ARC FLASH ANALYSIS

Final Report
Fall Semester 2010

Todd J Vedder

Prepared to Partially Fulfill the Requirements for ECE402

Department of Electrical and Computer Engineering

Colorado State University
Fort Collins, Colorado 80523

Project Advisor: Dr. George Collins .

1
 ABSTRACT

I chose to do my senior design project on the topic of Arc Flash Analysis. The

last few years have developed a great increase in the awareness of arc flash hazards. The

analysis is applied to the overall electrical system of utility companies. The purpose of

the study is to develop the best way to limit the amount of an arc flash a lineman can be

exposed to while doing maintenance in the field. The National Electric Safety Code

(NESC)-2007 Rule 410 states "employers shall ensure that an assessment is performed to

determine the 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 clothing systems that have an effective arc rating not less than the anticipated

level of arc energy." Electricity has proposed a serious hazard since its discovery by

Benjamin Franklin. Why though, after over a hundred years, is the awareness of this

hazard drawing so much attention?

Arc flash analysis can propose a serious problem to utility companies. Most

injuries that occur out in the field with lineman who work for power utility companies

don’t result from electrocution, but rather from an arc flash. Over the years, these

companies install protective devices all throughout a system. However, much effort, time

and cost is involved to ensure these protective devices coordinate with other devices and

are used to their best efficiency. These protective devices cannot be changed

instantaneously to help arc flashes. One job of a consulting engineer is to calculate the

arc flash incident energy at the point of contact. It then can be determined if the up line

protective device is adequate, or if a recommendation to their protective devices needs to

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be applied. When the first arc flash assessment was created there were a few key design

questions that needed to be thought about:

1. What are the requirements?

2. How long do we have to design?

3. How will it be tested?

4. What recommended improvements can be made to client?

This study has shown that a procedure can be implemented for utility companies.

Steps and procedures were developed to perform an accurate arc flash analysis.

However, is this the best method that can be used? How accurate are these calculations?

Although it has been learned that there isn’t a 100% right solution, an accurate and

reliable analysis can be created. Future work for this study will be to come up with the

most accurate and reliable method.

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Table
of
Contents

Title
Page.................................................................................................................................... 1

Abstract....................................................................................................................................... 2

Table
of
Contents..................................................................................................................... 4

List
of
Figures............................................................................................................................ 5

Introduction .............................................................................................................................. 6

Arc
Flash
Characteristics ...................................................................................................... 8

Why
perform
an
arc
flash
assessment? ................................................................................................. 8

How
might
an
arc
flash
occur? .................................................................................................................. 8

What
are
the
results
of
an
arc
flash
and
why
is
it
such
a
concern? ........................................... 9

Dependents
of
survivability
from
arc
flash.......................................................................................... 9

Units
of
measurement................................................................................................................................... 9

Degree
of
burns..............................................................................................................................................10

Steps
Necessary
to
Prepare
for
Arc
Flash
Analysis ....................................................10

Checklist
Completed
by
Utility
Company ......................................................................11

Checklist
for
arc
flash
studies
for
electric
distribution
systems...............................................12

How
Does
an
Arc
Flash
Operate?......................................................................................15

Jacob’s
Ladder
Test ......................................................................................................................................15

Incident
Energy
Calculations
IEEE
1584........................................................................16

Arc
Flash
Analysis
Calculations ........................................................................................17

Improvements/Recommendations .......................................................................................................18

Official
Calculation
Spreadsheet ......................................................................................19

Arc
Flash
Boundary ..............................................................................................................21

Arc
flash
boundary
formula......................................................................................................................22

Economic
Tradeoff ................................................................................................................22

Future
Changes.......................................................................................................................24

Conclusion................................................................................................................................25

Appendix ..................................................................................................................................26

Official
calculation
spreadsheet..............................................................................................................27

Budget
analysis ..............................................................................................................................................28

Definitions ........................................................................................................................................................29

Recommendation
for
project
continuation .......................................................................................32

References........................................................................................................................................................33

Acknowledgements ......................................................................................................................................34


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 List of Figures & Tables

Fig 1: Power System Flow Layout ................................................................. 7

Fig 2: Jacob’s Ladder Test............................................................................ 15
Fig 3: Existing System Model ...................................................................... 17
Fig 4: Hazard Category as a Function of Incident Energy Table ................. 18
Fig 5: Recommended System Model............................................................ 19
Fig 6: Variable Factors For Different Types of Equipment ......................... 20
Fig 7: Fuse vs. Recloser Economic Cost ...................................................... 22
Fig 8: Fuse vs. Recloser Payoff Chart .......................................................... 23
Fig 9: Blank Calculation Spreadsheet........................................................... 27
Fig 10: Time Current Curve ......................................................................... 30

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Introduction:

With the development of technology, society has seen an increase in benefits.

