19th Electrical Engineering Safety Seminar Nov.

09

Arc Fault containment design of LV boards

1) Fault Level: (System & Equipment)
Mechanical strength of the system (I peak =r.m.s. x 2.1)

3) Construction: (Operator safety)

Form of construction & Segregation

2) Current Rating:
Thermal Heating = I2t Watts loss Heat dissipation

Fault Rating of LV system. Typical installation

Feeder CCT=??A 50kA

MSB 2000A / 50kA

CCT=2000A 50kA

415V LV Transformer Rating; 2000A /50kA @ Terminals

11kV

MV Cable (& cable fixing) ??kA

Standards
AS3000 Section 3 Selection and Installation of Wiring Systems
3.1.2 Selection and Installation. Wiring systems shall be selected and installed to perform the following functions associated with the safe design and construction and proper operation of the electrical installation.
a) b) c) d) e) f)

Protection against physical contact with live parts Satisfy minimum current carrying capacity Provide Reliability connections and joints. Provide adequate strength of supports, suspensions and fixings. Suit intended use e.g. fire resistance, safety services etc. Protection against mechanical damage

Typical Cable Fixing

Stainless steal cable ties
220mm spacing
Single Core 33kA

3 Core 28kA

Singe Core 50kA

How many stainless steel cable ties do I need??

The Breaking Strength: Heavy duty 316 Grade S/Steal cable tie = 1,112N (250lb)
(This does not allow for impact strength or safety factor)

EN 50368:2003 CABLE CLEATS FOR ELECTRICAL INSTALLATION

Applying the formula - Ft = (0.17 x ip2) / S

Ft = Maximum Force on Conductor (N/m) ip = Peak Short Circuit Current (105kA) S = Cable Diameter if cables in trefoil (0.0354mm dia)

@50kA

105kA Peak2 x 0.17 = 53,550Nm 0.035mmDia = 48/mtr

1mtr / 53,550Nm

How many stainless steel cable ties do I need??

kA SPACING 20 mtr run = Qty Qty 1,000 Qty 714 Qty 408 Qty 180

50kA = 20mm = 40kA = 28mm = 30kA = 49mm = 20kA = 111mm =

Cable cleats @ 457mm spacing 118kA peak short circuit current for 0.1 sec.

Fault rating of Switchboard

Additions to AS/NZS 3439.1:2002
Main Circuits Within an Assembly
7.5.5.1.2

The conductors between busbars and the supply side of a single functional unit, as well as the components in this unit, may be rated on the basis of reduced shortcircuit stresses occurring in the load side of the short-circuit protective device in this unit provided that such conductors:
are tested as part of the short-circuit test on the functional units;

are substantial and not less than the rating of the functional units and, in no case, less than 4.0mm in cross-sectional area; are not more than 1M in length; and are provided with solid insulation (7.4.2.1) or shrouded in normal service to prevent faults between phases or between phases and earth or neutral

Additions to AS/NZS 3439.1:2002 Now in English

+ 50kA

Additions to AS3439.1:2002
Main Circuits Within an Assembly

Short Circuit Strength Tests

conducted at TCA Sydney (Test Report 101740-1) GE MCCBs rated 160A, 250A, 400A & 630A at a prospective fault level of 63kA

Arcing Fault Video 50kA- Elsteel

Construction: Operator safety Basics or Arcing Faults

An arc fault has to be manually started by something creating the path of conduction, dropping a metal part or by a failure, such as a breakdown in insulation. Arc faults <120V (At 120 volts and below, the fault will normally not sustain an arc). The cause of the short normally burns away during the initial flash and the establishment of highly conductive plasma then sustains the arc fault. The plasma will conduct as much energy as is available and is only limited by the impedance of the arc and the overall electrical system impedance.

Construction: Operator safety

Arc Flash Can reach 35,000 F. Exposure burns the skin directly and causes ignition of clothing, which adds to the burn injury. The majority of hospital admissions due to electrical accidents are from arc-flash burns, not from shocks. Each year people are admitted to burn centres with severe arc-flash burns. Arc-flashes can and do kill at distances of 3m.

Arc Blast The tremendous temperatures of the arc cause the explosive expansion of both the surrounding air and the metal in the arc path. - copper expands by a factor of 67,000 times when it turns from a solid to a vapour. The danger associated with this expansion is one of high pressures, sound, and shrapnel. - The high pressures can easily exceed hundreds or even thousands of kg per square meter, knocking workers off ladders, rupturing ear drums, and collapsing lungs. -The sounds associated with these pressures can exceed 160dB. - Material and molten metal is expelled away from the arc at speeds exceeding 1600km/hr, fast enough for shrapnel to completely penetrate the human body.

Effects of an arcing fault

Arcing Fault Video Unrestricted arcing Fault

Arcing Fault Video 50kA- Elsteel

Arcing Fault Video Operator

Operator & System Safety:

Australian Standards
- AS3000 change - AS3439 Arc Fault containment

AS3000 - 2007 wiring Rules Protection against Arcing Faults 2.5.5 Protection against switchboard internal arcing fault currents
2.5.5.1 General

Protection against arcing fault currents while the equipment is in service, or is undergoing maintenance, shall be provided for heavy current switchboards.

NOTE: Heavy current circuits are regarded as those where the nominal supply current to the switchboard is 800 A or more per phase.

