Fault Current Calculations

BY BRIAN MCFADDEN

A fault current is an unintended, uncontrolled, high current flow through an electrical

system. Fault currents are caused by very low impedance short circuits. These may be
shorts to ground or across phases. The resulting high current flow can result in
overheating of equipment and conductors, excesses forces, and at times even serious
arcs, blasts, and explosions. Causes of faults include things such as lightning strikes,
animals, dirt and debris, dropped tools, corrosion, and human error.

Fault current calculations are based on Ohm's Law in which the current (I) equals the
voltage (V) divided by the resistance (R). The formula is I = V/R. When there is a short
circuit the resistance becomes very small, and that means the current becomes very
large.

If the resistance was zero, then the calculated fault current would go to infinity.
However, even copper wire has some resistance; it is not a perfect conductor.
Determining the fault current involves knowing the total resistance from the power
source to the location of the fault.

Fault Current Calculations Are Required

Knowing the available fault current is important when selecting protection devices,
however it is also required by code. The National Electric Code (NEC) 110.24(A) states:

"Service equipment in other than dwelling units shall be legibly marked in the field with
the maximum available fault current. The field marking(s) shall include the date the fault
current calculation was performed and be of sufficient durability to withstand the
environment involved."

This means there must be field installed labels on electrical equipment, such as service
entrance equipment, that gives the available short-circuit fault current. This allows
the Short Circuit Current Rating (SCCR) of the equipment to be easily compared with
the maximum available fault current.

Any time there is a change in equipment the fault current calculation must be redone.
This is specified in NEC 110.24(B):

“When modifications to the electrical installation occur that affect the maximum
available fault current at the service, the maximum available fault current shall be
verified or recalculated as necessary to ensure the service equipment ratings are
sufficient for the maximum available fault current at the line terminals of the equipment.
The required field marking(s) in 110.24(A) shall be adjusted to reflect the new level of
maximum available fault current.”

Types of Faults
In an electrical system there are several types of possible faults:

 A short circuit that results in the current bypassing the normal load.
 A "ground fault" in which current flows into the ground.
 In three-phase systems there may be a short between one or more phases.  This
type of fault typically creates the highest fault currents.

The fourth type of fault, an open-circuit fault, does not generate a short-circuit current.
An open-fault results from the current being unintentionally interrupted.

Protective systems need to prevent equipment damage and protect people in all of the
above situations. That means fault current calculations must be done so that the
appropriate protective devices can be selected.

Bolted Faults vs. Arc Faults

An electrical fault can either be a bolted fault or an arc fault.

In a bolted fault there is a solid connection. This allows the fault current to flow through
a conductor. This type of fault might happen when an installer connects to a power
source to ground instead of to the point where it should be connected. When the power
is switched on there will be an immediate bolted fault that trips the protective device.
Because the current flow was contained, the damage is typically limited. However, a
bolted fault creates the highest fault currents.

An arc fault results when there is not a solid connection, but conductors come close
enough such that current jumps across the gap creating an arc. The initial arc ionizes
the air creating a plasma that allows the current flow to rapidly increase and be
sustained, resulting in an arc flash or arc blast. When an arc flash is possible then fault
current calculations must be done to determine safe protection boundaries and required
PPE, as well as to provide the information needed for arc flash labels that must be
installed in addition to the required NEC 110.24 fault current labels.

Three Phase Faults

IEC 60909 "Short Circuit Currents in Three-Phase Systems" gives the accepted
calculation method for three-phase fault currents.

A fault in a three-phase system can either be symmetrical (balanced) or unsymmetrical

(unbalanced). In a symmetrical fault all three phases are equally affected. However, this
rarely happens. Most three phase faults are unsymmetrical, and that makes doing the
fault current calculation more difficult.

