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What is an arc flash?

Example of an arcing fault

ARC-FLASH
As much as 80% of all electrical injuries are
burns resulting from an arc-flash and ignition
of flammable clothing.
Arc temperature can reach 35,000F - this is
four times hotter than the surface of the sun
Fatal burns can occur at distances over 10 ft.
Over 2000 people are admitted into burn
centers each year with severe electrical burns

480-vac, 22.6 kA, 6 cycle clearing time

Cooper Bussmann, Newsletter, New for 2002, 110.16 Flash Protection Field Marking; Cooper Bussmann, Safety Basics

Cooper Bussmann, Inc. ,Safety Basics.

ARC-BLAST

Electrical Arc-Flash can

create blast pressure in
excess of 200 lbs/ft2.
Arc-Blast can cause
collateral damage and
extreme personal
damage.
Explode switchgear
Send molten metal at
extreme high velocities.

Results: Test No.4

Sound

141.5 db @ 2 ft.

P1

T2

>2160 lbs/sq.ft

> 225 C /437 F

T3
50 C / 122 F

T1
> 225 C /
437 F

> Indicates Meter Pegged

Cooper Bussmann, Inc., Safety Basics.

Where is it on our Equipment?

Adjacent to all HV switchgear

Adjacent to 480/415/380 volt panelboards
Next to Motor Control Centers or Auxiliary
cabinets
In front of thyristors on Converter and RPC
switch cabinets

Five risk categories

Category 0 Minimal
Category 1 Some
Category 2 Moderate
Category 3 High
Category 4 Dangerous

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NFPA 70E Hazard Risk 0

Minimal

This hazard risk category poses minimal risk.

Some examples of tasks in this category are
tasks that involve:
Circuit breaker or fused switch operation with
covers on when working with Panelboards rated
240 V and below. (LIGHTING, OUTLETS)
Main Contactor operation with enclosure doors
closed when working with NEMA E2 (fused
contactor) Motor Starters, 2.3 kV through 7.2 kV.
(HV Cabinet)

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NFPA 70E Hazard Risk 1

Some

This hazard risk category poses

some risk. Some examples of
tasks in this category are tasks
that involve:
Circuit breaker or fused switch
operation with covers off when
working with Panel boards rated
240 V and below.
Opening hinged covers (to
expose bare, energized parts)
when working with "Other 600 V
Class (277 V through 600 V,
nominal) Equipment.

WORKING ON CONTROLS
WITH CABINET DOORS
OPEN (COMMISSIONING
AND TROUBLESHOOTING)

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NFPA 70E Hazard Risk 2

Moderate

This hazard risk category involves tasks that

pose a moderate risk. Some examples of
tasks in this category are tasks that involve:
Circuit breaker or fused switch operation with
enclosure doors closed when working with 600 V
Class Motor Control Centers (MCCs) Operating
480/415/380 volt breakers)
Work on control circuits with energized parts 120
V or below, exposed when working on
unenergized Metal Clad Switchgear, 1 kV and
above (commissioning and troubleshooting)

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NFPA 70E Hazard Risk 3

High

This hazard risk category involves tasks that pose a

high risk. Some examples of tasks in this category
are tasks that involve:
Insertion or removal of live circuit breakers from cubicles,
doors open, when working with 600 V Class Switchgear
(with power circuit breakers or fused switches). P&H does
not recommend this as a practice.
Opening hinged covers (to expose bare, energized parts)
when working with live "Metal Clad Switchgear, 1 kV and
above. Commissioning and troubleshooting work on
control circuits inside cabinets and enclosures with trail
cable voltage inside (HV cabinets, transformers, HV
collector rings.)

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NFPA 70E Hazard Risk 4

Dangerous

This hazard risk category

represents tasks that pose the
greatest risk. Some examples
of tasks in this category are
tasks that involve:
Removal of bolted covers (to
expose bare, energized parts)
when working with NEMA E2
(fused contactor) Motor
Starters, 2.3 kV through 7.2 kV.
Opening voltage transformer or
control power transformer
compartments when working
with Metal Clad Switchgear,
1kV and above.
Commissioning and
troubleshooting work on HV
circuits inside cabinets and
enclosures with trail cable
voltage inside (HV cabinets,
transformers, HV collector
rings.)

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Protective Clothing

For most low-energy work (240 volts or below),

natural-fiber, non-melting clothing is adequate; some
higher risk tasks require Flame Resistant (FR)
clothing.
Most work on or near systems rated 480 volts and
above requires at least one layer of flame-resistant
(FR) clothing worn over natural-fiber clothing.
High-energy tasks require FR flash suits and flash
hoods worn over FR clothing

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Insulating Gloves
Rubber Insulating Gloves
are among the most
important articles of
personal protective
equipment for electrical
workers. They are the first
line of defense for contact
with any energized
components or lines.

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Arc Flash Clothing

Shirt jacket, parka
jacket, pants,
coveralls and
overalls with ARC
Rating 11 cal/cm2 to
100 cal/cm2 ATPV
values.

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Code Documents

Industry standards and regulations

U.S.: NFPA 70E-2009 Edition, MSHA at
this point uses this as a guideline
Canada: CSA Z462-08 Workplace
Electrical Safety, mandatory
Australia: has not adopted either
standard yet

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What is required to comply?

Arc flash warning signage with energy ratings

In order for engineering to calculate the energy, we
need input from the mine
The shovel, drill, dragline, or MMC is at the end of the
power distribution system
Each mines system determines the amount of
energy available to our machine
Two machines in the same mine may have different
energy available to them
An energy flow study is needed for each sale
This is the minimum we must do to comply

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Sample NEC Warning Article 110.16

LEVEL 1 PPE REQUIRED

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Output of
study

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Output of
study

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Output of
study

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Output of
study

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Arc Fault Energy Studies

Studies are by nature serial number specific

P&H currently using outside contractor
P&H investigating software so we can perform
our own studies
Cost of first study: $6,000
Time to complete study: 2 months
Necessary for code compliance, cost of doing
business
Need to build into the cost of machine

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Questions?

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