Electric Flash Suit

Safety Standard
Document no: SFT/PRO-04
Version: 6.0, Issue Date: 18th Apr 2019

Name Umesh Prasad A Ghosh Anurag Saxena

Sr
Head EHV, Manager,
Shared Services Technology Safety
Designation Group
i o n Chief, Electrical T & D

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Prepared by

f o r Authorized by

e
Du

CONFIDENTIALITY
The information contained in this document is confidential to Tata Steel. Accordingly, copyright of
this document is retained with Tata Steel and no copying in any format of this document is permitted
without the written permission from the approver of this document.
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SFT/PRO-04, Version-06 18th Apr’19

Change Authorization
Document Number SFT/PRO-04
Apex Safety Management System & Audit
Overall Process Owner
Sub-committee, Tata Steel.
Process Change Authorization Standard Owner - TSL
To be Reviewed By Standard Owner – TSL

Periodicity of Review of this Document Three years

Version Control History

Revision details
Ver. Date Prepared by Authorized by
U Prasad, A. Old UMCs replaced with new
6.0 18th Apr’19 Anurag Saxena
Ghosh UMCs, injury list updated
COEM Office Order dated
26.06.17 on Minimum PPE
U Prasad, A.
5.0 14TH July 2017 Anurag Saxena requirement for entering
Ghosh
o n 415V & above Electrical

24th October U Prasad, A.

v i si room is included
Old UMC of Arc face Shield
4.0
2016 Ghosh
r re Anurag Saxena changed with new UMC no-
0294A0128

3.0 9th Dec 2015 f o

U Prasad Anurag Saxena
Use of Arc face shield and
hand gloves, clause no-6D,

u e introduced
2.0
D
31st Jan 2015 U Prasad Anurag Saxena

1.0 1st Jan 2010 U Prasad Anurag Saxena

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SFT/PRO-04, Version-06 18th Apr’19

Table of Contents
1.0 Purpose.................................................................................................................................................... 4
2.0 Reference……………………………………………………………………………………………….4
3.0 Applicability ........................................................................................................................................... 4
4.0 Responsibility……………………………….…………………………………………………………..4
5.0 Associated Hazards ................................................................................................................................. 4
6A Definitions............................................................................................................................................... 4
6B Standards /Guideline for Electric Arc Flash Suit suitable for HV area .................................................. 4
6C Standards /Guideline for LV Arc flash Jacket/FR Blue Jacket (9.8 Cal/cm2) for use in >260V
<=690V …7
6D Uses of Arc face shield and Electrical safety hand gloves in>260V <=690V 9
7.0 Training and communication requirement.……………………………………………………… 10
8.0 Audit requirements ……………………………………………………………………..……… 10
9.0 Annexures …………………………………………………………………..……… 11

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1.0 Purpose: The specifications are intended to be used for the Electric Arc Flash suit which
Electrician shall wear while operating on HT switch gear (>690 Volt). The list of jobs along with the
Risk involved is attached in Annexure-l. It also covers the specification of Arc Flash Jacket, uses of
Arc face shield and Electrical safety hand gloves in voltage >260V <=690V

2.0 Reference: NFPA 70E (Standard for Electrical safety Requirement for Employee workplaces),
ASTM -F1506 (Standard performance specifications for flame resistant Textile materials for wearing
Apparel for Use by Electrical workers exposed to momentary Electric Arc and related thermal
hazards), ASTM-F1958/F1958M-99 (Standard test method for determining the ignitability of Non-
flame resistant materials for clothing by Electric Arc exposure method using Mannequins).
3.0 Applicability: Inside Tata Steel

4.0 Responsibility: TSL Departments, Contractors.

5.0 Associated Hazards: Exposure to Electric Arc Flash

6A Definitions:

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i. Arc Flash Suit: Ref. NFPA-70E clause 3-3.9.5. Flash suits and their closure design shall permit

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easy and rapid removal. The entire flash suit, including the window, shall have energy absorbing
characteristics that are suitable for arc-flash exposure.

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ii. ATPV: ATPV is the minimum energy causing the predicted onset of second-degree burns.
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iii. Break down threshold energy EBT: It is the average of the five highest incident energy
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exposure values below the stoll curve where the fabric does not exhibit break open. EBT is reported
when ATPV cannot be measured due to FR fabric break open.

iv. Factors affecting the worker injury when exposed to electric Arc:-- Electric arc intensity
depends on fault current, system voltage, electrode gap, number of phases involved, open arc
configuration or enclosure, electric Arc duration, distance of the worker from the electric Arc,
Type and fit of the clothing worn, Age and health factors.

v. Findings – Ref ASTM-F1506 clause 3.2.7. Miscellaneous fabrics in garments such as zipper
tape, lining, pockets, waistbands, and facings.

vi. Closures -- Ref ASTM-F1506 clause 6.1. The fasteners or closures are for example
Zippers, snaps or buttons or a combination thereof.