Things have become easier, more precise, and satisfying. Technology has brought a

significant increase to the world of power and electricity. Arc Flash injuries have been a

concern since the discovery of electricity. So why is it that these hazards are only

drawing high attention over the past few years? A primary reason is the high increase in

magnitude and volume to electricity being generated over the world. Many companies

are requiring more power and higher voltages. Probably the most important reason is the

increased need to perform work on energized equipment. If a line has to be de-energized

in order to perform maintenance, then buildings and homes must go without power. This

provokes not only a loss in revenue for the Power Company, but can upset many

customers. The exponential increase in technology has made it difficult for companies to

keep up with training standards to keep employees aware of the risk of arc flash hazard.

The last important reason arc flash hazards have become a concern is the increase in

liability from lawsuits. Companies are adopting procedures and methods relating to arc

flash hazards not only to provide safety to their employees, but the company as well.

The focus of this study will be on the distribution side of the power utility

system. This is the final stage of delivery of power to end consumers. A distribution

system carries power from the transmission system and delivers it to its consumers. The

diagram below shows how power is developed starting at a power plant, traveling to

transmission lines where it feeds into a power substation. The power substation

downsizes the voltage (typically from 69k volts to 12.47k volts). Here power is traveled

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throughout the town until it reaches the transformer drum and downsized (typically from

12.47k volts to 480 volts). Here power is supplied to houses and commercial industries.

Figure 1: Power System Flow Layout

According to the NESC an arc flash is the result of a rapid release of energy due

to a short circuit between two conductors, or conductor and ground. The arc flash is not

the direct short between two conductors but rather it is the arc created in the air after a

short circuit occurs. During an arc the air acts as a conductor. This develops problems

for utility companies who have lineman working on energized equipment. Majority of

accidents that occur in power utility companies are not from the result of electrocution,

but instead from an arc flash. Why is an arc flash important to understand? It can kill

you!

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Arc Flash Characteristics

Why perform an arc flash assessment?

The following statement comes from Rule 410A3 of the National Electric Safety

Code: “Effective as of January 1, 2009, the employer shall ensure that an assessment is

performed to determine potential exposure to an electric arc for employees who work on

or near energized lines, parts or equipment.” In the event that an employee exposure is

greater than 2 cal/cm2 exists, the employer shall:

A. Perform a detailed arc flash assessment to determine the effective arc rating of

clothing or clothing system to be worn by employees working on or near

energized lines, parts, or equipment at voltages 50-800,000 volts. The arc

flash assessment shall include a calculation of the available short circuit

current, time it takes for arc to clear, and the distance from arc to employee.

B. Require employees to wear clothing or a clothing system with an effective arc

rating not less than the anticipated level of arc energy. Unless flame resistant,

when exposed to an electric arc or flame, clothing or a clothing system made

from acetate, nylon, polyester or polypropylene shall not be worn.

How might an arc flash occur?

Arcing fault current can be easily created through poor electrical contact, failed

insulation and carelessness. There is no way to eliminate arc fault hazard when working

on an energized line, but we can decrease the amount of energy dissipated from an arc

and the injury it can create to a lineman.

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 What are the results from an arc flash and why is it such a great concern?

Injury is the primary reason we are focused on studying the system analysis of arc

flashes. Temperatures up to 35,000 degrees Fahrenheit are created at the point of contact

(4 times greater than the sun)! Upon contact molten metal is blasted forward from

terminal material resulting in serious burns to victims. A large shockwave is produced

that could throw a human off ladders or against walls. The light developed from a flash

contains UV rays that can cause blindness. The sound pressure from a blast is enough to

cause serious ear injury. If an arc occurs and a worker is in close proximity, the survival

rate of the worker is dependent upon the following:

Dependents of Survivability from Arc Flash

1. Clearing time- time of the over current protective device to operate. It

determines how fast the device will create an open in the circuit and clear arc

fault.

2. Magnitude-amount of arc fault current created.

3. Distance-length worker is away from point of contact (arc).

4. Personal Protective Equipment (PPE)-clothing material worker is wearing to

protect him or herself.