Sources of Content
Before a fault current calculation can be performed, all of the possible sources of
current must be identified. This can include some sources of current that may not have
been considered. There are four possible sources of short-circuit fault current:

 On-site electric generators: These are close and the fault current is only limited
by the impedance of the generator itself and the electric circuit.
 Synchronous motors: a synchronous motor is an AC motor in which the speed of
the motor is proportional to the frequency of the electric power.  When the power
fails, as will happen if there is a short-circuit, the inertia of the mechanical load on
the motor will continue rotating the motor. The motor will then act as a generator
supplying current, and this will contribute to the total current flowing to the fault.
 Induction Motors: this type of motor will also become a generator should there be
a short-circuit fault somewhere else in the system. However, the fault current
generated by an induction motor will only last for a few cycles.  The current will
be approximately equal to the locked-rotor starting current of the motor.
 Electric utility system: most of the fault current typically comes from the electric
utility. The level of the short circuit current will depend on:
o the transformer secondary voltage rating and impedance
o the impedance of the generators
o the impedance of the circuit from the transformer to the short.

To simplify the fault current calculation, it is assumed that all electrical generators in the
system are in phase, and that they are operating at the nominal system voltage.
Bolted Three - Phase Condition
A short circuit study is conducted so that the fault current can be calculated. This
normally involves looking at the worst case scenario, which is the bolted three-phase
fault condition. Based on this situation other fault condition can be approximated.

The fault current contribution from motors in the system is important. In many cases
motors can contribute four to six times their normal full load current. Even if the current
is for a very short duration, it is critical that it be included in the fault current calculation.

When an arc flash study is being done, the fault current calculation should still be for the
highest bolted three-phase short circuit current.

Fault Current Labeling

Once the fault current has been calculated, labels made giving the available short circuit
fault current, should be applied to the equipment. If an arc flash label is required, it
should also be printed and applied in the appropriate location. Each label requires
custom information that comes from the fault current calculation.

Take the next step!

Now that you have a basic understanding of the variables in arc flash calculations,
download our free Arc Flash Energy Guide for detailed advice on how to implement a
safety system in your facility. Download your free copy today!

Available Fault Current

The National Electric Code, or NEC, requires that equipment be marked with the
available fault current, and that this labeling be kept up-to-date when there are changes
that affect the available fault current.

What Is Available Fault Current?

The available fault current is also known as the short circuit current. It is the maximum
current available should there be a short circuit, such as a ground fault, that could cause
an arc flash. The labeling of available fault current is not a part of arc flash labeling and
a separate label is typically used.

Before the available fault current for equipment within your facility can be determined,
you need to know the available fault current at the secondary terminals on the utility
transformer feeding your facility. This is usually provided by the utility and gives the
maximum possible fault current.
Based on the utility's transformer available fault current the available fault current for the
electrical equipment and panels throughout the facility can then be calculated. Each
must be calculated separately as the available fault current varies based on the circuit
impedance. The circuit impedance is unique at every point in the system. For example,
circuit impedance is affected by factors such as the type and length of the wiring, as
well as the other equipment that is in the circuit.

The addition or removal of electrical equipment from a circuit can change the
impedance and change the available fault current in other parts of the circuit. For that
reason, the NEC 110 code requires that available fault current be recalculated
whenever electrical changes are made.

Available Fault Current Labels

Having a DuraLabel printer available for making needed NEC 110 required labels
makes your job easier. You'll be able to print all the electrical labels you need, including
available fault current labels, arc flash labels, and electrical warning and danger labels,
as well as labels and signs used in non-electrical systems. With over 50 types of
supplies available, DuraLabel printers are the most versatile and productive label
printers available. Call us today for more information.

SCCR Short Circuit Current Rating

NEC 409/UL 508A

NEC defines the Short Circuit Current Rating (SCCR) as: "The prospective symmetrical
fault current at a nominal voltage to which an apparatus or system is able to be
connected without sustaining damage exceeding defined acceptance criteria."

What this means is that the SCCR is the maximum short-circuit current equipment can
survive without damage or without causing a hazardous condition. SCCR applies to
equipment and components. It does not apply to fuses or breakers, which are intended
to interrupt current. However, it does apply to the panel where the interrupt devices are
installed as well as the equipment they protect.
However, the SCCR and the interrupt device are related. For example, can equipment
withstand short circuit conditions until the interrupt device stops the current flow? What
is the maximum current that can exist during the time it takes the interrupt device to stop
the current flow?

