A Practical Approach to Arc Flash

Hazard Analysis and its Reduction

1
 Contents
What is Arc Flash Hazard & Arc Flash Study ?
Standards related to Arc Flash Hazard
Arc Flash Calculation Steps
Different terminologies related with Arc flash
C-lines employed for sizing of protective devices
Arc Flash Calculation Example
Methods to reduce the Arc Flash Hazard

2
 Arc Flash Hazard
A dangerous condition associated with release of
energy caused by an Electric Arc.

A B A B

Bolted Short Circuit Arcing Short Circuit 3

 Arcing Short Circuit
Extreme Heat 20,000 C Molten Metal
( 5 times temp. of sun )

Pressure Waves

Sound Waves

Shrapnel
Copper Vapor:
Solid to Vapor
Expands by Hot Air-Rapid Expansion
67,000 times

Intense Light ( More than 2000

times that of normal office light ) 4
 Causes of Electric Arc
Loose connections
Insulation failure
Poorly maintained equipment
Voltage transients
Unsuccessful Short Circuit Interruption
Dust and impurities
Corrosion
Condensation
Spark discharge
Overvoltage across narrow gaps
Improper work procedures
5
 Impact of Electric Arcs

Serious Injuries & Medical Costs

Fractures, serious burns or even death.

Equipment damage & Repair Cost

Switchgear replacement
Other gear in close proximity

Production Loss
Considerable costs due to Lost
Production and delayed deliveries

OSHA Fines

6
What is an Arc flash Study ?

A study investigating a
workers potential exposure
to arc flash energy,
conducted for the purpose of
injury prevention
and the determination of safe
work practices
and appropriate levels of
PPE.

7
 Standards Related to Safety
NFPA 70E-2004 :
Standard for Electrical Safety in the Workplace

OSHA 29 Code of Federal Regulations (CFR)

Part 1910, Subpart S

IEEE 1584-2002 :
Guide for Arc Flash Hazard Analysis

IEEE C37.20.7-2001:
IEEE Guide for Testing Medium-Voltage Metal-
Enclosed Switchgear for Internal Arcing Faults

NEC - Article No.-110.16

8
ARC Flash Standard Summary

16
 Arc Flash Analysis Process
1 Collect system and installation data
2 Determine system modes of operation
3 Determine bolted fault current
4 Calculate arcing fault current
5 Find protective device characteristics
and arc duration
6 Select working distances
7 Calculate incident energy
8 Calculate flash protection boundary
9 Determine PPE (risk hazard) category

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 Arcing Fault Current
For bus voltage < 1 kV and 700A IB 106kA
log (IA) = K + 0.662 log (IB) + 0.0966 V + 0.000526 G
+ 0.5588 V log (IB) 0.00304 G log (IB)
where
log log10
IA arcing fault current
K 0.153 for open configuration and
0.097 for box configuration
IB bolted fault current 3phase sym rms kA at the bus
V bus voltage in kV
G bus bar gap between conductors in mm

For bus voltage >= 1 kV and 700A IB 106kA

log (IA) =0.00402 + 0.983 log (IB)

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 Incident Energy
Energy Per Unit of Area Received On A Surface
Located A Specific Distance Away From The Electric
Arc, Both Radiant And Convective, in Units of
cal/cm2.

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 Incident Energy
log (En) = K1 + K2 + 1.081 log (Ia) + 0.0011 G
En Incident energy (J/cm2) normalized for 0.2s arcing duration
and 610mm working distance
K1 0.792 for open configuration
0.555 for box configuration (switchgear, panel)
K2 0 for ungrounded and high resistance grounded systems
-0.113 for grounded systems
Ia Arcing fault current
G gap between bus bar conductors in mm

solve En = 10 log En

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 Incident Energy
Incident Energy convert from normalized:

E = 4.184 Cf En (t/0.2) (610X / DX)

E incident energy (J/cm2)

Cf 1.0 for voltage above 1 kV and
1.5 for voltage at or below 1 kV
t arcing duration in seconds
D working distance
x distance exponent

x Equipment Type kV
1.473 Switchgear <= 1
1.641 Panel <= 1
0.973 Switchgear >1
2 Cable, Open Air

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 Flash Boundary
DB arc flash boundary (mm)

DB = [ 4.184 Cf En (t/0.2) (610X / EB) ]1/X

where
EB incident energy set 5.0 (J/cm2)
Cf 1.0 for voltage above 1 kV and
1.5 for voltage at or below 1 kV
t arcing duration in seconds
x distance exponent

x Equipment Type kV
1.473 Switchgear <= 1
1.641 Panel <= 1
0.973 Switchgear >1
2 all others

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Flash Protection Boundary (FPB)

FPB dependent on fault level and time duration.

