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8/11/2019 Understanding Arc Flash.pdf
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S – Stop
top
A – Arcrc
F – Flash
lash
E – Episodes
pisodes
T – Through
hrough
Y – Your Knowledge
our Knowledge
Presented by
resented by
Timothy W. Trotter, P.E., RCDD, LEED AP
imothy W. Trotter, P.E., RCDD, LEED AP
S.A.F.E.T.Y.
.A.F.E.T.Y.
Understanding
nderstanding
Arc Flash
rc Flash
What is Arc Flash?
hat is Arc Flash?
NFPA 70E defines flash hazard as “a
dangerous condition associated with the
release of energy caused by an
electric arc.”
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A calorie is the energy required to raise one
gram of water one degree Celsius at one
atmosphere. At 1 second, 1.2 cal/cm
2
of
heat energy can cause a second degree burn.
One cal/cm
2
is equivalent to the amount of
energy produced by a cigarette lighter in
one second.
What is a Calorie?
hat is a Calorie?
Incident Energy
ncident Energy
The incident energy is a measure of
thermal energy at a working distance from
an arc fault. The unit of incident energy is
cal/cm
2
or J/cm
2
.
Arc Flash Incident
rc Flash Incident
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Background
ackground
May 2003
Troubleshooting energized outdoor switchgear
Three workers,
all wearing
polyester blend clothing
Voltage = 13,200V
A company security
camera filmed the entire
accident
AF Incident
F Incident
The next scene shows a ball
of flame totally engulfing the
three workers
AF Incident
F Incident
The worker who was standing in front of the equipment
on the left hand side is engulfed in flames
The worker laying in
the cell is propelled
outward in a ball of
flames
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AF Incident
F Incident
The worker who was at the bottom of the compartment is
crawling away from the equipment with his clothing on
fire
The worker on the
right lands on his back
with his feet in the air
The worker on the left
is running away
AF Incident
F Incident
State of shock
Panic after the Arc Flash
and Arc Blast
AF Incident
F Incident
The worker on fire is frantically tearing his coveralls from
his body
As he is doing this, we
can see the workpants
he is wearing underneath
his coveralls are on fire
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Injuries
njuries
Two workers 2
nd
& 3
rd
degree burns over 60% of the body
Synthetic hair nets and hardhat suspension burned into
scalp
One burn victim in
drug-induced coma
for 6 weeks while
burns being scrubbed
Injuries
njuries
3
rd
worker not burned but suffered neurological damage
from the blast
Note: He weighed
approximately 300 lbs.
and was thrown almost
12 feet backwards
Currently OSHA has
$148,000 in penalties
pending for serious
and willful violations
Injury Facts
njury Facts
Numerous workers are injured or killed each year while
working on energized equipment.
Defining incident energy hazards raises awareness of the
harm to humans that can result from an electric arc.
Injuries often include:
Severe skin burns
Hearing damage
Face and eye injuries
Blast pressure injuries
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Skin Damage
kin Damage
Skin damage will occur based on the intensity of the heat
generated by an electrical arc accident. The heat reaching
the skin of the worker is dependent on the following three
factors:
Power of the arc at the arc location
Distance of the worker to the arc
Time duration of the arc exposure
1992
992
-2000 Arc Flash Reports
000 Arc Flash Reports
Nonfatal shock and burn injuries
When is it acceptable to work on
hen is it acceptable to work on
Energized Equipment?
nergized Equipment?
Examples of increased or additional hazards
Interruption of:
Life Support
Emergency alarm systems
Hazardous location ventilation
Examples of unfeasibility:
Start-up testing
Trouble shooting diagnostics
Continuous process segment
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Causes of an Electric Arc
auses of an Electric Arc
Inadvertent contact
Loose connections
Insulation failure
Faulty equipment
Voltage transients
Unsuccessful Short Circuit interruption
Animals – squirrels, snakes, etc.
Types of Faults
ypes of Faults
Bolted Faults are characterized by a solidly connected fault
path causing high levels of current to flow through this solid
connection
Arcing Faults differ in the fact that the current actually
flows through ionized air causing an arc.
Major difference between these two types of faults is that
the energy in a bolted fault condition is dissipated in the
faulted equipment while an arcing fault releases energy out
into the surrounding environment.
