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Arc-Flash Mitigation
A SYSTEMATIC APPROACH FOR COMPANY STANDARD POWER SYSTEM SCHEMES
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types. This knowledge makes planning and budgeting 1) to improve overall electrical safety by reducing the risk
for implementing arc-flash mitigation predictable from of an arc flash
a corporate perspective. Specific arc-flash mitigation 2) to ensure personnel survivability after an arc-flash event
techniques can be embedded in the specifications of 3) to ensure a reliable power supply by limiting equip-
new projects as well as company material standards to ment damage caused by an arc-flash event.
avoid unnecessary retrofit activities after installation. In addition to the GI, the companys engineering
Maintenance personnel can also be effectively trained design standard has minimum requirements for power
on arc-flash mitigation and safe work practices when system design. These include requiring arc-flash analysis
consistent solutions are implemented. This article dem- for all new electrical distribution equipment rated up to
onstrates a systematic approach to address dangerous 38 kV in accordance with IEEE 1584 [2]. The maximum
arc-flash locations for corporate planning purposes allowable amount for incident energy shall not exceed
and provides practical mitigation solutions that can be 8 cal/cm2. The arc-flash analysis is to be performed in
applied at many company facilities. conjunction with short circuit and protective device coor-
dination analysis in the detailed design phase.
Considerations for Safety Risks There are 1,500 substations distributed over 100 oper-
An electrical arc flash can damage equipment and injure ating facilities, and the company mandated the imple-
personnel. These injuries can range from minor burns mentation of arc-flash safety hazard assessments in all of
to third-degree burns as well as blindness, hearing loss, them. A best practice procedure was developed to guide
nerve damage, cardiac arrest, and potentially death. engineers in performing and reviewing arc-flash hazard
After a string of arc flashrelated injuries and fatalities, analysis using commercially available power system analy-
a large oil and gas company responded with a corporate sis and design software.
initiativethe Arc Flash Electrical Safe Operations Pro-
gram. The program implements arc-flash safety require- Current Mitigation Strategy
ments in all company facilities, deploys and evaluates The current mitigation strategy involves the deployment
new technologies, develops company-wide electrical of proven technology such as universal remote racking
worker certification, develops uniform company proce-
dures, provides clear delineation of responsibilities, and
promotes awareness programs for all electrical workers.
The companys electrical system operators (ESOs)
and technicians are the most exposed to the potential
dangers of arc flash. Arc-flash incidents can occur due
to lack of maintenance or when ESOs or technicians
ignore procedures, take shortcuts, or become overcon-
fident. They can also be caused by equipment failure
(such as mechanical misalignment or insulation failure)
or human error. Figure 1 shows a 15-kV switchgear
cubicle after an arc-flash incident, the result of cata-
strophic equipment failure.
Corporate History
The company published a general instruction (GI) doc-
ument in October 2009, which is the guiding document
of the Arc Flash Electrical Safe Operations Program.
However, the groundwork for this GI started much
earlier. The GI provides minimum safe work require-
ments for the protection of personnel against electrical
arc-flash hazards in the workplace in accordance with
the National Fire Protection Association 70E. Standard
for Electrical Safety in the Workplace [1]. The document
applies to construction, commissioning, start-up, opera-
tion, maintenance, and demolition activities at electri-
cal installations whenever there is the possibility that
an electrical arc flash may occur. The GI was recently
updated to include effective hazard mitigation solutions
using engineering and administrative controls. The
main reasons for the update were FIGURE 1. A damaged medium-voltage switchgear cubicle.
and remote switching devices to move the electrical arc-flash boundary. When the calculated arc-flash energy
worker outside the arc-flash boundary. In addition to exceeds 40 cal/cm2, then the equipment must be placed
these devices, the program requires arc-flash warning in an electrically safe work condition prior to any live
labels to be installed on all power distribution equipment work. Furthermore, personal protective equipment with
rated 38 kV and below. The label must show the calcu- arc thermal protective value greater than 40 cal/cm 2
lated arc-flash incident energy along with the calculated should be stored and available in all electrical substations,
ready for use. These initial strategies were put in place
to reduce risk to personnel while the various operating
facilities worked on completing arc-flash hazard analy-
sis. When the calculated arc-flash incident energy and
arc-flash boundaries became available and dangerous
locations (those with arc-flash incident energy greater than
40 cal/cm2) were identified, further arc-flash mitigation
was required for each facility. Figures 24 show normal
daily energized work activities performed throughout
the company. Figure 4 shows the method preferred by
company ESOs: use of a remote racking device available
in nearly all substations throughout the company.
Planning
While the company standards address new projects, they
are retroactive when it comes to safety. A plan was formu-
lated to address dangerous arc-flash locations in existing
facilities even before arc-flash studies are completed. Con-
sequently, the company assembled a corporate team to put
together a master power systems plan. The main purpose
FIGURE 3. An operator using a low-voltage breaker. is to budget for expenditures on power systems over the
next five years. The plan included arc-flash mitigation as an
integral safety element. The team had to rely on completed
extreme arc-flash incident energy of 118 cal/cm2. While the 13.8-kV switchgear (bus A), arc-flash incident energy
less probable because clearing time is typically lower than is, in all cases, below 4 cal/cm2 due to the sensitivity of
the case described earlier, dangerous arc-flash incident the applied high-impedance-bus differential protective
energy could also be present in LV and MV MCCs. As for relaying (87B) [3]. It is worth mentioning that 87B does
not cover the line side of bus A, and the fast clearing
time should only be considered for the line side when a
transformer differential (87T) scheme is overlapping with
the bus differential (87B) (Figure 5). The same discussion
T4 FDR applies to the load side of feeder breakers because the
typical location of differential current transformers (CTs)
is not where the cables exit the switchgear; therefore, the
300/5 OCR incident energy could exceed the incident energy allowed
50/51 T4 by the bus differential scheme. These facts could lead to
a false sense of safety; hence, electrical personnel need to
be aware of the capabilities of the implemented protec-
tion scheme.