6B Standards /Guideline for Electric Arc Flash Suit suitable for HV area:
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6B.1. Basis for the specification:-- These specification has been prepared on the basis of the
NFPA-70E standard of USA which is specifically made for the Electrical safety
requirements for the employee at work places. To further confirm the specifications with
reference to the working condition at Tata Steel the Duke Heat flux calculator available
on Internet at site www.whsalisbury.com was also used to calculate the incident energy on
the operator.
These calculations were done for metal clad indoor circuit breakers at various
voltage levels like 3.3Kv, 6.6kV, 11kV, and 33kV. The calculation shows that in worst
condition at 33kV when three phase bolted fault remains for 1 sec (normally it is expected
to be cleared in 200millisecon) then the maximum incident energy on the operator is 32
cal/cm2 (see calculation in Annexure-III). The NFPA has identified the highest risk category i.e.
Category-4 and for which minimum ATPV required is 40 cal/cm2.

Note: ATPV is defined in the ASTM P S58 standard arc test method for flame resistant
(FR) fabrics as incident energy that would just cause the onset of second degree burn (1.2
cal/cm2). EBT (Break open Threshold energy) is reported according to ASTM P S58 and is
defined as the highest energy which did not cause FR fabric break open and did not exceed
the second-degree burn criteria. EBT is reported when ATPV can not be measured due to
FR fabric break open.
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6B.2. Specifications: ELECTRIC ARC FLASH SUIT KIT UMC No: 5854A0051
6B.2.1 High Voltage Arc Flash Suit (above 600 volts) suitable for hazard risk
category-4 as specified in NFPA-70E:

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The electric Arc flash suit shall consist of FR pant and FR shirt and Double layer switching coat

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(It is assumed that operator shall wear cotton underwear beneath the Arc flash suit). The

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combination of both should be suitable for hazard risk category-4 as defined in NFPA-70E. The
total weight of the complete Arc flash suit should be in the range of 24-30 oz/yd2. The Minimum
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Arc Thermal performance exposure value (ATPV) or breakdown threshold energy (EBT) rating of
complete Arc Flash suit should be 40 cal/cm2 as specified in NFPA-70E
6B. 2.2 Hand gloves (Inner & Outer), Hard Hat as per NFPA 70E requirement to be supplied along with the
HT Electric Arc Flash Suit Kit (UMC No 5854A0051)
6B.3. Apparel Use: The electric Arc Flash suit shall be used by the operator while executing
those jobs which are category-3 & above jobs categorized on the basis of risk involved, Ref
Annexure-1. The basis of the list is table 3-3.9.1 of NFPA-70E. However based on the fault
clearing time and present operating practices & experience in Tata Steel some of the jobs has been
categorized in the higher risk category. In none of the case the risk category has been reduced. The
list mentioned in Annexure-1 is indicative and not exhaustive. In case of confusion it is advised
the electric Arc suit should be used depending on the particular condition of the switchgear or the
type of job involved. In some of the cases the working on live system has been categorized as low
risk job. This specification recommends that in no case, work on the live parts should be done
even with PPE.
Unless an exemption can be justified for technical reasons, Electric arc flash suit shall be worn by
all persons while executing those jobs which are category -3 and above categorized on the basis of

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SFT/PRO-04, Version-05 18th Apr’19

risk involved, ref Annexure-1. Technical justification to deviate from the requirements of this
standard must be documented and approved as described in section 11.4.

6B. 4.0 Clothing material characteristics: Flame-retardant, treated cotton, Meta-

aramid, para-aramid and poly-benzimidazole (PBI) fibers provide thermal protection. Para-
aramid adds strength to a fabric to prevent the fabric from breaking open due to the blast of
energy of the Arc. Clothing made from natural materials such as cotton, wool or silk shall
be considered acceptable if it is determined by flash hazard analysis that the fabric will not
ignite and continue to burn under the arc conditions to which it will be exposed.
Clothing made from synthetic material such as acetate, nylon, polyester, rayon either alone or in
blends with cotton shall not be acceptable.