! WARNING
Ar c F la sh a n d S h ock Haz ar d
Ap p r op ria te PP E Req u ire d
Warning label
provides
34 i nch Flash Hazar d Boundary
3. 46 cal/cm^2 Flash Hazard at 18 inches
VR Gloves -Tool s, Proper C l othes, Safety Glasses,
C l ass 1
Hardhat
480 V AC Shock Haz ard wh en cov er i s removed
42 i nch Lim ited A ppr oach
12 i nch Restri cted A ppro ach
1 inch Prohi bited A ppr oach
B us Name: PP-MC C-G81, Prot D evi ce: PP-PD P- G71-6

boundary
information

Flash Boundary 4 ft. or calculated

Limited Restricted Prohibited

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 Flash
Flash Protection
Protection Boundary
Boundary (FPB)
(FPB)
Must
Must wear
wear appropriate
appropriate PPE
PPE
Equipment

Prohibited Shock Boundary: Qualified Persons Only. PPE as

if direct contact with live part
Restricted Shock Boundary: Qualified Persons Only

Limited Shock Boundary: Qualified or Unqualified Persons*

* Only if accompanied by Qualified Person

Note: shock boundaries dependent on system voltage level 24

Appropriate PPE

25
 Category 4
Category Category
Cotton
3
2 Underwear
Cotton
Short PPE Category Level
Cotton Underwear
Underwear
Sleeved T Shirt (Natural Fiber)
Category 1 Sleeved
Short Sleeved T Shirt (Natural Fiber)
Short
FR Sleeved
Long T Shirt
shirt (Natural
& Long Fiber)
Pants
Category
FR
Cotton OUnderwear
Long Sleeved shirt & Long Pants
FR Long
FR Sleeved
Coverall shirt
( Over the&above)
long Pants
Cotton Underwear

FR LongFR Coverall
Sleeved ( Over
shirt the above)
& long Pants or FR Coverall
Arc
orLong
FR Flash
Coverall
Sleeved
Suit Hood
instead
shirt (Natural Fiber)
Arc Flash Suit Hood
instead
Arc Flash Suit Jacket (multi-layer )
Arc Rated Wrap around
Long Pants
Hard (Natural
Hat Fiber)Face Shield

Hard
HardArc Hat
Flash
Hat
Safety SuitorPants
Glasses (multi-layer )
Goggles
Safety
Hard Hat
Glasses or Goggles
Safety
Safety Glasses or Goggles
GlassesProtection
Hearing or Goggles
Safety
Leather
Hearing
Glasses
Gloves or Shoes
& Gogglesas needed
Protection
Leather Gloves
Hearing Protection
& Shoes as needed
Leather Gloves & Shoes as needed
Leather Gloves & Shoes as needed

Hazard Risk Hazard Risk

Category 0 Category 4
Hazard Risk Hazard Risk
Category 1 Hazard Risk 26
Category 2
Category 3
Constant Energy lines ( C Lines )

Constant energy with respect to Time & Current 27

Fuse TCC Adjustable circuit Breaker TCC 28
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 Derivation of C- line points
Arcing fault Current (Ia):
log (Ia) = K + 0.662 log (IB) + 0.0966 V + 0.000526 G
+ 0.5588 V log (IB) 0.00304 G log (IB) ..(1)

Incident Energy (E):

E = 4.184 Cf .[10 (K1 + K2 + 1.081 log (Ia) + 0.0011 G) ] .(t/0.2).(610X / DX)

.(2)
t = [E.(0.2).4.1667] / { 4.184.(610X / DX). Cf .[10 (K1 + K2 + 1.081 log (Ia) + 0.0011 G) ] }
...(3)
.(4)
t = f [ k.(Ia)-1.081 ]

Constant ( C ) = t / [ k.(Ia)-1.081 ] .(5) 31

 Plotting a C-line

Procedure :

1] Select value of k
2] select ( Ia1,t1) to correspond
max. arcing fault current
3] Calculate C from eq. no. (5)
4] Select Ia2
5] Calculate t2
Mark the point (Ia2,t2)
6] Connect the two point with
A line segment.

32
 A
A
A

Fig B - Changes in Main CB

Fig A - Original Setting 33
settings & Fuse type
 Arc Flash Calculation - Case Study 1

46kA,3Phase bolted fault Current on Station bus

Questions:
1] What is Arcing Fault ?
2] How long does it take for
main breaker or primary
fuse to clear ?
3] What is incident Energy ?
4] What is proper PPE?

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SOLUTIONS THAT REDUCE ARC FLASH INJURIES
and DAMAGE
Faster Clearing Time
Reduce Available Fault Current
Label Equipment
Train Personnel
Use PPE
Minimize Risk with Good Safety Practices
Move People Further Away
Redirect Blast Energy
Prevent Fault

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Arcing Fault Clear Time
CURRENT IN AMPERES

1000

Min Max
A4BQ Fuse

100 Trip Time

for Low
Arcing
Fault
10

TIME IN SECONDS
1

0.10

0.01
0.5 1 10 100 1K 10K

tcc3.tcc Ref. Voltage: 480 Current Scale x10^0

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 Arc Flash Incident
480 Volt System
22,600 Amp Symmetrical Fault
Motor Controller Enclosure
6-Cycle Arcing Fault (0.1 sec)

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 Issues Current Limiting
CURRENT IN AMPERES

1000

Fuse
100 In Current Limiting Range
Operates in < Cycle
Limits Current from 0 to >90%

TIME IN SECONDS
10
Limits More at Higher Currents

0.10

0.01
0.5 1 10 100 1K 10K

tcc8.tcc Ref. Voltage: 480 Current Scale x10^0

Current Limiting Range

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 Arc Flash Incident
480 Volt System
22,600 Amp Symmetrical Fault
Motor Controller Enclosure
Current Limiting Device with < Cycle operation
(.0083 sec). Note that Arcing Fault must be in
current limiting range.

