Hilton Hotel and Royale Palms

Myrtle Beach, South Carolina

July 11, 2011

Michael C. Dougherty, PE
A.J. Molnar, PE
Southeastern Consulting Engineers, Inc.
Charlotte, NC

What is Arc Flash?

Definitions
Per the National Fire Protection Association

(NFPA):
Arc Occurs when an insulating medium such as air

is breached by a conducting component.

Arc Flash The energy released during an arcing
fault. This occurs when current flows through a
medium that is not intended to conduct electrical
current. Because the arc current is not intended, the
arc current releases energy that also is not intended,
thus exposing a worker to unexpected hazards.

What is Arc Flash?

Definitions (continued)
Arc Flash Hazard - a dangerous condition

associated with the release of energy caused by an

electric arc.
Flash Hazard Analysis 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 the
appropriate levels of Personal Protective Equipment
(PPE).

ARC FLASH EXAMPLE

ARC FLASH EXAMPLE

Types of Electric Faults

Bolted Fault - solidly connected fault path

Arcing Fault current flows through ionized air

Arcing faults release most of the energy of the
fault out into the surrounding environment.
Bolted faults most of the energy flows through
the faulted equipment.

Arc Flash Facts

An arc flash is a source of intense heat, light,

sound, and pressure.
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.
Five to ten Arc Flash explosions occur in electric
equipment every day in the United States.
Over 2000 people per year are treated for
severe burns from electrical arcs.
As much as 80% of all electrical injuries are
burns resulting from an arc-flash and/or the
ignition of flammable clothing.

Personnel Hazards
Direct injury
Pressure wave
Contact with energized parts
Radiation burns from intense heat & light
Indirect injury
Shrapnel from component parts - the blast can
hurl shrapnel at velocities over 700mph.
Molten Copper and Steel
Breathing superheated air & arc by-products

Potential Causes of Arc Flash

An arc flash can be caused a number of

ways, including:

Tracking across insulation surfaces

Accidental contact with energized parts
Inadequate short circuit ratings
Tools dropped on energized parts
Wiring errors and loose connections
Contamination, such as dust on insulating
surfaces
Corrosion of equipment parts and contacts
Improper work procedures
Equipment failures
Animals

Interrupting 500kV with Air

Break Switch

Industry Standards and Regulations

used to protect workers from Arc Flash
NEC 2008

OSHA 29 CFR 1910

NFPA 70E - 2009

IEEE 1584
National Electrical Safety Code

(NESC) - 2007

2007 NESC Article 410.A.3

Effective as of January 1, 2009, employers are

to ensure that an assessment is performed to
determine potential exposure to an electric arc
for employees who work on or near energized
parts or equipment. If the assessment
determines a potential employee exposure
greater than 2 cal/cm2 exists, the employer
shall require employees to wear clothing or a
clothing system that has an effective arc rating
not less than the anticipated level of arc
energy.

How do you comply with NESC 410.A.3?

Utilities must perform an assessment of their entire

electric system and verify that their PPE is providing

adequate protection.
The assessment utilizes voltage, clearing time and fault
current to determine the available incident energy.
You can determine this by using NESC tables 410-1 and
410-2 or by performing an arc flash hazard analysis.
When an arc hazard analysis is performed, it shall include a

calculation of the estimated arc energy based on the available

fault current, the duration of the arc(cycles), and the distance
from the arc to the employee

A comparison of these two options

NESC Tables 410-1 & 410-2

To utilize the tables, you must calculate single phase

to ground fault current and then identify upstream

protective device clearing times.
Not very accurate for actual fault current and
clearing time.

Perform an Arc flash hazard analysis, and

document the incident energy exposure.
IEEE 1584 (SKM, ETAP, Easypower, Duke Heat Flux,

and others)
ArcPro Software by Kinectrics

IEEE 1584

Guide for performing Arc Flash Hazard

calculations for incident energy and
determining proper PPE.
Calculations verified over voltage range from
208V to 15kV.
Three-phase arcs in enclosures or open air.
No single phase faults
Shifts from lab tested standard formula to Lee
Method for 25kV faults and above.
Lee method is based on theoretical behavior of arcs.
No data indicating Lee Method has been verified for

25kV and above.

