Getting started

at an industrial site

BY BRIAN TURESKI &

S. DOUGLAS CROMEY
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PRACTICAL AP-

A proach to undertaking an
arc-flash study at an industrial met-
E
VILL
RT

als facility is described. This article is based on

©A

the experience of the authors in undertaking an arc-flash study and the

process of rolling out an overall system approach to arc flash at an industrial site.
The arc-flash study procedure is primarily based on current arc-flash standards, such as
National Fire Protection Association (NFPA) 70E, Canadian Standards Association (CSA) Z462,
and IEEE Standard 1584; however, insight is provided in areas that require practical consideration during
the process that may not be intuitively obvious before participating in this process. This article is a discussion of
the shared experiences from the concept stage to arc-flash system completion.
Much has been said about arc flash in many forums with both generalities and sobering examples. Hopefully, we are at
the point where we are beyond the question why and have moved into the region where the questions are how to move
efficiently, effectively, and with the shared experience of many.
10 Digital Object Identifier 10.1109/MIAS.2010.939618
Date of publication: 17 May 2011

1077-2618/11/$26.00©2011 IEEE
 The objective of this article is to collect some tools cases where old habits must be unlearned and replaced
together to help with understanding the process of deter- immediately with the new ones.
mining the risks associated with electrical equipment pan- A number of people were not satisfied with the current
els. Developing a model for a system that may be more level of safety and worked to develop effective standards
typical of metals industry installations and understanding and tools. They were able to provide two levels of educa-
the results of a study run from this model will be discussed. tion—presentations of actual cases (both laboratory and
The steps that can be used to mitigate the risks identified real life) and workable standards. Seeing the effects of an
in the studies will be considered. This article was the first arc flash and having better descriptive tools does make one
presentation of the four articles at the Focus Session spon- much more aware of the issue and able to act appropriately.
sored by the Metal Industry Committee at the 2009 IEEE One of us had the occasion to generate a computer
Industry Applications Society (IAS) Annual Meeting and presentation that focuses on the risks associated with
conference. The other three articles, which are also part of electrical panels, both in and near the panel. This was
this issue, provide insights on the standards of the United presented to a group of people who would need access to a
States, Canada, and Europe; new equipment to deal with room where the electrical panels are located. At the end of
arc-flash energies; and methods that can be used to reduce the presentation, a number of people (security, operators,
energies for the existing equipment. etc.) came up and said that they had no idea that such seri-
ous risks existed in the areas indicated. It did not take a full
Data, Analysis, Interpretation, and Planning worst-case scenario to catch their attention.
Understanding the standards and why they exist give us
Getting Started the understanding and the insight to tackle the problem.
Where does one start? There has been a great deal of work Standards, experience, consultants, and groups such as this
done to create standards such as NFPA 70E (United one (IEEE and the various subcommittees who have and
States) and CSA Z462 (Canada). Although these provide are working on this topic) provide us with the knowledge
the standards on which to base our decisions, for design base. Keeping this fresh and active will be the challenge as
and measurement, the process of gathering data, analyz- time goes on.
ing data, making decisions, and taking action can still be Understanding the process and the opportunity that is
a daunting one. Fortunately, we are not alone or isolated in set before us is the first major step in the action plan.
this area. In fact this is one area, as is the case in many others, 1) What is the true nature of the system?
where working collaboratively produces the required results 2) What information do we need to gather?
much more quickly and effectively. 3) How do we get at that information and where does
Undertaking this change needs to be considered as a sys- it hide—or rather reside?
tem change. Changes need to consider safety, code require- 4) Who should get the information?