T4
Y 3 MVA Technology Evaluation and Deployment
13.8/0.48 kV Arc-flash incident energy is proportional to working dis-
5.75 %z
tance, current, and time. As the working distance increas-
LV SWGR 1 MAIN LV SWGR TIE
es, the arc-flash energy decreases. The working distance
and the system voltage are normally factors that cannot
LV SWGR easily be adjusted. The time duration has the highest
0.48 kV
impact on energy levels. Because of this, most strategies
of arc-flash hazard mitigation focus on faster detection
LV MCC 1 FDR and clearing of the arc flash. It is very important to keep
the arcing time as short as possible. The company evaluat-
ed the following technologies to reduce arc-flash hazards:
LV MCC 1
0.48 kV Bus Differential Protection Relaying (87B)
Bus differential protection 87B is selective and fast with
a typical total operating time of 125 ms. When a fault
MTR 3 FDR MTR 5 FDR occurs in the zone of protection between the main and
feeder breakers, the protective device reacts by tripping
OL 1 OL 3
instantaneously. This limits personnel arc-flash exposure,
Cont 3 Cont 5
significantly reduces arc-flash incident energy, and limits
equipment damage. The application of bus differential
protection must be reviewed on a case-by-case basis
because it can be prohibitive due to the cost of retrofit-
MTR 3 MTR 5
ting: dedicated CTs must be installed on every circuit
100 HP 100 HP
breaker connected to the bus, and extensive field wiring
modification may be required. In addition, 87B cannot be
FIGURE 7. A Type III scheme showing a 0.48-kV switchgear/
implemented in LV systems due to spacelimitations in the
control gear.
switchgear. However, the company revised its standards
to mandate 87B for all 4.16-kV switchgear in Type II
schemes for all future projects [3].
Table 2. Arc-flash study resultsnumber of
locations/level Zone-Selective Interlocking (ZSI)
LV Line As mentioned previously, because the concept of bus dif-
Facility Level A Level B Level C Danger Side (%) ferential protection (87B) is difficult to implement for LV
switchgear, ZSI was developed to emulate the performance
F1 1 53 92 57 46
of 87B in a cost-effective manner. Fault clearing times of
F2 381 136 206 132 55 three to ten cycles can be reached by ZSI. This scheme
F3 1 198 59 152 50 utilizes communication signals between the main and
F4 4 81 96 30 90 outgoing feeder trip units to trip the main breaker with
no intentional delay when the fault is located on the bus
Acknowledgments
Level C
AFB = 14.74 The authors would like to thank Lisardo Lourido Martelo
IE = 22.76 and Ali Turken of Saudi Aramco for their contributions in
FCT = 0.383 developing this article.
LV SWGR 1
25.52 0.48 kV Author Information
.549 Rakan El-Mahayni (rakan.mahayni@aramco.com),
Level C
Jamal Bugshan, and Ritchie Pragale are with Saudi
AFB = 10.11
IE = 13.06 at 24 inch Aramco, Dhahran, Saudi Arabia. El-Mahayni and Prag-
FCT = 0.220 ale are Senior Members of the IEEE. Bugshan is a
Member of the IEEE. This article first appeared as Arc-
FIGURE 11. A Type III scheme showing a reduction in arc-flash incident Flash Mitigation for 1500 Substations; A Corporate
energy. Approach at the 2015 IEEE IAS Petroleum and Chemi-
cal Industry Committee Conference. This article was
reviewed by the IAS Petroleum and Chemical Industry
Committee.
50 MV 50-ms
Pickup Time Delay References
[1] Standard for Electrical Safety in the Workplace, NFPA 70E, 2015.
Trip
AND [2] IEEE Guide for Performing Arc-Flash Hazard Calculations, ANSI/IEEE
MV Circuit
Standard 1584, 2002.
50 LV Breaker
[3] J. L. Blackburn, Protective Relaying Principles and Applications, sec-
Pickup ond edition. New York: Marcel Dekker, pp. 335356.
NOT
[4] Eaton Consulting Application Guide, 15th ed., Eaton Corp., Glendale
Heights, IL, 2011, pp. 26.1.22.
50 LV Pickup: Low-Side Relay Instantaneous Pickup [5] Recommended Practice for Protection and Coordination of Industrial
and Commercial Power Systems, IEEE Standard 242, 2001.
50 MV Pickup: High-Side Relay Instantaneous Pickup
[6] F. Dixon, M. T. Yunas, V. Wedelich, J. Howard, H. E. Brown, S. N.
50 ms: Time Delay to Avoid Nuisance Tripping Sauer, Y. Xu, T. Markello, and W. Sheikh, Mitigating arc flashes using IEC
61850: examining a case at a chemical and refining facility, IEEE Ind.
Appl. Mag., vol. 20, no. 1, pp. 6469.
FIGURE 12. A suggested extended ZSI scheme using digital protective [7] R. Mahayni, J. Bugshan, and R. Pragale, ARC flash mitigation for 1500
relays. substations: A corporate approach, in Proc. IEEE Petroleum Chemical
Industry Conf., 2015, pp. 17.
arc-flash incident energy were identified. It was illus- [8] C. Mardegan and R. Rifaat, Considerations in applying IEEE recom-
mended practice for protection coordination in industrial and commer-
trated that the line side of LV switchgears constitutes a cial power systemsPart I, IEEE Trans. Industry Applicat., vol. 52, no. 5,
substantial portion of the overall dangerous locations in pp. 37053713, 2016.
any particular facility. Various technologies available on
the market were evaluated, and it was determined that,