ARCPRO

Physics based model which calculates the

thermal parameters of electric arcs.
Calculations are very similar to IEEE 1584 for
15kV systems.
Typically utilized for analysis of 25kV systems
and above.
Single-phase arcs in open air only. This is
typically more suited to the majority of
distribution system situations.
Multipliers (adjustment factors) are applied to
incident energy for three phase and faults in a
box (enclosures such as padmounted
transformers.

Arc Flash Analysis Steps

1. Data collection

1. Data Collection
Secure arc flash calculations and upstream
protective device settings from Wholesale
provider
Bring Electric system maps up to date and
create accurate substation one-lines if not
already available
Collect substation equipment nameplate
information and protective device settings
Collect distribution system information to
create typical feeder for overhead and
underground. This includes recloser and fuse
information.

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose

worst case

2. Determine System operating

modes
Identify modes of operation:

ie utility
only, extended parallel generation only,
multiple scenarios with generators in
parallel with utility, etc.
Run the analyses on worst case.

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system

3. Calculate the available fault

current
Utilizing data collected in Step 1, create a

system single line and system parameters

in SKM software.
In SKM, calculate the available fault current
at each bus identified in the system oneline.
For systems 25kV and above, first calculate
the single phase fault current in SKM,
identify clearing times and then input into
ARCPRO.

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system
4. Calculate arc flash incident energy levels

4. Calculate incident energy levels

In SKM, calculate the incident energy

levels at each bus in the system.

For systems 25kV and above, calculate
the single line to ground incident
energy in ARCPRO, then apply
adjustment factors to convert from
single phase faults to three phase
faults and faults in enclosures (such as
padmounts)

What is Incident Energy?

Unit of measure is cal/cm2 or Joules/cm2

A calorie is the energy required to raise one gram of water one degree
Celsius at one atmosphere.
One cal/cm2 is equivalent to the amount of energy produced by a
cigarette lighter in one second
The onset of second degree burns will occur at 1.2 cal/cm2 per second.
(See chart below)

Incident Energy
(cal/cm2)
1.2

Degree Burn
2nd degree burn to skin

Ignite a cotton shirt

3rd degree burn to bare skin

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system
4. Calculate arc flash incident energy levels
5. Calculate arc flash protection boundaries

5. Calculate the Arc Flash Protection

boundaries
In SKM or ARCPRO, calculate the Arc Flash

Protection boundaries at each bus.

ARC Flash protection boundaries are an
approach limit measured from exposed live
parts within which an unprotected person
could receive a second degree burn if an
arc flash were to occur.
Appropriate PPE must be worn inside this
boundary

Arc Flash Protection Boundaries

Arc

flash hazard and flash protection

boundary varies with:
Type of equipment and equipment

configuration
Available short circuit current
Voltage
Fault duration protectice devices upstream
of the arcing fault and their settings.

Approach Boundaries
Note: The flash protection boundary is the distance at which the incident energy
equals 1.2 cal/cm2.

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system
4. Calculate arc flash incident energy levels
5. Calculate arc flash protection boundaries
6. Determine protective device characteristic and arc
duration

6. Determine protective device

characteristic and arc duration
Using the SKM software calculate the

clearing times for the available faults.

Clearing times are determined by the
intersection of the available arcing fault
current and the protective device curve

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system
4. Calculate arc flash incident energy levels
5. Calculate arc flash protection boundaries
6. Determine protective device characteristic and arc
duration
7. Determine working distances

7. Determine working distances

IEEE 1584 (SKM) assigns working

distances based on equipment type and

voltage class. (You are permitted to
adjust these distances if within
acceptable range)

ARCPRO calculates incident energy at

various distances. Choose voltage
appropriate distance following footnotes
from NESC table 410-1 and 410-2.
Table 410-2 refers you to or 441-2 for
46kV and above.

Arc Flash Analysis Steps

1. Data collection

2. Determine system operating modeschoose worst case

3. Calculate available fault current throughout system
4. Calculate arc flash incident energy levels
5. Calculate arc flash protection boundaries
6. Determine protective device characteristic and arc
duration
7. Determine working distances

8. Determine required PPE (risk hazard) category

8. Determine required PPE

Using the SKM software calculate the

required PPE category.