Units of Measurement

There are two different units in measuring an arc flash. A joule is a standard unit

of energy in general scientific application. 1 joule = 1 watt/second of dissipated energy.

A calorie is a unit of heat and is a form of kinetic energy. It takes 1 calorie of heat energy

to raise one gram of pure liquid water 1 degree Celsius.

1 calorie = 4.1868 joules 1 joule = 0.2388 calorie

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 Degree of Burns

1st degree burns: Affects outer layer of skin. It can be painful, but it is usually not

permanent or life threatening.

2nd degree burns: Causes tissue damage. Creates blistering to the skin. It also destroys

outer skin layer.

3rd degree burns: Causes complete destruction of skin. Small areas may be recovered

through skin graphs.

Arc flash protection is aimed to limit the injury to no more than a 2nd degree burn. Even

though this is the goal for a system study, it can still cause a serious burn. 1.2 cal/cm2 is

the threshold of 2nd degree burns.

Steps Necessary to Prepare for an Arc Flash Analysis

1. Review the existing data

a. Existing sectionalizing/fault current study

b. Substation size/impedance/voltage/grounding configurations

c. Source impedance of transformers

d. Breaker/recloser settings

2. Collect new data (per substation area)

a. Update source impedance

b. Update substation size/impedance

c. Update engineering software model

d. Locate large 3 phase pad mounted transformer locations

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 i. Since pad mount transformers are in an enclosed area they

produce more energy to a lineman compared to an open aired

transformer where the energy is dissipated to open air.

e. Update all recloser/breaker settings, TCC opening/closing times etc

f. Fuse information: manufacturer, type, size/rating, speed

(standard/slow), and current limit of fuse.

g. Relays: Are they electronic or mechanical? Need type, manufacturer,

settings, current transformer rating, and opening/clearing times.

h. Transformer Data: kVA rating, primary/secondary voltage, impedance

percentage, connection configuration (Y-Y or Delta-Y)

i. Engineering model: Need all circuit configurations, wire size/section

lengths, operating voltages, and circuit configuration

3. Determine Personal Protective Equipment Settings (see above Arc-flash

Hazard Category table).

4. Conduct an Analysis Report:

a. Report should contain data collected from utility companies

including: Substation names, transformer sizes, primary/secondary

voltages, working distance, available bolted and arcing fault

current, incident energy level, and risk category for each scenario.

Checklist completed by utility company:

The following is a series of questions that a consulting firm is to ask utility

company. Questions answered are taken into consideration when performing arc flash

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assessment. The checklist must be thorough and answered as accurate as possible to have

the most precise assessment.

CHECKLIST FOR
ARC FLASH STUDIES FOR
ELECTRIC DISTRIBUTION SYSTEMS

A. Current utility safety procedures and PPE clothing

1. Clothing,
a. What is the calorie rating of the shirt/pants typically worn by employees?
b. When do line workers use eye protection?
i) When do they wear safety glasses?
ii) When do they wear safety glasses and a face shield?
c. Hearing protection. When is it used?
d. When do line workers use special arc flash protection clothing beyond the
normal fire retardant clothing?
2. Hot line work
a. When working on an energized primary line, does the utility set the
substation or closest circuit reclosers/breaker to non-reclose?
b. What are the minimum pickup settings and what curves are used on the
recloser/breaker for the non-reclose operation?
c. Working distances
i) Rubber gloving, 17 inches to chest?
d. Hot sticks, 4 feet?
e. When is line work done energized with
i) Rubber gloves?
ii) Hot sticks?
f. Secondary work, when is the 277/480 or 480 volt work done while the 480
volts is energized:
i) Visual checking, no contacts?
ii) Voltage measurements?

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 iii) Making connections?
iv) Replace equipment?
v) Metering work, change meters?
B. Transmission line data
1. Voltage(s)
2. Source substation transformer base kVA and impedance
3. Conductor size(s)
4. Type of construction
5. Is work done while a transmission line is energized? If yes what type of
work?
a. Installing and removing grounds
b. Phase checking, voltage measurements
c. Inter-setting a new pole
d. Changing insulators
e. Replacing an existing pole
f. Others explain.
C. Substation
1. Primary voltage(s).
2. Secondary voltage(s)
3. Transformer MVA capacities and impedances.
4. Available fault currents
5. Type of transformer and secondary bus protection
a. Fuses (type, speed and size)
b. Relaying.
i) Type and settings,
ii) Differential, does it protect only the transformer or does it also protect
the secondary bus up to the load side of the circuit breakers?
6. Work practices within the substation while substation is energized.
a. Visual inspections, no electrical contacts.
b. Installing and removing grounds.
c. Primary switching, pull or replace primary fuses?