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AF Incident
F Incident
480 Volt System
22,6000 Amp
Symmetrical Fault
Motor Controller
Enclosure
6-Cycle Arcing
Fault (0.1 sec)
Physical Effects of Arc Flash
hysical Effects of Arc Flash
Metal vapor and air expand very rapidly due to arc heating
Pressure wave knocks worker away from arc
Good – removes personnel from heat source
Bad – removes personnel from ladder
Pressure propels molten metal droplets out from arc source
Hot enough to ignite clothing
Structural damage to building
Damaging sound pressure
Eardrum rupture – Blindness - Lung Damage - Death
Arcing Short Circuit
rcing Short Circuit
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AF Incident
F Incident
Characteristics of an Electric Arc
haracteristics of an Electric Arc
An electrical arc will oscillate and escalate
if not constrained
A 1-ph arc can engulf a second or third
conductor in two cycles
Arc current propels the arc away from the
power source
Arc Terminals – up to 35,000 degrees F
Why Arc Flash is Dangerous
hy Arc Flash is Dangerous
An arc is a source of intense heat, light, sound & pressure
South Georgia in August: 100° (311k)
Surface of the Sun: 8,540 ° (5,000k)
Arc @ Arc Terminals: 35,540 ° (20,000+k)
Maximum arc power = ½ x bolted fault kW
Heat transfer depends on:
Size of arc (arc power)
Duration of arc
Distance from arc (1/x ^2)
Enclosure (“arc in box” focuses heat in one direction)
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How often Arc Flash occurs
ow often Arc Flash occurs
Five to 10 Arc Flash explosions occur in
electric equipment every day in the United
States. This number does not include cases
in which the victim is sent to an ordinary
hospital. Instead, these incidents are so
severe the victims require treatment from a
special burn center.
AF Incident
F Incident
Awareness is on the Rise
wareness is on the Rise
“Arc Flash” is the New Buzzword
Conferences/Seminars/Training
Language added to NFPA-70/70E
Technical Papers
Department of Labor (OSHA) Fines
Codes/Standards
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Codesodes
and
nd
Standards
tandards
NEC
EC
™2002 Article 110.16
002 Article 110.16
110.16 Flash Protection.
10.16 Flash Protection. Switchboards, panelboards,
industrial control panels, and motor control centers in
other than dwelling occupancies, that are likely to require
examination, adjustment, servicing or maintenance while
energized, shall be field marked to warn qualified persons
of potential electric arc flash hazards. The marking shall
be located so as to be clearly visible to qualified persons
before examination, adjustment, servicing or maintenance
of the equipment.
Warning for awareness, to prepare for future work
Field marked – not marked by manufacturer
No mention of values – only warning of hazard
NFPA 70E
FPA 70E
-2004
004
As a result of growing injuries, recent changes/additions
have been incorporated into the National Fire Protection
Association publication number 70E, the most recent
version being NFPA 70E-2004.
1) Work must be performed by a trained individual,
qualified for the work to be conducted (reference:
NFPA 70E-2004 110.6(D)(1)).
2) The best way to determine the potential hazard of
an arc flash is to conduct an arc flash hazard
assessment before work begins (reference: NFPA
70E-2004 130.3).
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NFPA 70E
FPA 70E
-2004
004
NFPA 70E: The fifth edition of the NFPA Std 70E Electrical
Safety Requirements for Employee Workplaces, published in
1995, established a flash protection boundary. This edition
gave recognition to the hazard of arc flash and required
employee protection from the flash hazard. The sixth
edition (published in 2000) expanded the requirement for
flash protection boundaries and the use of PPE.
Developments Leading to NFPA 70E
evelopments Leading to NFPA 70E
-2004
004
Large Hydro in Pacific NW
6.9kV Swgr
Racking in Breaker
AF occurred
One worker injured
5+ years
$10+ million
Developments Leading to NFPA 70E
evelopments Leading to NFPA 70E
-2004
004
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Developments Leading to NFPA 70E
evelopments Leading to NFPA 70E
-2004
004
Institute of Electrical and Electronics Engineers (IEEE)
In 1960 an AIEE paper was written that identified the potential for
injury from arching faults caused by such things as tools contacting bare
buses, rodents, dust, insulation failure or loose connections
In 1982, an IEEE paper was written that highlighted the electric
arc flash hazard. The paper described the electric arc blast as the
other electrical hazard
The Petro/Chem Industries Committee of the Industry
Applications Society of IEEE formed a working group to raise
awareness of electrical personnel to the hazards associated with
arching faults
In September 2002, IEEE issued the Guide for Performing Arc-
Flash Hazard Calculations, IEEEE Std P1584 – 2002
Developments Leading to NFPA 70E
evelopments Leading to NFPA 70E
-2004
004
The intent of NFPA 70E regarding arc
flash is to provide guidelines which
will limit injury to the onset of
second degree burns.