Personal Protective Equipment is the

complete clothing system required in order
to prevent an incurable burn during an
arcing fault.
PPE can include eye protection, ear
protection, face protection, gloves, &
clothing
Always perform work de-energized if
possible!

Classes of Protective Clothing

Incident

Clothing

Energy

Category

Description

ATPV

(cal/cm2)
0 - 1.2

Untreated Cotton
Long Sleeve shirt & Long
pants

n/a

1.2 -4

FR shirt and pants

Or FR coverall

Minimum 4

4-8

Minimum 8

Cotton Underwear + CL.1

8-25

Minimum 25
FR Coveralls + CL.2

25-40

Double Layer Switching

Coat + CL.2

ATPV - Arc thermal performance exposure value (cal/cm2)

Minimum 40

Personal Protective Equipment (PPE)

Category 0
Long-sleeve shirt and Long pants
Made of non-melting/flammable materials
Fabric weight at least 4.5 oz/yd2
Hard Hat
Safety Glasses
Leather Gloves
Leather Work Shoes

PPE
Category 1 Minimum Arc Rating of 4

cal/cm2
FR Shirt and Pants or FR Coverall
Hard Hat
Safety Glasses

Leather Gloves
Leather Work Shoes

PPE
Category 2 Minimum Arc Rating of 8

cal/cm2

Cotton Underwear plus FR Shirt and FR Pants

Cotton Underwear plus FR Coverall
Hard Hat
Safety Glasses/Goggles
Arc Rated Face Shield or Flash Suit Hood
Hearing Protection
Leather Protectors worn over rubber gloves
Leather Work Shoes

PPE
Category 3 Minimum Arc Rating of

25 cal/cm2
Cotton Underwear plus FR Shirt and FR Pants

plus FR Coverall
Hard Hat with FR Hard Hat Liner
Safety Glasses/Goggles
Flash Suit Hood
Hearing Protection
Leather Protectors worn over rubber gloves
Leather Work Shoes

PPE
Category 4 Minimum Arc Rating of 40

cal/cm2
Cotton Underwear plus FR Shirt and FR Pants plus

Multilayer Flash Suit

Cotton Underwear plus FR Coverall plus Multilayer Flash
Suit
Hard Hat with FR Hard Hat Liner
Safety Glasses/Goggles
Flash Suit Hood
Hearing Protection
Leather Protectors worn over rubber gloves
Leather Work Shoes

Arc Flash Mitigation

Reduce the Arcing Fault Current

Current Limiting Protective Devices

Increase the Working Distance

Operating Devices remotely
SCADA
Relays and Breaker controls in Equipment
House
Extension tools

Reduce the Clearing Time

Lower protective device settings
Differential relaying

Arc Flash Mitigation

Reduce Clearing Time:

Upstream Circuit Breaker

Reduce protective device settings

Enable Instantaneous Trip Function
Disable Reclosing when working on circuit
Utilize maintenance mode with alternate Settings if
necessary (digital relays)

Differential relaying
Removes fault in minimum time (2 or 3 cycles)

Arc Flash relaying

Compares over current value to light flash

magnitude.

Arc Flash Mitigation

Reduce the Arcing Fault Current

Current Limiting Protective Devices

Increase the Working Distance

Operating Devices remotely
SCADA
Relays and Breaker controls in Equipment House
Extension tools

Reduce the Clearing Time

Lower protective device settings
Maintenance mode with alternate settings (Digital
relays). Instantaneous covers circuit backbone
Differential relaying

Arc Flash design

Arc Flash Mitigation

Arc Flash Design Strategies:
Relocate Relays & Controls to the
Equipment House
For new substations perform a preliminary
Arc Flash analysis to aid in design.
Specify digital relays to provide flexibility
with regards to settings and
communications.
Specify equipment with an emphasis on
minimizing arc flash exposure.