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 d. Low side: change arresters, circuit breaker by-pass, reclosers/breakers and
isolating switches?
e. Energized work practices.
i) Working distances from energized equipment.
ii) Current PPE, calorie rating, face and eye protection
iii) Are changes feasible?
D. Primary distribution lines, voltage(s) i.e. 12.47/7.2 kV or 24.9/14.4 kV?
1. Recloser types and settings. i.e. “L,” “VWVE,” “E”?
2. Primary fuse type and sizes used to protect laterals and underground risers.
3. Does the utility have a policy of setting the reclosers to non-reclose while
working on energized primaries?
a. Substation
b. Line reclosers
c. Alternate fast trip capability?
4. Voltage and phase checking with hot sticks?
5. Energized work procedures
a. Rubber glove?
b. Hot sticks?
c. When is insulated cover up used?
6. Pad-mounted primary switchgear including pad-mounted transformers.
a. Work practices, hot sticks for removing and connecting load break
elbows?
b. Opening and closing pad-mounted load break switches?
c. Working distances?
7. Distribution transformers
a. Pad-mount 277/480 volt.
i) Size(s)
ii) Impedance(s)
iii) If riser fuses protect pad-mount transformers, type & size?
iv) Do the transformers have bayonet fuses, if yes type and size.
b. Overhead three-phase 277/480 banks

14
 i) Size(s)
ii) Impedances
iii) Fusing standards, type and size
8. Metering for 277/480 volt services.
a. Work energized or de-energized?
b. To check voltage or make amp measurements?
c. Replace meter.
d. Check CT ratio.
Conductor, type, size and length to meter.

How does an arc flash operate?

Jacob’s Ladder Test

Figure 2: Jacob's Ladder Test

http://sub.allaboutcircuits.com/images/quiz/00561x01.png

The Jacob’s Ladder is a device, which is used to show how electric sparks

operate. The figure above shows a Jacob’s ladder, more formally known as a high

voltage-traveling arc. This is a device designed to produce a continuous train of large

sparks, which rise upwards. The top of the figure shows two wires that start close

together and gradually diverge away from each other to form the “V” shape.

15
 The high-voltage transformer creates a potential difference between the vertical

wires. The electrons repel from each other causing them to jump from one wire to try

and get as far apart as possible.

When high enough voltage is applied to the bottom of the wires a spark forms

across them, which quickly changes into an electric arc. Air breaks down around 30

kV/cm factoring in humidity, temperature etc. Besides the anode and cathode voltage

drops, the arc behaves as a short circuit, drawing as much current as the electrical power

supply can deliver, and the heavy load dramatically reduces the voltage across the gap.

Since hot air rises, the spark continues to climb until the voltage provided by the power

source is not enough. It then dies and a new spark starts at the bottom again. A spark can

jump between two conductors, which relative to each other can carry a high voltage. The

gases in the atmosphere are pulled apart, at an atomic level, by the high electric fields

generated between such conductors. The air can conduct, just like a wire, but with a few

side effects like light and sound (like thunder and lightning but on a much smaller scale).

Incident Energy Calculations (IEEE1584):

To determine the incident energy at the worker location:

• Incident Energy = 4.184 x Cf x Ea[(t/0.2) x (610x/Dx)]

• Log(Ea) = k1 + k2 + [1.081 x (log(Ia))] + 0.0011G

•
Ea = 10(Log Ea)

• Ea is normalized for 0.2 sec. and 610 mm gap. For actual Incident energy………..

• Incident Energy = 4.184 x Cf x Ea[(t/0.2) x (610x/Dx)]

Ia=Arcing fault current in kA G = conductor gap in millimeters (mm)

K1=Open air or in a box factor K2 = ground/ungrounded factor

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Cf = calculation factor t = arcing time in seconds

X = Distance exponent

Arc Flash Analysis Calculations:

The following illustration shows a Milsoft model being used to calculate the

incident energy that a lineman could be exposed to.