Both NEC 409 and UL508A require the marking of industrial control panels with their
SCCR. This means that anyone who assembles electrical equipment such as panels,
disconnect switches and power circuit components is required to test the equipment and
label them with their SCCR. This includes manufacturers, contractors, system
integrators and end users.

The SCCR typically is included on the equipment nameplate label, along with such
information as the name and location of the manufacturer, the panel type, electrical
wiring diagram or a reference number to the electrical drawings, and various other
information.

It is crucial that this label be permanent and the information it contains be specific to the
equipment. The best way to make these labels is using a DuraLabel printer. With
DuraLabel you can print labels, of various sizes, using nearly any software you have.
Labels can include text, diagrams and logos. And each label can be custom designed
with as many copies as needed quickly printed.
 1. Safety
2. Arc Flash

Identifying Pitfalls in the Arc Flash Calculation

Process
Why arc flash hazard assessments and analysis results aren’t always foolproof

D. Edwin Scherry, P.E.

Oct 16, 2013

An electrical arc flash can occur when someone is verifying the presence of voltage,
checking the balance of current, operating a switch, inspecting an energized cable or
bus connections during routine maintenance, or simply standing in the vicinity of
energized equipment. This is a reason to perform an arc flash hazard assessment study
— to discern the degree of arc flash hazard present and the level of PPE required at a
given location on the power distribution system. In addition, this type of study helps
determine the possible means to reduce the energy through time and/or distance
adjustments. Many times, however, this requires you to run through a series of
calculations using available commercial engineering software or lengthy hand
calculations. However, mistakes can be made during the calculations process. That’s
why it’s critical for you to understand the limitations of these methodologies.
The basics

Arc flash studies require input from short circuit and coordination analysis to calculate
incident energy based upon bolted and arcing fault current levels, arcing time duration,
and distance to arc. Arcing faults are the result of current passing through the air. At a
particular point in the distribution system, this current is always less than that possible
for a bolted fault, which is a result of the direct metallic connection between conductors.
The incident energy created during an arcing fault is calculated in the form of calories
per square centimeter (cal/cm2).

The approach taken by the engineering professional performing the analysis needs to
consider some items that are not necessarily addressed in performing short circuit and
coordination analysis. This discussion will concentrate on the approach taken using
IEEE Std 1584-2002 with two amendments: IEEE Std 1584a-2004 and 1584b-2011.

The objective of any arc flash assessment is to calculate the incident energy and
determine the arc flash boundary distance. The arc flash boundary is defined as the
approach limit, at a distance from exposed live parts, within which a person could
receive a second-degree burn if an electrical arc flash were to occur. The reliability of
overcurrent protective devices is critical to escalation of an arc flash to higher levels
than expected, so system maintenance is very important.

Required data
An arc flash hazard assessment requires the following input data about the distribution
system:

• Single-line diagram of the power distribution system from the electric utility source to
the low-voltage panel boards and motors (50 hp and larger).

• Electric utility source data, indicating minimum and maximum available bolted fault
current, X/R ratio, and supply voltage.

• Transformer data, indicating ratings, impedances, types, and primary/secondary

protection.

• Equipment type and voltage rating of current transformers (CTs), breakers, switches,
and fuses in switchgear, motor control centers (MCCs), and panel boards, indicating
manufacturer, types, ratings, ratios, settings, and short circuit withstand capabilities.

• Protective device characteristics from time current curves (TCCs), indicating CT ratios,
manufacturer, model, type, and settings.

• Feeder cable material (Cu/Al), sizes and lengths and raceway material (magnetic /
non-magnetic).
• Size and rating of motors or loads, especially 40kW or larger, connected to switchgear,
distribution panels, or MCCs.

• Working distance of worker to equipment bus or energized component.

Fig. 1. Radial portion of a distribution system.