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ments, and best practices and changing the way we think, the In an ideal circumstance, all equipment is arc-flash
way we work, the existing equipment, our expectations of rated, every worker is arc-flash trained, and the arc-flash
new equipment, and the way equipment builders deliver the program is well defined and maintained. This may be the
equipment for today’s environments. Trying to do all of this case in new facilities (not a given). Time can introduce the
at one time is probably impossible, but considering these in following issues that must be considered:
an overall plan with realistic time expectations can be done: Plant People
1) understand the objectives, tools, and team members n Promotions
2) move on to create a successful step n The skills may not be transferred.
3) build on those successes n Replacement training may be taken for granted.
4) make the process sustainable and robust. n Retirements
We implement this by focusing on the starting point and n The skills may not be transferred.
some of the considerations for implementing the changes. n Replacement training may be taken for granted.
Standards such as NFPA 70E and CSA Z462 exist and n Replacements
provide the basis for good practice. Based on these standards, n The skill requirements may not be understood.
tools have been developed by a number of manufacturers n Replacement training may be taken for granted.
that give the basis for communicating the risk to both n Too many conflicting demands on time may take
informed and uninformed people. Here, we need to stop and focus off the tasks required for the arc-flash program.
look at our normal assumptions. Plant Equipment
Those of us who have worked around electrical equip- n Drawings
ment for a number of years have been aware of the signifi- n up to date
cant dangers due to shock and of the other failure modes n some up to date and some are not
that have been quite devastating. We had learned to work n unknown status of some.
safely and effectively, or so we thought. n Manuals
The old phrase “familiarity breeds contempt” could be n available, up to date, and relevant
restated in a more day-to-day form as “familiarity breeds n unknown state
overconfidence and erodes caution.” The daily exercise n cannot be found or replaced.
should be one where the awareness is strengthened through n Maintenance
continually refreshing and enhancing knowledge (through n up to date with good records
acquiring new knowledge and reminders of the existing n not up to date
11
key knowledge). To be complete, we must also consider n unknown.
 Maintenance Records globalization shifts to understand the reality of the issues
n up to date with good records and how they complicate the process.
n not up to date One of the most difficult facilities to tackle is the one
n unknown. that has had a number of cycles, especially a downturn
Business where the staffs were downsized severely. This often
n Priority produced valuable skill (and history) losses, minimum
n the “if it is not broken, do not fix it” attitude maintenance practices (emergency only), and near non-
n one of the many objectives, some competing and existent record keeping. When a reprieve came, the focus
conflicting. shifted to the “here and now” option, without the consid-
n Attitudes eration being given to the restoration of good standards,
n safety may be the top priority and the require- resulting in a continual erosion of critical data and equip-
ments well understood ment. Recognition of this condition or similar ones will
n skills required may or may not be understood help to identify the data that may be difficult to determine
n safety may be taken for granted. and identify the methods to get the information required
n Climate or suitable substitutes.
n swings in business may tax the resources Where do we start? We will take the case of an older
— too busy: not enough resources and time facility that has seen several cycles and has multigenera-
— not busy: time but no money or downsize until tional equipment and resources. If your facility is younger,
the resources are taxed. then this process can be simplified.
Facility
n Age Scope
n new: in construction How much of the power system should be analyzed?
n aging: still young but upgrades are necessary Does one take a top-down or bottom-up approach? In
n seasoned: wealth of multigenerational equipment this case, top-down is the only practical choice. It drives
and resources. or influences everything else. Where is the top? In many
n Business metals facilities, this is either the power utility or the
n growing: good investment, training, and standards power utility with some on-site generation. The top
n holding its own: investment ongoing but more selective must be the generation of power and the constraints that
n declining: difficult to get the necessary resources it (or they) places on the system. The bottom constraint
n recovering: (could be the most challenging) invest- will be driven by the arc-flash incident energy levels.
ment available, but the time and effort required The process may be iterative: plan on getting a base
for proper documentation and record keeping have study done and then review it for areas that need addi-
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suffered because of the lack of resources on the tional data.