AS3000 - 2007 wiring Rules Protection against Arcing Faults

The supply conductors within the switchboard shall have additional insulation or segregated

In addition, the switchboard shall comply with one of the following:

(a) Clause 2.5.5.2 to reduce the probability of initiation of arcing fault. (b) Clause 2.5.5.3. to limit the harmful effects of an arcing fault. (c) Both a) & b)

AS3000 - 2007 wiring Rules Protection against Arcing Faults

2.5.5.2 Reduction of the probability of the initiation of a switchboard internal arcing fault Heavy current switchboards shall be provided with internal separation in accordance with AS/NZS 3439.1 for (a) busbars from functional units; and (b) functional units from one another; and (c) terminals provided for external conductors from the busbar; and (d) a safety service circuit section of the switchboard,

NOTES: 1. Separation i.e. by the use of a Form 3b, Form 3bi, Form 3bh, Form 3bih, Form 4a, Form 4ah, Form 4aih, or Form 4b, Form 4bi, Form 4bh, Form 4bih constructed switchboard. 2. The required degree of protection, IP2X or IP1XB,

AS3000 - 2007 wiring Rules Protection against Arcing Faults

AS3000 - 2007 wiring Rules Protection against Arcing Faults

AS3000 - 2.5.5.2 Reduction of the probability of the initiation of a switchboard internal arcing fault Heavy current switchboards shall be provided with internal separation in accordance with AS/NZS 3439.1 Clause 8.1.1 of AS.NZS 3439.1:2002 TYPE TESTS Sub clause 8.1.1.(g) asks for Verification of the Degree of Protection & INTERNAL SEPARATION

Test Report 29540 from TEST SAFE Australia confirms degree of protection IP55 and Internal Separation IP2X on Elsteel TECHNO Switchboard System

AS3000 - 2007 wiring Rules AS/NZ3000 - 2007 wiring Rules Protection against Arcing Faults

Switchgear
Protection against Arcing Faults
2.5.5 Protection against switchboard internal arcing fault currents
In addition, the switchboard shall comply with one of the following: (a) Clause 2.5.5.2 to reduce the probability of initiation of arcing fault. (b) Clause 2.5.5.3. to limit the harmful effects of an arcing fault. (c) Both a) & b)

2.5.5.3 Limitation of the harmful effects of a switchboard internal arcing fault

Protective devices shall limit, the harmful effects of a switchboard internal arcing fault by automatic disconnection. Protection shall be initiated, i.e. pick up at a current less than 30% of the three-phase prospective fault level.

Clearing time = Maximum operating time

NOTE: Overcurrent protective devices should be set to as low an initiation current as possible while still maintaining the correct function of the installation, e.g. set higher than motor-starting currents. Earth fault protective devices shall have a maximum setting of 1200 A.

Arc Fault containment

AS3000 2007 Wiring Rules
Protection against Arcing Faults
Addresses prevention of arcing faults.

OPTIONAL - AS3439 Internal arcing fault

containment.

Designed to limit damage to the rest of the board. To enable the switchboard to be returned to service. (Down time and rectification cost)

Designed to protect the operator

Arc Fault containment

Points to NOTE:
Generally ARC FAULT CONTAINMENT refers to LIMITED Arc Fault Containment. (Limited to the operating time of the upstream protective device. ACB / MCCB / Fuse etc)

The protection setting of the device is important.

It is impossible to build a board for Unlimited arc fault containment for 1 sec.

Design Considerations for Arcing faults

1. Impact Shock of the ionised gas: - Blows off doors bends covers and smashes insulating barriers. 1. Volume of Gas: - Blows open doors and bends /breaks barriers

2.

Destructive effect of the arc. - Eats through metal and copper

3.

Travelling of the Arc in the conductive atmosphere of the Ionised gas. - Arc can travel in with the volume of gas to new conductive parts EARTH. - Into other compartments. - On to the line side bars creating an unlimited fault

Design concepts

Front Door

Front Door

Internal Arcing Fault Containment

FIXED TYPE COMPARTMENTS

Safety Options
NOTE: The switchboard will not protect the operator if - The doors are opened. - The covers are not properly fitted.

Safety options PPE Rack Breakers remotely RELT setting on Breakers Use Arc Vault type device

US standards - NFPA-based level of PPE required

Temperature Rise

Standards;

Switchboards: AS/NZ 3439.1 2002 Switchgear AS/NZ 60947-2

Temperature Rise
Standards SUMMARY
Switchboards: AS/NZ 3439.1 2002 (Cl 7.3-Table 2.)
Busbar and conductors. 70K temp. ..do not exceed.1050C

1050C 70K = 350C = Max. Switchroom Ambient Temp

Switchgear AS/NZ 60947-2 (Cl 8.3.3.6-Table 7.)

Max. Terminals of the device - 80K on ambient

1050C 80K = 250C = Max. Switchgear Ambient Temp Switchgear is in a Switchboard

Temperature Rise
Switchboards: AS/NZ 3439.1 2002

8.2.1.3 Temperature-rise test using currents on all apparatus

.For this test the incoming circuit is loaded to its rated current and each outgoing circuit is loaded with its rated current multiplied by the rated diversity factor.

Number of main circuits 2&3

Rated diversity factor 0.9 MCCB

125A/113A 160A/144A 250A/225A 400A/360A 125A/100A 160A/128A 250A/200A 400A/320A 125A/87.5A 160A/112A 250A/175A 400A/280A 125A/75A 160A/96A 250A/150A 400A/240A

4&5 6 to 9 10 & above

0.8 0.7 0.6

Temperature Rise

Temperature Rise

Temperature Rise
IDEAL RESULT= Enclosed Rated Switchboard and Switchgear
No de-rated main bars

No de-rated Flex or Cu bars

No de-rated circuit breakers

Elsteel / GE TestingReport No. TR-08-05-2

Ambient

RESULTS
MCCB LOAD Diversity Factor FG400A 400A 1

Temp 30C Temp Rise K 700

FE250A 250A FE160A 160A FE125A 126A

1 1 1

670 700 540

Temperature Rise Monitoring products

Elsteel Temp. Monitoring Software

Elsteel Temperature Vision

END