Example scenario
Let’s begin with a simple example of a radial portion of a distribution system (Fig. 1)
having a 5kV overhead electric utility distribution line, using a pole-mounted fused
disconnect, to feed an underground feeder serving an oil-filled, pad-mounted 1,500kVA
transformer with 5.75% impedance. The primary full load ampacity (FLA) of the
transformer is 208A. According to NEC Table 450.3(A), a primary fuse up to 300%
could be used.

Let’s begin with a 500A, 5kV fuse, which is about 240% of primary FLA. There are
cables connecting the 480/277V wye transformer secondary with a solidly grounded
neutral to a main power circuit breaker in 480V switchgear. The secondary FLA of the
transformer is 1,804A. Again, according to the NEC, a protective device could be sized
up to 250% (in supervised locations), but a 125% limit (for unsupervised locations) is
more common and useful for arc flash considerations. So 1.25 × 1,804A = 2,255A.
However, because there is not a device of that rating, let’s begin with a 2,400A power
circuit breaker. This main breaker could be set with a long time pick-up of 0.9 or 2,160A
to properly protect the transformer and possibly the secondary conductors. One of the
feeders from this switchgear is an 800A power circuit breaker feeding an 800A rated
MCC. Finally, there is a 600A fused switch in the MCC serving a downstream panel
load.

The primary conductors are routed in underground PVC conduits. The transformer
primary is 100 ft of 2-250kcmil shielded copper 5kV conductors per phase with a 90°C
conductor temperature — and each rated to carry 260A. The secondary conductors are
routed in an underground ductbank, so you can use copper conductors with a 90°C
conductor temperature using 6-500kcmil conductors per phase to carry the 1,804 FLA.
However, these should be increased to 6-750kcmil per phase to carry 2,190A, which
would then be protected by the secondary main breaker from a downstream fault. The
conductors between the switchgear and the MCC are copper conductors with a 75°C
conductor temperature in a steel conduit. Using 2-500kcmil per phase to carry 760A
would allow the breaker to be set with a long time pick-up of 0.95 or 760A.
Fig. 2. Initial TCC 1,500kVA unit substation.

Once the available fault level is obtained from the electric utility, you can use the above
data to evaluate the available fault levels at the switchgear and the MCC. In addition,
when the equipment manufacturer and types of breakers are determined, a TCC can be
prepared reflecting the operating conditions of this system (Fig. 2). Then, with the push
of a button, if using commercially available software, the arc flash incident energy and
arc flash boundary can be determined. But do you really have the necessary information
for safe operation of the equipment at that point?

Other considerations

There are many locations within the power distribution system that are critical to
appropriately understanding the exposure to arc flash energies. First, a device cannot
protect itself. Thus, to evaluate the incident energy at any point, you must look upstream
from the point of the fault to the protective device ahead of the point being evaluated.
Second, to use the main to protect the bus during an arc flash, it must be physically
isolated from the bus and from the downstream feeders.

Fig. 3. Partially modified portion of distribution system.

To accomplish appropriate arc flash evaluation, one suggestion is to add buses (Fig. 3)
at system connection points into the model. A bus could be added after any impedance
item like a transformer or cable and before any protective device. A main breaker would
have a bus shown on the input and output of the breaker. For our example, to calculate
the arc flash energy at the main breaker, the primary fuse protecting the transformer
must be investigated. However, to permit the main breaker to provide protection of the
equipment bus and feeder breakers, it needs to be determined if the main breaker is
isolated from the bus and feeder breakers (e.g., for switchgear).

In considering a distribution board with an included main, generally in a common

enclosure with the bus and feeders, the main would not be considered isolated. The
same is true for many switchboards, MCCs, and panelboards. One way to use a main to
protect its downstream bus is to place the main in its own isolated enclosure and then
use cable and conduit to the bus with fire stop in the conduit. The isolated main would
have higher arc flash incident energy than the bus and downstream feeders.
Available fault current

Fig. 4. Calculating transformer secondary short circuit current.