decline phase, and tackling too much on the
recover phase can be as risky as doing nothing. Data
n Climate The data gathering will be defined in the “Data Gath-
n swings in business may tax the resources ering” section. History will play a significant factor in the
— too busy: not enough resources and time quality and quantity of the data.
— not busy: time but no money or downsize until
the resources are taxed. Who
Supplier Business/People Who is best suited to gather the data in a time-efficient
n Expertise manner? The process can very easily be underestimated.
n may be at optimum: best in business Given a good set of tools at the opportune time, data can be
n may be increasing: investing in people and other resources gathered efficiently. Cost and resources will be a big factor.
n may be declining: highly skilled people have Cost may be a factor for outsourcing or not or both.
retired, moved on, etc. n Advantages of internal resources
n may no longer exist: out of business, merger, and n when good tools and proper training are avail-
new focus. able, the costs can be lower for data gathering by
n Data using internal resources
n records retained and maintained n increased or refreshed familiarity with the equipment
n records retained but not maintained n improved engagement with the overall process.
n records transferred to another company n Advantages of external resources
n records lost or no longer exist. n may be able to keep to a schedule more effec-
n Equipment tively (less prone to procrastination because of
n leading the market other priorities)
n at market level n experience from multiple sites (and companies)
n trailing market. available for best practices and data verification
Understanding where you are in this environment is n may be able to better estimate older equipment
essential to building a productive game plan. Generally, parameters if data is not available or difficult to
the newer plants should face fewer issues than the older find on site
ones. One only has to look at the roller coaster ride we n more engaged to ensure that the data are com-
12
have had over the last 30-plus years and the impact of the plete and suitable for data-analysis stage.
Process n The number of bus locations that are required.
Determine the overall process, tune it as required, and have n The requirements of coordination and arc flash
a plan. If necessary, start in one area and then expand. apart from short circuit.
Know what you have. 5) Once the decision is made to use a specific brand
n Find a partner who is knowledgeable and can help you get of software and the data is entered, it becomes
the job done efficiently and accurately: There are a number expensive and time consuming to change to a new
of companies that have developed expertise in this brand of software.
area. If the company has the maintenance capability The data will be collected in a number of forms such as
for this type of equipment, it will be able to include spreadsheets, documents (files), and drawings. The process
its first-hand experience in the overall program. for collecting the information and the location for storage
n Prepare the data-gathering tools: Give consideration should be planned. One must consider the longer term
to ongoing data updates, deletions, and additions when constructing the data-gathering tools.
in the design of the tool. Future updates are much
more effective if the tools are reusable. What Data Is Required?
n Decide who should be involved in the data gathering: If The data required will be defined by IEEE Standard 1584,
resources are available, then set a time limit and the analysis software chosen, and your consultant (internal
get the data via internal resources. Use at least one or external).
of the external resources as a consultant to be able
to keep the data gathering on task and be able to Start with Data from Your Utility
quickly answer the questions. This can be a long lead item and can be done in parallel
n Decide on the analysis tool: Consideration should be with other activities.
given on internal training or use the external resour-
ces. Be practical on the question of sustainability (a How Many Feeds from Supply (Grid)?
difficult task in most times including today’s climate). It is important to accurately model the actual utility supply
n Gather the data. system showing each transmission and distribution supply
Analyze circuit individually. The actual arc-flash analysis will
n Run a preliminary analysis. require consideration of all possible switching configura-
n Fine-tune the data; get more if required. tions, including the utility supply circuits.
n Analyze the data.
n Review the results. What Information Is Required from the Utility (Grid)?
Act The required utility information for each supply circuit is
n Develop an implementation plan. as follows:

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n Implement. 1) Maximum utility fault levels at the point of com-
Review—Ongoing mon coupling:
n Assume changes are coming; build in review dates n maximum available three-phase short-circuit current
and teams. in amperes or megavolt-amperes (MVA)
n Sustainability issues. n maximum available three-phase short-circuit
X/R ratio
Data Gathering n maximum available single line-to-ground short-
The overall objective of the data is to build a model of circuit current in amperes or MVA
the power system for your facility, which can be used to n maximum available single line-to-ground short-
generate the arc-flash incident energy levels and to circuit X/R ratio.
provide enough background to consider the environ- 2) Minimum utility fault levels at the point of com-
mental impact (such as space to move, frequency of mon coupling:
access) on the area being considered. Part of the data n minimum available three-phase short-circuit cur-
collection effort will involve opening covers that will rent in amperes or MVA
expose the worker to live exposed parts and conductors. n minimum available three-phase short-circuit
Care should be taken to follow the safety procedures X/R ratio
listed in NFPA 70E or CSA Z462 for facilities that n minimum available single line-to-ground short-
have not had an arc-flash study completed. circuit current in amperes or MVA
n minimum available single line-to-ground short-
Power System Study circuit X/R ratio.
One must determine which software will be used for the study. 3) Nominal voltage level of utility supply circuit(s).
It will drive the following data-collection requirements: Similar to the approach with utility supply circuits, it is
1) The cost required for purchasing and maintaining important to accurately model internal alternate supply cir-
the software. cuits to capture all possible switching and supply configura-
2) The time duration for which the software vendor is tions. The most common example of an alternate internal
in the business. supply is emergency generation or in some cases cogeneration.
3) The level of difficulty in learning how to use a
software (software complexity) The Next Key Step Is to Define the Data Deliverable
4) The ability of the software to meet the needs of Get all parties together and define the data scope, format,
13
your organization. packaging (such as spread sheets, drawing, and preliminary
 one line), team members (and responsibilities), due date, n Significant effort is required on newer microproces-
and recipients. This needs to be clearly defined and in a sor-based relays (interrogate information).
form that could be reused to gather additional data in the n Information is usually available.
near future or for future updates. n Reactors
n It is highly dependent on nameplate information
Preliminary One-Line Diagram n Transformer data.
The data collection one line is the backbone of the data-collec- n The nameplate is usually sufficient.
tion process. This is distinct from the one line normally created n Capacitors
in engineering software used to model and perform arc-flash n The nameplate is usually sufficient.
analysis. The data collection one line is typically created in a n Low-voltage metal-enclosed switchgear
large format using pencil and paper. Ideally, all data col- n On older switchgear, short-circuit bracing may
lected are added to the line adjacent to the corresponding not be on the nameplate or drawings.
system component. Some systems are so large that they n It needs to verify that the incoming section is
require multiple large sheets to complete and spreadsheets compartmentalized.
linked to the one line with the descriptive nomenclature. n Low-voltage switchboards and panelboards
n On older switchboards and panelboards, short-circuit