Figure 3: Existing System

The previous example shows the calculations for distribution transformers. The

substation is providing 12.47k volts to a distribution transformer. Here the 12.47k volts

are stepped down to 480 volts, which is supplied to a commercial building. A 30-amp

fuse is currently protecting the transformer since the current carrying capacity of

transformers is 23.2 amps. The bold black circle simulates a lineman working on the

secondary side of transformers. Power remains constant through a transformer. Since

the equation for power is P=volts x amps, if the voltage decreases the amperage must

increase providing more danger to the lineman. The calculated data box shows results of

17
what happens if a lineman creates a short circuit while doing maintenance. With a

distance of 431.8mm (17inches) between point of contact and worker’s face/body and

arcing fault current of 5.027k amps, there are 57.34 joules (13.704 cal/cm2) of energy

exposed to the lineman. The following chart shows the hazard category levels as a

function of incident energy. 13.704 cal/cm2 has a risk factor of 3.

Figure 4: Hazard Category as a Function of Incident Energy

Improvements/Recommendations

After reviewing the chart of “Hazard Category as a Function of Incident Energy”,

we can see that this provides a risk category of 3. If the goal is to try and maintain a

category of 2 or lower some recommendations are applied. The following illustration

shows transformers being protected by a 70-4H hydraulic recloser.

18
 Figure 5: Recommended System

It can be seen that the working distance and arc fault current remain constant.

However, the incident energy and clearing time of reclosers have decreased substantially,

providing incident energy levels of 18.59 joules (4.4441cal/cm2). After reviewing the

chart we can see that this puts us at a risk category of 2. Reclosers act differently than

fuses in that they can operate on an instantaneous setting where as a fuse has melting

time. Reclosers are much more precise in reactance time and helps reduce incident

energy levels extremely.

Official Calculation Spreadsheet:

The appendix of this report on page 27 shows a blank calculation spreadsheet

used to insert the incident energy calculations along with necessary information. The

spreadsheet is designed to be a quick reference to locate what the incident energy

calculation is at a particular spot. The following is a brief description of what each

column heading represents 1-18 respectively.

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1. Sub - Lists substation short circuit calculation is taken from.

2. Item of Interest – Indicates what piece of equipment the calculation is

taken from. Typically load side of transformer indicating size and

location on the system.

3. Dist. From Sub (Miles) – Distance calculation is taken from substation.

4. Protective Device – Lists type and size of protective device that is up-line

from calculation. Generally device will be fuse or recloser.

5. Phase – Generally listed as three phase. However if single phase, which

phase is being concentrated on, A B or C phase?

6. Primary Voltage – What is the source side voltage of transformer

7. Service Voltage – What is the load side voltage of transformer

8. Bolted Fault Current – Short circuit current rating creating shortest path

between two conductive materials.

9. Arc Fault Current – Arcing current formed from bolted fault current but

uses air as the conductor.

10. Gap (mm) – Distance between two terminals of transformer measured in

millimeters. Following table lists the typical distances.

11. Gap (in) – Distance between two terminals of transformer measured in

inches.

Typical bus
distance, in Distance
Equipment class mm X-Factor
Open air 10-40 2.000
Low-V switchgear 32 1.473
15 kV switchgear 152 0.973
5 kV switchgear 104 0.973
Low-V MCCs and panel boards 25 1.641
Cable 13 2.000
Figure 6: Variable factors for different types of equipment

20
 12. Distance Factor – Calculation factor for different scenarios. Previous

tables list these as the “x-factor”.

13. % of max – Use 85% of fault current when during calculations on

equipment that is protected by fuses. This is to give more of a worst-case

scenario. The lower the current the longer the fuse will take to clear,

since fuses are dependent on time.

14. Arc Clearing Time – time it takes for up-line protective device to clear

short circuit measured in seconds.

15. Oper. Dist (in) – distance from arc to workers face/body measured in

inches

16. J/cm2 – Incident energy calculated in joules per centimeter squared. This

is 4.168 times greater than calories per centimeter squared.

17. Cal/cm2- Incident energy calculated in calories per centimeter squared

18. NESC level – National Electric Safety Code category level to determine

what type of personal protective equipment to wear. Levels are based on

a 0-4 scale.

Arc Flash Boundary

A perimeter must be set up around an area where maintenance is being done on

energized equipment. The perimeter is measured as distance from energized part. Only

qualified personnel must cross this boundary. Unqualified personnel may not cross

boundary unless escorted by a qualified person. The same PPE is required in this

boundary as if direct contact is made with live part. This is done to maximize safety and

minimize possible arc flash.