In the past, it was useful to consider an infinite electric utility short circuit current and
then, from the transformer size and impedance, evaluate the maximum available bolted
fault current. This was — and still is — helpful for ensuring the equipment has suitable
short circuit withstand ratings. However, with arcing current being a lower current than
the bolted fault current, it is also important to consider the actual or minimum available
electric utility fault capacity. Compare the secondary available bolted fault current of a
10,000MVA source to a 90MVA source supplying a 480V, 1,500kVA transformer. Note
that instead of a 31kA bolted fault, you could be looking at 24kA (Fig. 4). If you would
plot a series of available source MVA versus transformer secondary faults, you could
arrive at results depicted in Fig. 5.
Fig. 5. Transformer 480V secondary fault vs. source MVA.

However, it is not the bolted fault but the arcing fault that is important. It is well known
that an arcing fault is lower in value than the available bolted fault for any point in a
circuit. Using IEEE Std 1584 Equation 1 for under 1,000V, you can calculate that 480V
equipment arcing faults are roughly between 40% and 60% of the available bolted fault
current level. For quick calculations, a value of 50% can be used. For 208V equipment,
arcing faults are roughly between 20% and 35% of the available bolted fault. For quick
estimated calculations, a value of 25% can be used.

In addition, according to IEEE Std 1584, there is a recommendation to calculate a

second arc current equal to 85% of the calculated arcing fault current. This is done to
allow for discrepancies in matching the equation to the test points. Then, from the bolted
fault, the arcing fault and 85% of the arcing fault can be estimated.
Arcing faults are not predictable
Let’s recap what we’ve discussed so far. The electric utility is asked to provide an
estimate of the fault current at the point in its system where the equipment that is being
evaluated is said to exist (the position of which is an estimate). You use the
manufacturer’s estimate of the transformer impedance, which varies from no load to full
load — and with temperature. The conductor size and length are chosen, and, as a
result, its impedance is estimated — again, as it varies with temperature. Calculations
provide an estimate of the bolted fault current and subsequently estimate the arcing
fault current. Manufacturers’ estimated TCCs depict how a properly maintained
protective device is expected to respond to the bolted and arcing fault current. In other
words, our resulting calculation is a reasonable approximation of what is expected to
occur.

Expanding our facility distribution system to include bolted and arcing fault levels, it
should be realized that the fault current also has an impact on the conductors’ ability to
transmit that level of fault current. If a fault current of 24kA is available at the
transformer secondary, then a conductor rated to normally carry a full load current could
experience a lower fault current at a distance from the source to an estimated point by
as much as 200 ft (Fig. 6). With a 24kA available bolted fault, an 800A feeder circuit of
100 ft for the MCC would only see 83% of that available fault, or 20kA; and the arcing
fault would be roughly 50%, or 10kA. The 85% point is 8.5kA. So what started as 24kA
is now seen as 8.5kA. This certainly has an impact on the setting of the circuit protective
device.
 Fig.
6. Bolted fault vs. feeder length for 480V, 24,000A fault.

Mitigation

What can be adjusted to affect the arc flash incident energy in a system? The fault level
from the electric utility can’t be modified by the facility distribution system. The
transformer size and impedance can be adjusted, especially for large units, but this may
not allow for the appropriate total capacity of service to the facility. The location of
equipment could be adjusted, but other factors generally have the principal impact on
equipment location. The electrical protective devices and their settings can be selected
and have the greatest effect on the available incident energy at points throughout the
distribution system.

Looking back at the initial system TCC (Fig. 2), can anything be adjusted to reduce the
arc flash incident energies in the system? The primary fuse could be resized. This
would still allow for transformer inrush and full load capability. In general, medium-
voltage fuses do not provide a real means to reduce incident energy, especially on the
low-voltage side of the transformer.