Equipment and Common Data-Collection Challenges bracing may not be on the nameplate or drawings.
n Low-voltage power circuit breakers n This does not tend to be compartmentalized.
n The sensor ratings may be difficult to get and n Medium-voltage switchgear
may lead to incorrect trip times. n On older switchgear, short-circuit bracing may
n Low-voltage molded-case circuit breakers with not be on nameplate or drawings.
electronic trip units n It needs to verify that the incoming section is
n Most data are readily available. compartmentalized.
n Low-voltage thermal magnetic molded-case circuit breakers n Motor control center (MCC)
n It is common to have information hidden by pan- n On older MCCs, short-circuit bracing may not be
elboard covers, or lockout devices may lead to on nameplate or drawings.
incorrect assumptions on trip times. n It needs to verify that the incoming section is
n Medium-voltage circuit breakers compartmentalized and contains protection or
n Current transformer ratings may be difficult to main lugs only (MLO).
get and may lead to incorrect trip times.
n Medium-voltage starters Enclosure Types and Locations
n Current transformer ratings may be difficult to Several key elements in determining the amount of incident
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get and may lead to incorrect trip times. energy that may be released in an arc-flash event are as follows:
n High-voltage circuit breakers 1) The review of the available short-circuit current at the
n The information should be readily available. bus will be calculated by the engineering software.
n Fuses 2) The trip time is required by the upstream protec-
n Verification of the fuse element can be difficult tive device to remove the bus under review from
for expulsion fuses. service using a fault value that is derived from the
n The information may be difficult to get or read value in 1) above: this will also be calculated in the
because of the placement in the panel. engineering software.
n Cables 3) The working distance from the arc-flash event is
n It may not have legible manufacturer’s markings. defined in NFPA 70E and CSA Z462 based on
n It is difficult to determine cable routing to deter- equipment type and voltage level.
mine lengths. The previous data-collection elements have focused on
n Aerial lines providing enough information about the electrical system to
n The information on gauge and length may be dif- calculate items 1) and 2) above. Item 3) will have to be docu-
ficult to get. mented in each location where a worker could be exposed to
n Bus ducts an arc-flash event. Examples are low-voltage MCCs, low-
n The nameplate information may be hard to read voltage switchgear, and medium-voltage switchgear.
or missing. In addition to the above, it is critical during the data-
n Load interrupter switch collection process that consideration is given to the type
n The nameplate information may be hard to read of enclosure that houses a piece or several pieces of
or missing. electrical equipment. The question that requires docu-
n Motors: low-voltage induction or synchronous mentation in every case is when a worker opens a door or
listed individually panel that encloses a piece of electrical equipment, does that
n It is usually well defined based on nameplate worker become exposed to one bus location at a common
information and standards. voltage/short-circuit level and will be completely removed
n Motors: low-voltage induction lumped from service in the event of a short circuit by one upstream
n It is usually well defined based on nameplate protective device. Will there be two or more sections of bus
information and standards. with either different voltages and/or available short-circuit
n Protective relays levels? or will the line-side terminals of the protective
14
n Information is usually is available. device be exposed causing the two protective devices to be
removed with two or more different sections of bus from is common to find that a small percentage of the overall data
service within the same enclosure? requested is missing. Most engineering software has the func-
What this boils down to is the following: could the tionality to identify equipment that has been entered with
worker be exposed to two different arc-flash incident energy incomplete data. This ensures that no data will be missing
levels within the same enclosure? An example of this situa- when the analysis phase of the arc-flash study begins. In addi-
tion is within a control panel or switchboard being fed from tion, it is wise to compile a separate list of the missing data,
a feeder that terminates inside the enclosure at a molded-case which can be used by the personnel who collect the original
circuit breaker that will be used as the main circuit breaker data to get the missing ones and return to the field.
for the panel or switchboard. In this case, the main circuit The initial engineering analysis for arc-flash values will be
breaker has the line and load-side terminals exposed. It is conducted using the as-found equipment with as-found
necessary to determine whether a worker who opens the protective device settings and ratings. At the point in the
enclosure door can be exposed to two different arc-flash project where the missing data is being collected, it is a good
incident energy levels depending on what location the fault time to review the as-found protective device settings and rat-
occurs within the enclosure. In this case, the answer is yes. ings against the electrical code requirements for the overall
The working distance and available short-circuit values do distribution system (National Electrical Code–NFPA 70 in
not vary within this piece of equipment. The trip time does the United States and Canadian Electric Code–CSA C22.1 in
vary because a fault downstream of the main circuit breaker Canada). If the locations are identified where code compliance
will have one trip time, while the line-side terminals rely does not exist, a decision has to be made to identify the timing
on an upstream protective device, producing a longer trip of rectifying the noncompliant setting or rating. Ideally it
time for an identical fault. Two ratings exist within this would be possible to implement the protective device setting
equipment, and because a worker could be exposed to or rating change immediately. This way, when the arc-flash
either, it would be important to identify the higher arc- analysis is performed it is on a system that meets the electrical
flash incident energy value to use as the enclosure rating. code requirements. This is important to consider because when
Consider the same configuration with service entrance- the arc-flash analysis is performed, the system must be in the
rated metal-enclosed switchgear. The main circuit breaker same state that it will be in when the report is finished, and
is contained within an internal enclosure that is not accessi- the arc-flash hazard labels are applied. This will be referred to
ble to the worker, unless he or she specifically opens the as the base case in this article. Future changes to the base case
main breaker enclosure. Two ratings exist but, because they will require arc-flash updating of the one-line diagram and
are separately contained, it is possible to consider two dif- additional analysis of the revised arc-flash one-line diagram.
ferent locations within the same switchgear for labeling Examples of future changes are the decision to mitigate high
(main breaker cell, main bus, and feeder cells). arc-flash incident energy level locations by changing equip-
One other consideration that requires documentation is ment types or settings and future electrical system changes.