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 Arc Flash Boundary Formula

Dc=[2.65 x MVAbf x t]1/2

• Dc = Distance in feet of person from arc source based on limit of having incident

energy of 1.2 cal/cm2

• MVAbf = Bolted fault current in Mega volts at location of maintenance.

• T=time of arc exposure measured in seconds

Example: What is the flash protection boundary for the secondary side of a 3,750kVA

transformer rated at 480 volts line to line with short circuit current of 50,000 amps

and clearing time of 0.1 seconds (6 cycles)? The utility company provides this

information. 6 cycles is the standard instantaneous time of protective device to

operate.

MVAbf = [50,000amps x (1.74)1/3 x 480volts] = 41.57 MVAbf

Dc = [2.65 x 41.57 MVAbf x 0.1sec] ½ = 3.319 feet

Economic Tradeoff

As previously stated, it shows no question that a company might want to install a

recloser into their system to help the efficiency of arc flash hazards. However, is the

economic tradeoff worth the safety? The costs of fuses and reclosers, along with their

labor charges, are listed in the table below.

Material Cost(per phase) Material Cost(all three phases) Cost of Installation Total
FUSE $150 $450 $150 $700
RECLOSER $1,500 $4,500 $450 $4,950

Figure 7:Fuse vs Recloser Economic Cost

22
 Fuse vs. Recloser

These values do not include the cost to maintain these protective devices.

Reclosers have the capability to reclose on their own in the event a fault is cleared, such

as a tree branch falls on a power line. A fuse would stay open until a maintenance crew

came out to replace the fuse. Also, a recloser has the capability of being installed further

up line from the transfer and therefore is able to protect possibly 3 or 4 transformers. So

in this scenario we have one recloser protecting 4 transformers vs. 4 transformers being

protected by 4 different fuses. The initial cost of installing three reclosers (one recloser

per phase) with labor is approximately $5000. The cost of installing three fuses (one fuse

per phase) with labor is approximately $700. Since reclosers can reclose on their own, no

replacement or labor charges were affected after initial installation.

Figure 8: Fuse vs Recloser Payoff Chart

It can be seen that in order to have the recloser payoff the economic value of the

fuses, the fuses would have to blow and be replaced after 7 times. Utility companies

23
have to determine if this is feasible. If a company is looking to improve their system

through arc flash incidents, then yes, they might want to invest their money by installing

reclosers. If the company wants to invest their money in other areas of the industry, then

they may want to pass on this opportunity and replace the fuses.

Future Changes

Changes are currently being made to the National Electric Safety Code (NESC)

Rule 410 that effect arc flash assessments. Some future changes are as follows:

1. The original intent of Rule 410 was to limit the possibility of technicians or

the general public to contact two metallic surfaces that may be at different

voltage levels and thus receive an electric shock. It is appropriate that the

proper rule be presented as a mandatory “shall” requirement, and not as a

present “should requirement”.

2. “For work below 1000 volts, applicable rules required by this part and

engineering controls shall be utilized to limit exposure. In lieu of performing

an arc hazard analysis, clothing or a clothing system with a minimum

effective arc rating of 4 cal/cm2 shall be required to limit the likelihood of

ignition.

3. One except to the clothing rule is if the clothing that is required by arc flash

assessment produces additional and greater hazards than the possible exposure

to the heat energy of the electric arc, then clothing with an arc rating or arc

thermal performance value less than that required by the rule can be worn.

24
Conclusion:

An arc flash assessment for a power systems utility company can be a

complicated process. For recommendations, much more detailed analysis must be

provided that is out of the scope of this report. Conducting this report I have learned that

you cannot just jump into a project and focus only on the next step. As an example when

recommending reclosers, the decision can’t be made just on the arc flash assessment side,

but affects on the system as a whole need to be considered. Every protective device in

the system needs to coordinate with each other in relation to timing. You don’t want

protective devices upline clearing before protective devices down line do. This will

cause unnecessary outages and provide no purpose for the down line protective devices.

I also learned that although it may be easy to consider installing reclosers numerously

throughout the system, the economic tradeoff is not worth it.

A majority of the injuries that occur in power utility companies are not the result

of electrocution, but rather from an arc flash! This is a new problem to the electrical

engineering world but something that needs to be resolved or else more injuries will

occur. Results from improvements suggested by an arc flash analysis will not only save

lives, but also save a company from economic tragedy in the event of lawsuit or

equipment damage. Once my report is finally completed, I plan to provide a reliable

method to conduct an arc flash analysis; a benefit not only to myself, but also to the

power industry as a whole.