Arc Flash Mitigation

Safety and Design Considerations:
Arc Flash Boundary
Identified
Specify Arc Resistant

MV Switchgear
LV Switchgear

View Port for Infrared

inspection

Infrared Ports
Monitoring

without exposure

Arc Flash Mitigation

Safety and Design Considerations:

Arc Flash Boundary

Identified
Arc Resistant
View Port for Infrared
inspection
Hinged covers vs. bolted
Remote Racking
Mimic Bus (Touch panel)
PPE Storage on site if
necessary

Arc Flash Analysis Example #1

12.47kV system 12.47kV Circuit Breaker

Arc Flash Calculation Summary
Time Current Curve (TCC)

Protected by upstream CO-7 relay

Arc Flash Calculation Summary

12.47kV system

12.47kV Circuit Breaker

12.47kV Circuit Breaker

4640A

Arc Flash Analysis Example #2

12.47kV system Substation 240V AC

Panel
Arc Flash Calculation Summary

Time Current Curve (TCC)

Protected by upstream 3A Fuse

Arc Flash Calculation Summary

12.47kV system

240V AC Panel

240V AC Panel

Arc Flash Analysis Example #3

12.47kV system 100A Fuse

Time Current Curve (TCC)
Arc Flash Calculation Summary

Protected by upstream 3000A breaker

Arc Flash Calculation Summary

12.47kV system

12.47kV 100A FUSE

12.47kV 100A FUSE

Arc Flash Analysis Example #4

100kV system 100kV Circuit Switcher

Arc Flash Calculation Summary NESC 2007
Arc Flash Calculation Summary NESC IEEE 1584

ArcPro Total Heat Flux Calculation

ArcPro Heat vs. Distance Table

Protected by SEL 587Z Differential Relay

Arc Flash Calculation Summary

100kV system

100kV Circuit Switcher

100kV Circuit Switcher

Apply 3phase adjustment

factor of 2.2 to incident
energy. Total is 1.12
cal/cm@

Arc Flash Calculation Summary

100kV system

100kV Circuit Switcher

100kV Circuit Switcher

Typical Summary of Results

69kv & 100kV equipment can range from Category 0 to
Dangerous
This is dependent upon working distance and
clearing time
We recommend all work be performed de-energized
Most equipment on overhead 15kV and 25kV lines is
Category 1. Category will increase is instantaneous
function is disabled or fault location is past pickup.
Transformers
Secondary side below 240V

Category 0

Secondary side of 240V, less than 125 KVA

Category 0

Secondary side of 240V, 125 KVA and above

Category 2

Typical Summary of Results

Transformers Secondary side of large
transformers (208V or 480 V) have potential
for high incident energy levels.
Typical Hazard Risk Categories:

Transformer Size

PPE Category

Up to 300 KVA

Category 2

500 KVA to 1000 KVA

Category 3

1000kVA to 1500kVA

Category 4

2000kVA and Over

Dangerous

Perform all work on padmounted transformer

secondaries de-energized if possible.

Typical Summary of Results

Inside Substations
Line side of Feeder Circuit Breakers have

higher incident energy when the only

upstream device is Wholesale providers
relay or Fuse.
It is better to have control over relay settings
Load side of Feeder Circuit Breakers
Category can be any where from 0 up to 3.

FLASH PROTECTION
Flash Protection Boundary
An approach limit measured from exposed live parts within
which an unprotected person could receive a second
degree burn if an arc flash were to occur. Appropriate PPE
must be worn inside this boundary.

Approach Boundaries
Note: The flash protection boundary is the distance at which the incident energy
equals 1.2 cal/cm2.

Example of WARNING Label

Example of DANGER label

Brady GlobalMark Printer

How does the Arc Flash Analysis

effect your Safety Program?

Electric Utilities should provide proper PPE for

workers based on results of the study.
Work rules should be enacted for common work
tasks.
Provide customers with arc flash information
Typically do not provide upstream protective device info.

Contractors must wear properly rated PPE for

work being performed.
Mutual aid work must be coordinated very
carefully when working on other electric systems.
Crews should not work on any equipment that
has available incident energy greater than their
PPE.

Future of Arc Flash

Constantly evolving issue.
NESC 2012 will most likely have many
changes.

Proposed new Table 410-1 for voltages from

50 1000V (AC) that is Task specific.

Arc Flash research and testing on

systems 15kV and higher will continue.
This should provide better data for future
software programs.

QUESTIONS?

THANK YOU FOR

YOUR TIME
Michael C. Dougherty, PE
A.J. Molnar, PE
Southeastern Consulting Engineers, Inc.
Charlotte, NC