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the surrounding environment adjacent to the distribution
equipment being evaluated. During the analysis phase, an Arc-Flash Analysis
assumption is typically made that the worker, if physically Before running the analysis, it is important to plan the
able, will leave the area where an arc-flash event is occur- switching scenarios that you intend to include in the analy-
ring within two seconds. This is a reasonable assumption sis. Each scenario will be analyzed and arc-flash data will be
in most cases; however, should the surrounding environ- computed for each bus location that has been identified as
ment be a confined space, it is critical to document this requiring analysis. It is important to use a one-line bus lay-
and to note that the assumption is not appropriate for this out that takes into account the issue of multiple arc-flash
location. Some typical examples of confined space locations values residing within a common enclosure as identified pre-
are 1) an elevated bucket of a bucket truck and 2) a very viously in the “Data Gathering” section of this article.
congested area in an industrial facility. The minimum reasonable approach to choosing the sce-
The type of information described earlier is critical to narios to analyze is to include minimum fault and maxi-
have documented at the stage of the project where engi- mum fault values.
neering analysis is being undertaken and arc-flash incident Minimum Fault Values: This scenario may consider mini-
energy levels are being assigned. mum utility fault values, switching arrangement with the
highest internal system impedance, and no motor contri-
Preliminary Data Analysis bution from within the site.
Maximum Fault Values: This scenario may consider
Analyze Data maximum utility fault values, switching arrangement with
At this stage of the project, the data-collection one-line the lowest internal system impedance, and motor contribu-
diagram should be substantially complete. Therefore, a tion from within the site.
document exists (typically large-format paper based) that It may also be valuable to consider other scenarios such
shows the electrical system being studied with all equip- as normal operating conditions or multiple switching sce-
ment shown that is required for the analysis. The required narios where significant redundancy has been designed
equipment should have the data shown adjacent to it or, if into the electrical system.
that is not possible, an identifier is listed adjacent to the Once the scenarios to be considered have been chosen,
required equipment that is linked to a spreadsheet. the analysis can begin. Each scenario was put in place
The data one line is now used to develop the arc-flash one- within the arc-flash one line and the arc-flash calculations
line diagram that is entered into the chosen engineering soft- were produced. The same procedure shall be followed for
15
ware. As the arc-flash one-line diagram is being developed, it each scenario and the data saved for each. At the conclusion
 of all scenario calculations, a compilation of a single set of category 1 or 2. This is also the reason that many people are
data based on the highest arc-flash incident energy deter- looking for ways to mitigate the hazard by modifying the
mined from analysis of all the arc-flash data sets for the equipment and procedures to meet category 2 or below,
same location is required. especially on equipment with high-exposure frequency.
During the development of a single set of worst-case There are other hazards involved with an arc-flash event
incident energy data for each location, consideration other than incident energy (blast wave and molten metal) that
should be given to the physical layout of each bus and are not being considered as part of this article but do exist.
whether multiple incident energy levels exist within the
same equipment enclosure. Action Plan
Now that we have the worst-case incident energy data for This article is concerned with the study component, and
each bus compiled from the analysis, what are the key points, the full implementation considerations must consider com-
and what requires some interpretation? The study shows arc- ponents covered in other papers and programs. There are
flash boundary, working distance, incident energy, and considerations that must be made, such as
protective flame-resistant clothing class. Take the time to 1) immediate plan
understand each of these on an individual location basis. n review for mitigation options
We are reminded of a classroom teacher who—when n define the priorities
reinforcing the principle of mass balance—asks his stu- n identify which requirements may conflict with
dents, would the balance beam remain balanced (1-kg mitigation solutions and resolve
mass of lead and 1-kg mass of wood) in the classroom, on n identify labeling requirements and install labels
the top of a mountain, on the moon, and at the bottom of n train people who are affected by labeling
the sea. The students were puzzled when the answer was n review current projects for arc-flash implications
no. The explanation was that wood floats and that any and revise as required
investigation must take into account the actual environ- n review requirements with vendors for current
ment that the investigation considers. products that will help with mitigation options.
The incident energy drives both the clothing required for 2) intermediate plan
work on specific equipment or work in the vicinity of the n identify mitigation options that will require addi-
affected equipment. Often high levels of incident energy are tional planning
simply a confirmation that the only condition acceptable for n identify ongoing training requirements
working on the equipment is working on deenergized equip- n work with vendors to identify products that need
ment only (i.e., lockout tagout). Even with this practice, the to be developed
isolation of equipment (opening, closing, racking, and n analyze study for sensitivities