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 Issues Current Limiting
CURRENT IN AMPERES
Ignoring Current-Limiting Effects
1000 Operates in 0.01s
2.4 Cal/cm2 at 200 kA
2.3 Cal/cm2 at 100 kA
Fuse
100
1.2 Cal/cm2 at 50 kA

TIME IN SECONDS
200 kA for 0.01 seconds = 2.4 Cal/cm^2
10 100 kA for 0.01 seconds = 2.3 Cal/cm^2

50 kA for 0.01 seconds = 1.2 Cal/cm^2

All 3 values = Class 1

0.10

0.01
0.5 1 10 100 1K 10K 100K
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tcc1.tcc Ref. Voltage: 480 Current Scale x10^0
 Issues Fault Values
Maximum Faults used for Equipment Selection
Minimum Faults Often Worst Case for Arc Flash
Requires accurate utility fault contribution (not infinite source)
Consider lowest pre-fault voltage
Consider operating conditions with minimum motors
Consider operating conditions with/without generators
Consider stand-by operating modes

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Issues Long Trip Times
CURRENT IN AMPERES

1000

Arcing Fault Arcing Fault

Minimum Maximum
DSII
Tolerance Tolerance
100

Artificial 2
second
maximum
10 arc duration

TIME IN SECONDS
1

0.10

0.01
0.5 1 10 100 1K 10K

tcc2.tcc Ref. Voltage: 480 Current Scale x10^0

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Issues - Faster Trip Times
CURRENT IN AMPERES

1000
Arcing Fault Arcing Fault
Minimum Maximum
Tolerance Tolerance
DSII

100

Trip Time for

Minimum
10

TIME IN SECONDS
Arcing Fault

Trip Time for

Maximum
Arcing Fault
0.10

0.01
0.5 1 10 100 1K 10K

tcc2.tcc Ref. Voltage: 480 Current Scale x10^0

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 Issues - Coordination
Coordination Traditionally used for Equipment
Protection and System Reliability
Arc flash requirements brings new safety focus to coordination studies
looking at minimum faults and setting faster trip times.
Faster trip times may cause more nuisance trips.
Alternative protection schemes may gain popularity (differential
protection, zone interlocking, light sensors, etc.)

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 Reduce Available Fault Current
( Reduce Incident Energy )

High Resistance Grounding

Typically Under 5 Amps

Pulsing Contactor
Many Options
Does Not Preclude PPE

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Label Equipment

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Train Personnel

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Wear Personal Protective Equipments (PPE)

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 Minimize Risk with Good Safety Practices

Bad Exposed Back of Neck Good All Body Protected

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 Move People Further Away

Remain physically outside the flash protection boundary.

Therefore NO ARC FLASH HAZARD protection required!

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Remote Switching: Chicken Switch

Without With

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 Redirect Fault Energy

5/15 kV Arc Construction

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Arc Detection Relay Block Diagram

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Typical Optical Fibre Routing

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 Conclusion
With the increased emphasis on safety in the workplace ,
companies are required to perform an Arc Flash Hazard
analysis as per NFPA 70E and IEEE1584.
Constant Energy lines (C-Lines) are useful in sizing of
overcurrent devices for protection of equipment & personnel.

Selection of appropriate PPE, increasing the working distance

and modifying the work methods is the simple way to reduce
arc flash hazards.
Effective way to reduce an Incident Energy in an existing
electric system is to review and modify overcurrent
protection settings by
A] Reducing available fault current
B] Reducing the Clearing time
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 References

[1] IEEE Guide for Performing Arc-Flash Hazard Calculations,

IEEE 1584-2002.
[2] NFPA 70-2002. National Electrical Code & Electrical Safety
Requirements for Employee Workplaces, NFPA 70E-2004.
[3] IEEE Recommended Practice for Protection and Coordination,
IEEE 242-2001 (IEEE Buff Book).
[4] H.W. Tinsley III and M. Hodder, A practical approach to arc flash hazard
analysis and reduction in Proc. IEEE IAS Pulp and Paper Ind.Com. 2004.
[5] Robert A. Wilson, Arc flash hazard Analysis and Mitigation
in Western Protective Relay Conference Spokane, 2004
[6] M.Hodder,W.Vilcheck,F.Croyle,D.Mccue, Practical Arc flash Reduction,
IEEE Ind. Appl.Magzine, June 2004
[7] J. C. Das, Design Aspects industrial Distribution Systems
to limit Arc Flash Hazard IEEE Ind. Appl. Nov 2005.

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Thank You

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