IE ARC Flash hazard

Arc Flash Protection

LV Switchgear
In Switchgear internal arc faults are more of a potential hazard to life and limb than a bolted short circuit. Arcing
faults can produce enormous gas pressures and extreme temperatures. Personnel in the path of super-hot gases
created by the arc can be killed or suffer serious burn injuries confining arc faults are a major safety concern.
By David Stonebridge, ABB Australia and Bardo Bayer, ABB Germany

A
rc Flash or Arc Faults are a major safety risk. 5–10 people a
day are involved in arc flash incidents in the USA alone. The
potential risks of arc flash or internal arcing faults has become
a major discussion point. In The US they are enforcing new safety arc
flash regulations and this will impact around the world.
For some OHAS Managers it has become too complex and some
employers take the attitude that if they tell their employees they must
wear Category 4 PPE when entering a switch room then they have
met their safety obligations.

Wearing Category 4 clothing may not be pleasant - heat stress, poor

visibility and limited body and hand movement may be experienced.

Level Stategy & Risk Action

1 Elimination Work
de-energised

2 Keep your distance Remote control

Arcing fault can develop into a major fire that can destroy the complete
switchboard and even damage the surrounding plant.

arc flash damage 3 Contain Arc fault containment

PPE does not provide 100% protection against an arc flash. The suit
only protects against the heat and can only be regarded as flame
resistant. What about your:
• Eyes – to protect against arc flash you need a welders face mask
• Lungs
 – the toxic gases associated with an arc flash can damage
4 Protect For anything else - PPE
your lungs, sense of taste and smell
• Hearing
 – the noise associated with arc flash can result in headaches,
loss of hearing and tinnitus
• Physical damage – the pressure wave associated with the arc
flash can blow you across the room resulting in broken bones.
Part of TOP System is to establish the safety strategy.
The TOP System A TOP System is difficult to apply to existing old switchgear.
PPE alone is not the answer you need to have a complete, simple Old switchgear provides a greater arc flash risk than new switchgear:
safety system like the TOP System: i Open door operation
T – Technical (Build-in Safety into the design of switchgear) ii Ageing insulation
• Arc fault containment iii Component failures
• Fully withdrawable iv Lower technical standards and quality
• All operations behind closed door v Corrosion and ingress of dirt and foreign materials
O–O  rganisational (Build- in Safety into the culture of the business) vi Sluggish tripping of circuit breakers
• Safety strategy, manuals with clear responsibilities & instructions vii The exposure is higher and the risks are greater as old switchgear
• Work permits needs more attention and maintenance to keep them in service.
• Safety reviews & training programs 80% of Arcing faults are a result of human error.
P – Personal (Build-in Safety into the people) Owing to the processing in some plants it is almost impossible to get
• Qualified site trained people a shut down to enable withdrawal of a circuit breaker. Withdrawing
• Appropriate PPE to suit the task. an ageing ACB from a Live bus is a significant arc flash risk.

4 Industrial Electrix September/October 2008

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The process can’t be stopped to rack-out a breaker

Safety is built in to the design of switchgear by using the withdrawable

technique

TOP strategy Level 2 (keep your distance)

All operations should be done with the compartment doors fully
secured. It should be remembered that in ‘Demountable’ or ‘Fixed’
technique arc fault containment is not possible with the compartment
door open. The breaker should be racked-out from the service position
to the isolate position with the door closed. The breaker can also be
racked-in from the isolate position to the service position with the
door closed. The breaker should only be closed with the door closed.
The breaker can be remote controlled.
The compartment door must be open to rack-out the breaker
Installing arc flash protection systems will help to minimise the arc TOP strategy Level 3 (Arc Fault Containment)
duration. The time is dependant on the operation of the up-steam To verify the safety of anyone standing in front of the switchgear
protection. Installing remote racking may not be possible. A solution against an internal arc fault, type tests are conducted to the
would be very costly. A Cat.4 PPE suit would be required to remove appropriate IEC or AS/NZ standards for the nominated prospective
this breaker. There is still a significant risk of the ACB being ejected fault current at a certified testing laboratory.
from the switchgear as a result of the arc pressure. To verify the safety of
anyone standing in front
Replace the ageing switchgear of the switchgear cotton
Switchgear has a life expectancy of around 25 years. Refurbishing the screens are fitted around
the switchgear to simulate
switchgear may extend the life by a few years this can be expensive clothing.
especially if you want to improve the safety. The safest and in the long
Each functional unit is tested
term most economical solution is to replace the ageing switchgear by initiating an arc inside
with type tested arc fault contained switchgear. Then you can the unit with a piece of wire
implement a TOP System. across all 3 phases.
To verify maximum safety
against internal arcing faults
the complete switchgear
should be tested. Incoming
Breaker, line and load side,
main busbars and the line
side of the functional units.

TOP strategy Level 4 (Personal Protection)

Build-in safety into the design of the switchgear with arc fault containment
and fully withdrawable switchgear. All operations are behind closed doors.
TOP System
T-Technical (Build-in Safety into the design of the switchgear) with Arc
fault containment and Fully withdrawable switchgear. All operations
are behind closed doors.
Providing you have achieved Levels 1, 2 and 3 no special arc resistant
PPE should be required for normal switchgear operations, Racking–in
or Racking–out of beakers and starters or the closing of breakers and
starters.
If it is necessary to access the busbars or do any modifications to the
switchgear the switchgear should be de-energised. This work should
be conducted under a TOP Safety 7-step work plan.

TOP strategy Level 1 (work de-energised)

Safety is built in to the design of switchgear by using the withdrawable
technique. Withdrawable functional units ensure working is de-
energised. The unit is switched off and withdrawn. It is not possible
to work on live equipment. A faulty unit can be removed and taken
away to the safety of a workshop for repair. A replacement unit can
be installed within minutes and withdrawable units have the added For further information, please contact David Stonebridge
safety advantage of a ‘Test’ and ‘Isolate’ position. email: david.stonebridge@au.abb.com

www.powertrans.com.au Industrial Electrix 5