker
of TRL3A
Load side of the LV motor
breakers
Load side of the LV Panels
breakers
Load side of the LV panel
Line side of secondary breaker
of TRL3B
Load side of secondary breaker
of TRL3B
Load side of the LV motor
breakers
Load side of the LV Panels
Load side of the LV VFD panel

AFB
(mm)
100%

AFB
(mm)
80%

4518

4585

2882

2934

704

633

704

633

704

633

4480

4537

2583

2622

713

640

713
487

640
437

Based on the results of Low-voltage arc-flash calculation,

the maximum incident energy will be generated by an arc-flash
event at the line side of secondary breaker of TRL3A/B with a
calculated energy at 100% arcing current of 33.97/33.51 cal/cm2
and at 85% arcing current of 33.77/33.19 cal/cm2. For both
situation, the hazard level is 4 and requires PPE rating of 40cal/cm2
and an arc-flash boundaries of about 4.6m. These distances from
the breaker cubicle must be maintained in case there is a need to
perform live inspection and maintenance and that these boundaries
should only be accessed by personnel with appropriate training and
equipped with arc-flash suit rated at 40cal/cm2. As shown on table
7.9, the minimum arc-flash boundary is at the load side of the LV
VFD panel which is about 437mm and requires an arc-flash suit of
5cal/cm2.
Chapter 1-Introduction

Page 379