6B. 5. Design Considerations for:

6B. 5.1 Apparel selection :The following are some of the principles (Based on
ASTM-1506) that should be considered in the design and use of wearing apparel
for protection from momentary electric Arc and related thermal hazards:-
• Clothing should cover potentially exposed areas as completely as practicable. This should include
proper interfacing of related items.
•
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Garment design should permit easy and rapid removal. Closure design should be appropriate for
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easy removal.
•
provides the necessary protection.
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Garment design should be such that garment interfere the least with the work function but still

•
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Logos, name tags and other heraldry should be limited in number and surface area.
The fasteners or closures are, for example Zippers, snaps or buttons or a combination thereof, shall

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be used in a manner in which they are in contact with the skin, they can increase the heat transfer

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and burn injury due to heat conduction or melting onto the skin. Fasteners or closures that are used
in this manner should be covered with the layer of fabric between the fastener or the closure and
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the skin. The fabric used for this purpose shall meet the requirement of this performance
specification.
6B. 5.2 Arc Flash protective hood (for protection of face and head) should be suitable for
protecting from energy level of 40 cal/cm2 & meets current ASTM, F1506 and NFPA-70E
standard requirement. The viewing area should be 1 0’’ x 20’’. Wide arc rated anti-fog amber lens,
excellent breathability & cotton comfort having universal hard hat bracket. The size should be
such that one size fits to all.

6B. 6 Marking: Each electric Arc flash suit shall be marked with:

• Name, trademark or identification of manufacturer.

• Tracking ID code.
• Label indicating the conformation or exceeding the requirement of ASTMF-1506 and NFPA-
70E hazard Risk category- IV.
• ATPV or EBT value in Cal/cm2.

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SFT/PRO-04, Version-05 18th Apr’19

• Washing instruction
• No of washes allowed
The marking shall be durable and shall not impair the quality of electric Arc flash suit.

6B. 7 Inspections: User has to inspect his protective apparel every time before use. In
addition periodic inspection procedures for Electric arc flash suit should be established and
documented as advised by the supplier.

6B.8 Decontamination and cleaning: Decontamination and cleaning for Electric arc flash suit
should be established as per advice of suppliers and records for the same to be maintained.

6B.9. Repairs: Repair to Electric arc flash suit should only be done by personnel skilled in FR
garment making techniques, using methods and materials approved by the apparel manufacturers.

6B.10 Storage: Electric arc flash suit should be stored in a well-ventilated location away from
chemical contamination, excessive heat, direct sun light, and where it is unlikely to receive
mechanical damage (e.g : rips, tears)

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6B.11 Management records: Items to be documented as discussed in section 7 and 8 and records
shall be maintained by the department.

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6C Standards /Guideline for LV Arc flash Jacket / FR Jacket (8.5 ~ 9 Cal/cm2) for use
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in system >260V <=690V:
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6C.1

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The Electric LV Arc flash Jacket / FR Jacket (8.5 ~ 9 Cal/cm2) shall be worn continuously by all
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the persons entering the sub-station, while working on the any electric equipment inside the sub-
station or anywhere outside at Shop floor. This Jacket is mandatory even if person is standing in
front of the LV panel (indoor/outdoor) and not doing the work. The LV Arc Flash jacket/ FR
Jacket must be worn with full sleeves ON and all buttons closed. Please refer Personal Protective
Equipment & clothing standard general specification SS/GEN-58 for UMC No of FR jacket.
Specification of the Electric flash Jacket is given below for reference-
UMC No- 5854A0021 LV ARC FLASH JACKET (LARGE), COLOUR: BLUE
UMC No- 5854A0022 LV ARC FLASH JACKET (MEDIUM), COLOUR: BLUE
UMC No- 5854A0023 LV ARC FLASH JACKET (SMALL), COLOUR: BLUE
UMC No-5854A0020 LV ARC FLASH JACKET (EXTRA LARGE), COLOUR: BLUE
UMC No- 5854A0053 LV ARC FLASH JACKET (EXTRA SMALL), COLOUR: BLUE
Short Description: LV ARC FLASH JACKET (Size- Small, Medium, Large, Extra Large, Extra
small), COLOUR BLUE.
Technical specification: ARC Flash Jacket suitable for low voltage system for Arc Thermal
Protective Value (ATPV) 8.5 ~ 9 Cal / cm2 (refer Annexure-II for selection).
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SFT/PRO-04, Version-05 18th Apr’19