Developments Leading to NFPA 70E
evelopments Leading to NFPA 70E
-2004
004
NFPA 70E and IEEE P1584 joined
forces to do further research on
Arc Flash (Feb 2006)
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Occupational Health & Safety Administration
ccupational Health & Safety Administration
On 4 August 1991, OSHA included
language in its Title 29 Code of Federal
Regulations, Subpart S, for the electrical safe
work practices for general industry that
added arc flash as an additional hazard to
the shock hazard
OSHA 29 CFR 1910.333
SHA 29 CFR 1910.333
Safety related work practices shall be employed to prevent electric
shock or other injuries resulting from either direct or indirect
electrical contacts
“Live parts to which an employee may be exposed shall be de-
energized before the employee works on or near them, unless the
employer can demonstrate that de-energizing introduces additional
or increased hazards or is infeasible.”
The fundamental requirements is to de
he fundamental requirements is to de
-energize
nergize
Working on energized equipment is always a risk
orking on energized equipment is always a risk
OSHA 29 CFR 1910.335
SHA 29 CFR 1910.335
Personal Protective Equipment
“Employees working in areas where there are potential electrical
hazards shall be provided with, and shall use, electrical protective
equipment that is appropriate for the specific parts of the body to
be protected and for the work to be performed.”
Notice that OSHA does not specifically mention calculation of NFPA 70E.
However, since NFPA 70E is a recognized, published standard available to the
industry, OSHA will cite using requirements of NFPA 70E.
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What can be done
hat can be done
to ensureo ensure
compliance with
ompliance with
these Codes?
hese Codes?
Standards?
tandards?
Arc Flash
rc Flash
Analysis
nalysis
What is Arc Flash Analysis?
hat is Arc Flash Analysis?
A study for the
Investigation of a worker’s potential
exposure to arc flash energy
Prevention of worker injury
Determination of safe work practices
and appropriate levels of Personal
Protective Equipment (PPE)
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Coordination Study
oordination Study
Coordination traditionally used for Equipment
Protection and System Reliability
Arc Flash requirements bring 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
Two Methods
wo Methods
of
f
Analysis
nalysis
NFPA 70E 2
FPA 70E 2
-1.3.3
.3.3
“Flash hazard analysis shall be done before a person approaches any
exposed electrical conductor or circuit part that has not been placed
in an electrically safe work condition.”
IEEE 1584
EEE 1584
-2002
002
“IEEE Guide for Performing Arc Flash Hazard Calculations”
Incorporates results of extensive testing performed by several parties
Provides tools to calculating incident arc flash energy and protection
boundaries
Does not reduce NEC or 70E – instead, works with and alongside of
them
NFPA 70E 2
FPA 70E 2
-1.3.3
.3.3
Calculations for predicting the incident
energy produced by a three phase arc
Equations are complex and not very
intuitive
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IEEE 1584
EEE 1584
-2002
002
Provides a method of conducting an arc flash hazard analysis
This method uses equations that were developed using statistical
analysis of data from arc flash testing performed at laboratories
This standard includes a spreadsheet calculator that can be used
to solve the equations
A detailed arc flash hazard analysis using this method requires
the steps shown on the following slide
IEEE 1584
EEE 1584
-2002
002
Step 1: Collect power system data
Step 2: Determine the power system’s modes of operation
Step 3: Determine the bolted fault currents
Step 4: Determine the arc fault currents
Step 5: From the protective device characteristics find the arcing duration
Step 6: Record system voltages and equipment classes
Step 7: Determine working distances
Step 8: Determine incident energy for each work location in the study
Step 9: Determine the flash-protection boundary for each work location
in the study
Arc Flash Boundary
rc Flash Boundary
Distance from exposed live parts within which a person
could receive a second degree burn if electrical arc flash
were to occur.
The onset of second degree burns is at the 1.2 cal/cm
2
(5.0 J/cm
2
) level.
It is assumed that a second-degree burn will be curable
and will not result in death.