For the 1,500kVA transformer with a 90MVA source, there is 12.5kA bolted fault current
at 4,160V. The medium-voltage arcing fault is roughly 1% to 2% less than the bolted
fault per Equation 2 of IEEE Std 1584. Then, looking at 85%, the 4,160V arcing fault
level is approximately 10.6kA. A 500A fuse would respond in about 0.02 sec, yielding an
arc flash energy at the transformer primary of less than 1cal/cm2. The secondary
24.3kA of bolted fault at 480V would have about 12kA of arcing fault and 10.3kA of
reduced arcing fault. The medium-voltage fuses respond much too slowly, resulting in
energy above 50 cal/cm2. However, looking at Fig. 7, the short-time pickup (STPU) of
the secondary main could be reduced from 5 to 3. This would reduce the reaction time
for the main breaker from 12 sec to 0.31 sec and thus, the arc flash incident energy
from 50 cal/cm2 (for 2 sec maximum) to 12 cal/cm2. The MCC feeder STPU could be
reduced from 9 to 5 to maintain coordination with the main. This would overlap the 600A
fuse, but if the fuse size could be reduced to 400A, coordination would be maintained.

Fig. 7. Revised TCC 1,500kVA unit substation.

Option for Class L fuses

During this design, you could use other protective devices, such as a 2,000A secondary
main fuse. When large low-voltage fuses are used, they respond in about 1 sec to a
fault at seven to eight times their FLA rating and in about 0.01 sec to about 15 times
their FLA rating. Keeping in mind that the arcing fault level is less than the bolted fault
level (about 10kA for our example), a 2,000A secondary Class L fuse would respond to
the arcing fault in about 7 sec. In fact, smaller fuses (even of the same current rating) of
different types have differing responses at various current levels.

Various breaker types

Breakers also have differing characteristics. For example, an 800A adjustable power
circuit breaker and an 800A thermal magnetic breaker are quite different. The power
circuit breaker has long time (LTPU & LTD), short time (STPU & STD), and
instantaneous (INST) settings, as well as, I2t and zone selective interlock options. The
thermal magnetic breaker typically has LTPU and INST settings with possible
adjustment of the INST (5 to 10 or some similar range) and possible zone selective
interlock option.

It should be noted, with experience, that 480V equipment reaction times over
approximately 0.5 sec for bolted fault values above 42kA — and reaction times of 1 sec
for bolted fault values above 22kA — result in PPE Class 4 protective clothing level or
higher.

In addition to the re-evaluation of protective devices and their settings, there are other
mitigation approaches to consider:

• Replace the medium-voltage fuse or add a medium-voltage breaker with a short time
adjustment to reduce secondary arc fault energy.

• Add a maintenance switch to provide lower relay settings or an instantaneous

adjustment to a lower fault pick-up level in accordance with the arcing current.

• Add an arc mitigation relay that senses a flash of light from an arcing fault and the rate
of rise of the current from the fault.

• Provide a reactor in the distribution circuit to reduce a high fault current

• Use zone selective interlocking to recognize and localize a fault more quickly.

• Install an ultra-fast earthing switch (UFES) between the medium-voltage fuse and
transformer primary.
In many situations, the above may require an alternate scenario to the original design.

Increase the distance to equipment especially during operating and racking procedures:

• Provide a longer cranking rod to rack breakers. At 480V, doubling a nominal 18-in.
distance would reduce the energy to about one-third. At 15kV, doubling a nominal 24-in.
distance would reduce the energy about in half.

• Provide a remote racking device.

• Provide a remote operator.

Other non-direct effects on incident energy:

• Be aware of standby generators having lower available fault current than the electric
utility power feed.

• Install arc resistant switchgear (Note: This equipment is only arc resistant when the
doors are closed).

• A neutral grounded resistor (must be supervised) reduces the magnitude of single-

phase arcs.

• Insulate the bus, which reduces the probability for single-phase and 3-phase arcs.

Conclusion

Although arc flash is a serious workplace hazard, there are means to evaluate its
intensity and to mitigate the effect on electrical workers. IEEE Std 1584 and NFPA-70E
provide mechanisms to calculate its intensity and to recommend appropriate PPE.
Engineers should also be encouraged to determine other effective mitigation techniques
such as providing barriers, increasing working distance from an arc, and reducing the
time an arc would exist.                   

Scherry is a registered professional electrical engineer with Scherry Engineering and

Consulting, Inc. in St. Louis. He can be reached at scherryengineering@swbell.net.