grounding) must be carefully considered and signed and — utility fault levels
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workers trained. Another element that must be considered is — areas of the plant power system that will be
the location of the different circuit components that schemati- more sensitive related to additions to the power
cally appears to be the same but with respect to the arc flash system or deletions from the power system
very different. The downstream circuit may be more current n maintenance of electrical equipment based on arc-
limited because of resistance but may be at a higher incident flash requirements
energy level because of a slower protection trip time. n database updates
The arc-flash boundary gives a good indication of the reach n codes and standards updates and impacts
of the arc-flash event for a specific level of impact on the indi- n analysis software maintenance
vidual. Sometimes the people involved are equipped for the n skill-base maintenance: training and documentation
activity, but others in the area may not be aware of the danger 3) long-range plan
because they are standing further back. The boundary will n some systems will require a multiyear plan to
also give an indication of the affected area. From this informa- bring them up to optimum
tion, work practices can be developed for the area affected. 4) review basis plan
The working distance is the distance to be used if ener- n review program yearly for robustness and sustainability.
gized work is to be considered and will drive the risk evalu-
ation. It is important to remember that the incident energy Maintainability
calculated is only valid at the stated working distance. The system must be built to be maintainable. Reality demands
Required protective clothing should be part of the study. that shifts and changes be addressed as a normal and expected
This is a simple extension that will help with the im- part of the process. Here are some things to keep in mind:
plementation portion of the work. n An arc-flash study is based on a snapshot of system
The arc-flash hazard risk category levels are based on the conditions at a specific point in time.
ranges of incident energy and correspond to the minimum per- n Once the initial arc-flash study has been completed,
sonal protective equipment (PPE) that will be required to be all future on-site changes to the site power distribution
worn by a worker. The hazard risk categories range from zero (0) system will require an update to the arc-flash study
to four (4) and are documented in NFPA 70E and CSA Z462. with revised or new system information.
Many industrial facilities have standardized on a base n There should be a systematic approach to this
level of PPE for day-to-day use at hazard risk category 2. update where all on-site changes are automatically
Therefore, there is minimal additional effort to complete updated in the arc-flash study.
the level 2 equipment (face shield and gloves) required for n It is recommended that the system described above
16
those activities where the worker is exposed to hazard risk be defined as written, communicated, measurable,
 and audited. The arc-flash system should be included 3) Long-range plan
with the site-business systems. n define skill-base requirements (training for ana-
n Utility grid changes are less obvious and beyond the lysts, training for workers, man power planning,
control of the utility customer. It is recommended and transition planning) review periods and who
that the utility system parameters used in the arc-flash will be responsible for the review
study are well documented and periodically requested n define the review period for standards review and
from the utility to determine whether the values have who will be responsible for the review
changed. If changes were noted after review, this n define the review period for the model software and
would trigger an update to the overall arc-flash study. other tools and who will be responsible for the review
This process of utility system parameter review should n define arc-flash study update triggers (changes)
also be documented in the written system with maxi- and refresh review dates
mum time frame between each review. n identify ways to keep the topic fresh, interesting,
Examples of utility operating changes and equipment and enjoyable.
changes that may impact the available short-circuit levels at the
point of common coupling with a customer site are given below. Summary
n Generation change Undertaking an arc-flash study can be a challenging task
n replacement of equipment with different output at the best of times and is essential to meet best practices,
n addition of new generation safe practices, and both codes and standards. We have
n removing generation from service—end of life highlighted a number of areas that will help to understand
n operating conditions—hydraulic generation relies the process and issues that must be considered. The process
on natural water conditions for prime mover and can be made more effective and time efficient when these
thus creates variable output are factored in at the beginning of a new study (or in some
n maintenance of generation cases when updating an existing study).
n base load generation versus peak load generation— During the analysis stage, care must be taken to under-
constant system change. stand the ratings. The values have physical constraints
n Load distribution change related to the physical location and the interconnecting
n base load versus peak load—constant system mechanism (physical barriers within switchgear). There
change. Customer loading changes on an ongoing will also be areas that will be identified (or reaffirmed) as
basis, which mainly drives the amount of genera- lockout tagout only. One of the clear results of these stud-
tion on the grid at any one time ies can be to identify high-risk areas, which traditionally
n additionally, some industrial customers operate would have been considered less risky.
rotating equipment of such large size; it has Finally, the study is not a single event if done well. As