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Arc Flash Boundary
rc Flash Boundary
Arc Flash Boundary
rc Flash Boundary
Arc Flash Analysis Deliverables
rc Flash Analysis Deliverables
Input
nput - Single-line diagram
Study
tudy
- Short circuit duty assessment
Time-current coordination setting
Output
utput - Equipment labels
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Arc Flashrc Flash
Sample Labels
ample Labels
Sample Label
ample Label
Sample Label
ample Label
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Sample Label
ample Label
Protective
rotective
Clothing and
lothing and
PPEPE
PPE Categories
PE Categories
Category
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The selection of a level of Personal Protective Equipment (PPE)
should be a balance between the calculated incident energy
exposure and the work activity being performed while meeting the
following:
Provide enough protection to limit injury to a second
degree burn in all cases
Avoid having more protection than is needed and the
consequent risk of heat stress, poor visibility, and limited
body movement.
PPE Extent
PE Extent
PPE Rating
PE Rating
Arc Thermal Performance Exposure Value (ATPV)
Minimum incident thermal energy on a fabric or
material that results in sufficient heat transfer through
the fabric or material to cause the onset of a second
degree burn based on the energy transmitted through the
clothing
ATPV is expressed in cal/cm2. This energy is related to
the Stoll curve
The ATPV rating is an average of 20 tests performed
using the ATM F1959-99 standard
PPE ASTM Standard
PE ASTM Standard
ASTM F1506-02a – Standard Performance Specification for
Textile Material for Wearing Apparel for Use by Electrical
Workers Exposed to Momentary Electric Arc and Related
Thermal Hazards 2002a
Developed to give minimum performance specs for
protective clothing
Major requirement being that the fabric is flame
resistant
Results must be reported to the end user as an Arc Rating
on a garment label
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PPE Material
PE Material
OSHA requires that the clothing, which an employee wears,
does not contribute to the severity of any injuries he or she
incurs as a result of an electric arc
Includes the use of the prohibited fabrics in any layer of a
multi-layer outfit (inside, middle or outer)
Best to use some type of flame-resistant or flame-retardant (FR)
clothing
Examples include FR cotton and wool. Nomex and PBI/Kevlar
PPE Flame Resistance
PE Flame Resistance
Flame resistance is characteristic of a fabric that causes it to not
burn in air
Often confused with flame retardant which is a term used to
describe a chemical substance that imparts flame resistance on
fabric
Government reports note the majority of severe and fatal burn
injuries are due to clothing igniting and continuing to burn, not
by the exposure itself
PPE Layering
PE Layering
Layering significantly increases the level of protection
Two thin layers are better than one thick layer
Layer of air acts as a “buffer zone” between layers of flame
resistant fabrics
Some multi-layer testing has been done by various fabric
manufacturers and ASTM Task Groups (varies dramatically
with different two-ply systems.)
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Protective Clothing and PPE
rotective Clothing and PPE
Multi-layering Testing
PPE Care
PE Care
Expected Lifetime and Effects of Cleaning
Wear life is affected by laundering
Industrial laundering will create more wear on a garment
than home laundering
Garments manufacturer’s provide the expected lifetime
based on use and laundering
Repeated abrasion of any type will shorten wear life in the
area on the garment where the abrasion occurs
PPE Suit Versus Synthetic Blend
PE Suit Versus Synthetic Blend
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NFPA 70E Methods for Selecting Protective Clothing & PPE
FPA 70E Methods for Selecting Protective Clothing & PPE
Matrix Approach Using Table 130.7(C) (9)(a) And Table 130.7
(C) (10) From NFPA 70E-2004
Table 130.7(C) (9)(a) from NFPA 70E-2004 lists a number of
common work tasks with the respective Hazard/Risk Category
associated with each task
If the work task is not shown in the table, then a flash hazard
analysis is required
If the work location has greater than assumed short circuit
capacity or longer than assumed fault clearing times as shown
in the notes of the table, then a flash hazard analysis is required
NFPA 70E Methods for Selecting Protective Clothing & PPE
FPA 70E Methods for Selecting Protective Clothing & PPE
IEEE Methods for Selecting Protective Clothing & PPE
EEE Methods for Selecting Protective Clothing & PPE
Takes the NFPA 70E model to the next level
Uses systematic approach to calculations and
PPE selection
Method incorporated into powerful Electrical
analysis software such as SKM PowerTools
™
Produces more accurate results – no longer
relies on table lookup
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Ok, we have established the
fact that Arc Flash is not
only dangerous but
potentially
FATAL
ATAL. What
can you do, as an Owner, to
reduce risk for you and your
workers?