25
Appendix

26
Figure 9: Blank Calculation Spreadsheet

27
 Budget Analysis

Software Budget:

1. Milsoft/Windmil

i. Initial Cost = $15,000 per license

ii. Annual Fee = $1,200 per license

2. ArcPro

i. One time fee = $1,500 per license

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 Definitions

Arch Flash Hazard- Dangerous condition associated with the release of energy caused by

an electric arc.

Arc Fault Current- Fault current flowing through electric arc plasma.

Available Fault Current- The electrical current that can be provided by the serving utility

and facility-owned electrical generating devices and large electric motors, considering the

amount of impedance in the current path.

Bolted fault current- Electrical contact between two conductors at different potential in

which the impedance or resistance between the conductors is essentially zero.

Arc Fault Current- Current that flows from a conductor to either ground or another

conductor when energized, due to an abnormal condition.

Flash Hazard Analysis- Method used to determine the risk of personal injury as a result

of exposure to incident energy released from an electrical arc flash.

Incident Energy- Amount of energy impressed on a surface, a certain distance from the

source, generated during an electrical arc event.

Shock Hazard- Dangerous condition associated with the possible release of energy

caused by contact or approach to energized parts.

Voltage (nominal) - Nominal value assigned to a circuit or system for the purpose of

conveniently identifying its voltage class.

Working Distance- Distance between possible arc points and the head and body of the

worker positioned in place to perform the assigned task

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Arc Gap- Distance between two contacts where possible arc(s) can arise. When high

voltage is applied to the gap, an arc has the possibility of crossing between two

conductors.

Clearing Time- Amount of time it takes for an over current protection device to clear

once fault occurs and protective device settings are past their settings. An example is

below.

Figure 10: Time Current Curve

The previous graph shows a Time Current Curve (TCC) chart. It denotes the time

(located on “y” axis) in seconds and the current amount (located on “x” axis) in amperes.

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The graph shows the curve settings of an 85 “T” fuse. Notice that as the fault current

increases, it takes less time for a fuse to clear. The bottom line of the black curve

indicates the time a fuse begins to melt. After a short amount of time, at same fault

current, the top line is reached. This line indicates the complete melting time of fuses for

which circuit is open and arc flash has diminished.

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 Recommendations for Project Continuation

Arc flash events are a serious hazard that can potentially put people in life

threatening situations. National Electric Safety Code and OSHA are in the process of

introducing changes to electrical safety rules that require electric utilities to perform arc

flash hazard analysis of all electric facilities operating at and above 1000 volts.

In 2008, EPRI started a supplemental project to research arc flash issues with over

20 utility members. This effort uncovered new areas where further research could

improve arc flash protection approaches. 2008 unveiled that there is still much concern

for arc flash when network systems were the main topic for worry when most utilities

were sought the need for future improvements.

Open-air medium voltage systems, after recent testing and analysis of monitoring

data revealed several insights on arc characteristics. One of the findings is that realistic

arc lengths under work-type scenarios are longer than the 2 to 6 inch lengths assumed in

the National Electric Safety Code table 410-1.

Better personal protective equipment is still needed and requires testing to help

understand the best assessment approaches and protection options for specific utility

equipment. As arc flash assessments can still be conducted and used as professional

studies, there are still improvements that can be incorporated to achieve improved arc

flash analyses.

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 References
T2G Technical Training Group “www.brainfiller.com” Jim Phillips, P.E.

ESC Engineering, Jerry Hager, P.E.

IEEE1584 Based Arc Flash Calculator and Warning Label Creator,

http://www.arcadvisor.com/arcflash/ieee1584.html

Electrical Solutions with Energy and Integrity “Mayer Electric,”

http://mayerelec.com/arc.htm

Arc Flash Information Resource Center: IEEE 1584 Arc Flash Calculations,

http://www.arcflash.me/ieee-1584-arc-flash-calculations.php

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 Acknowledgements

I would like to acknowledge the following individuals with their help in this

project:

Dr. George Collins

– Professor Colorado State University, Electrical and Computer Engineering

– http://www.engr.colostate.edu/ece/facultystaff/facultypage.cfm?pass=9

Gerald H. Hager

- ESC engineering: Vice President, Senior Engineer P.E.

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