IEEE INDUSTRY APPLICATIONS MAGAZINE  JULY j AUG 2011  WWW.IEEE.ORG/IAS

some impact on system short-circuit parameters with any equipment, the arc-flash program, and conse-
when placed in service. quently the arc-flash study, must be maintained. Sustain-
n Grid structure change ability must be built into the program by building the
n construction of additional transmission or distribu- required activities in as the original program is being imple-
tion circuits mented or immediately afterward.
n construction of additional switching configurations— Finally, use the resources around you in your organization
radial feeds from multiple possible sources or external organizations (the IEEE is an excellent resource).
n utility switching operating configurations for Expanding the resource base and using it effectively will
n maintenance build a better system.
n equipment failure
n construction/modernization Acknowledgment
n customer outage condition guarantee. The authors gratefully acknowledge the contributions of
The overall plan should have the following elements: M. Hodder and J. Rankin for their support and guidance
1) An immediate plan during the review stage of this article.
n decide which elements are to be addressed within
a year References
n generate the documentation upfront [1] Standard for Electrical Safety in the Workplace, NFPA 70E, 2009.
[2] Workplace Electrical Safety, CSA Z462, 2008.
n save the data in its various forms in at least two
[4] IEEE Guide to Performing Arc-Flash Hazard Calculations, IEEE Standard
locations (plant and with consultant, assuming a 1584, 2002.
consultant is being used) [5] IEEE Recommended Practice for Protection and Coordination of Industrial and
n identify and train at least one backup person. Commercial Power Systems (IEEE Buff Book), IEEE Standard 242, 2001.
2) An intermediate plan [6] IEEE Recommended Practice for Electric Power Distribution for Industrial
Plants (IEEE Red Book), IEEE Standard 141, 1993.
n identify the elements that will require a longer
time frame to implement and set a schedule and
team members Brian Tureski (brianmtureski@eaton.com) is with Eaton
n identify period of review—yearly for some items Electrical in Kingston, Ontario, Canada. S. Douglas Cromey is
n review ongoing projects for impact on the study with Novelis Inc. in Kingston, Ontario, Canada. Tureski is a
n software maintenance Member of the IEEE. Cromey is a Senior Member of the IEEE.
n codes and standards maintenance This article first appeared as “Arc Flash—Getting Started” at
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n business systems maintenance. the 2009 IAS Annual Meeting.