Reducing
educing
Arc Flash
rc Flash
Minimize Risk with Good Safety
inimize Risk with Good Safety
Practices
ractices
De-Energize Equipment versus
“Working It Live” unless increased
hazards exist or infeasible due to design
or operational limitations
Switching remotely (if possible)
Closing and tightening door latches or
door bolts before operating a switch
Standing to the side and away as much
as possible during switching operations
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Minimize Risk with Good Safety
inimize Risk with Good Safety
Practices
ractices
Minimize Risk with Good Safety
inimize Risk with Good Safety
Practices
ractices
Electrically Safe
lectrically Safe
The following steps must be taken to ensure an electrically safe
work condition
Find all possible sources of supply
Open the disconnecting device for each source
Where possible visually verify the device is open
Apply lock-out/tag-out devices
Test voltage on each conductor to verify that it is de-energized
Apply grounding devices where stored energy or induced volt age could exist
or where de-energized parts could contact live parts
Remember personal protective equipment must be worn when workingwithin the flash
protective boundary until the circuit is verified to be de-energized
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Safe Operations
afe Operations
Design Methods for Reducing
esign Methods for Reducing
Incident Energy
ncident Energy
Lower available Fault Current
Faster Tripping Time
Equipment Alternatives
Equipment Alternatives
quipment Alternatives
Current-Limiting Breakers/Fuses – Reduces the clearing time
which reduces the incident energy
Metal-Clad Switchgear – Structural design reduces the possibility
of arcing faults within the enclosure
Arc Resistant Switchgear – Structural design includes robust
design and pressure relief vents which re-direct the blast away
from the worker
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AF Incident
F Incident
AF Incident
F Incident
AF Incident
F Incident
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AF Incident
F Incident
AF Incident
F Incident
AF Incident
F Incident
Same system
Add Current
Limiting Device
with <1/2 cycle
operation (.0083
sec)
Note that Arcing Fault
must be in current
limiting range
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AF Incident
F Incident
AF Incident
F Incident
AF Incident
F Incident
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AF Incident
F Incident
AF Incident
F Incident
Equipment Alternatives
quipment Alternatives
Arc Flash Reduction Maintenance
Switch (ARMS)
Remote Power Racking (RPR)
Zone-Selective Interlocking (ZAI)
Current-Limiting MCCBs
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Arc Flash Reduction Maintenance
rc Flash Reduction Maintenance
Switch
witch
™ (ARMS) Retrofit of LVPCBs
ARMS) Retrofit of LVPCBs
Arc Flash Reduction Maintenance
rc Flash Reduction Maintenance
Switch
witch
™ (ARMS) Retrofit of LVPCBs
ARMS) Retrofit of LVPCBs
An external over-ride switch and circuitry are connected to a
breaker’s trip unit and is adjustable between 2.5x - 10x.
When a person wants to perform maintenance they close the
switch, which automatically over-rides all of the delay functions,
and causes the breaker to trip without any intentional delay
whenever a fault is detected. Use its lockout features for normal
lockout – tag-out procedures
Integral ARMS
ntegral ARMS
Has 5 user-selectable levels of
protection to choose maximum
protection, while avoiding
nuisance tripping
Blue color LED indicating
Maintenance mode
Can be remotely activated
through IR communication with
PDA
Available 3Q 2005
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Conclusiononclusion
First line of defense – DEENERGIZE
If Deenergization is not possible, make sure
EVERY feasible effort has been taken to REDUCE
the level of Incident Energy exposure
Develop and Maintain Arc Flash Hazard Analysis
Labels
Proper PPE
Be Prepared for Arc Flash
e Prepared for Arc Flash
This
his
…
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Not this
ot this
…
S A F E T Y
A F E T Y
–
Stop Arc Flash Episodes
top Arc Flash Episodes
Through Your Knowledge
hrough Your Knowledge
information gleaned from
nformation gleaned from
presentations by:
resentations by:
Questions?uestions?
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Thank youhank you
Timothy W. Trotter, P.E., RCDD, LEED AP
imothy W. Trotter, P.E., RCDD, LEED AP