Detail specifications:
i) Electric Arc Flash Jacket Hazard Risk Category as mentioned in NFPA70E 4; Clothing
Description-FR Jacket made of fabric having ATPV rating of 8.5 ~ 9 Cal/CM2.
ii) Jacket should have 2 front pockets with flap with non-metallic flame retardant buttons. Each
electric Arc flash jacket shall be marked with following information: A) Name; trademark or
identification of manufacturer B) Size C) Tracking ID code. D) Label indicating the conformation
or exceeding the requirement of ASTMF1506 and NFPA70E hazard Risk category E) ATPV or
EBT value in Cal/cm2.; F) Washing instruction; G) No of washes allowed H) Care instruction and
fibre content, inside the collar of the Jacket; the marking shall be durable and shall not impair the
quality of electric Arc flash jacket.
Clothing material characteristics: Clothing made from synthetic material such as acetate; nylon;
polyester; rayon either alone or in blends with cotton shall not be acceptable.
Design Considerations: The following are some of the principles (Based on ASTM1506) that
should be considered in the design and use of wearing apparel for protection from momentary
electric Arc and related thermal hazards: Clothing should cover potentially exposed areas as
completely as practicable. This should include proper interfacing of related items. b) Garment
design should permit easy and rapid removal c) Garment design should be such that garment
interfere the least with the work function but still provides the necessary protection. d) Logos;
“LV ARC FLASH JACKET, TATA STEEL” shall be inscribe on the top of the left side pocket e)

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Heavy duty buttons in pocket, front and sleeve shall be used in a manner in which they are not in
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contact with the skin; they can increase the heat transfer and burn injury due to heat conduction or

flame retardant material.

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melting onto the skin, f) Logo, name tag, thread for stitching, buttons, etc. should be made of

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Laundering: The garment manufacturer in conjunction with the fiber and fabric supplier should
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provide instructions for the care and maintenance of protective wearing apparel. The supplier shall
provide type test report for the 8.5 ~9 Cal/Cm2 incident energy withstanding capacity of the fabric
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from approved laboratory, also the type test report for the Jacket is preferred.
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SFT/PRO-04, Version-05 18th Apr’19

6C.2 COEM Office Order dated 26.06.17 on Minimum PPE requirement for entering 415V
& above Electrical room

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6D Uses of Arc face shield and Electrical safety hand gloves in system voltage >260V
<=690V is over and above the present SOP & positive isolation system to take
care of human mistake:
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SFT/PRO-04, Version-05 18th Apr’19

6D.1 Mandatory use of Arc Face shield of 12 Cal/Cm2 (UMC no-5323A0012) for the jobs listed
in Note-1 for the voltage >260V <=690V. The list given in Note-1 is not exhaustive;
Engineer in-charge can add some more jobs as per the site requirement but cannot omit any
of the listed jobs.
Technical Specification of ELECTRIC FLASH ARC FACE SHIELD KIT (UMC no-5323A0012)
DESCRIPTION:TO BE FITTED IN THE HELMET
MATERIAL: POLYCARBONATE
TYPE: POLYCARBONATE VISOR
===============================
Additional Specification :
ELECTRIC ARC FLASH FACE SHIELD EXCEEDS NFPA 70E MEETS/TESTED ASTM F21
78 ANSI Z87+S RATED ATPV 12 CAL/CM2 ENGRAVED ON PRODUCT,
POLYCARBONATE
; SHATTERPROOF; Premium Permanent coating having helmet bracket with elastomeric band
for slotted and non slotted cap style helmets. Permanent chin protector; the polycarbonate Arc
Shield is injection moulded with corrected optic s and is moulded to shape. The significant quality
the coating to provide a permanent anti fog and adds abrasion and scratch resistant properties
which prolongs the life of the shield up to four times longer in the field. The coating for extra
protection from sun damage to be provided. It should provide zero distortion and also provides
better VLT and has a higher impact value. Make approved by TSL

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6D.2
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Mandatory use of 12Cal/Cm2 Safety Hand gloves for the voltage >260V <=690V for the
jobs listed Note-2 if isolation of power with Positive Isolation at least at two levels is not
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done. The list given in Note-2 is not exhaustive; Engineer in-charge can add some
more jobs as per the site requirement but cannot omit any of the listed jobs. Ref Note-3

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for UMC details of various sizes of the gloves.
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Note-1: The List of Jobs-- a) Rack in and rack out of the modules like ACB/MCCB/SFU etc. b) Inspection of
Power rail (DSL for Cranes, Power lines for Coke oven machines etc.).

Note-2: The List of Jobs-- a) Rack in and rack out of the modules like ACB/MCCB/SFU etc. b) Inspection of
Power rail (DSL for Cranes, power lines for Coke oven machines etc. c) Working on Bus bar / Conductor /
Power line / Motor T.B etc. d) Switching on and off of SFU and Isolators e) Power testing f) Earthing etc.

Note-3: The List of UMC’s – a) Hand Gloves - Size 8, UMC no- 5775A0003, b) Hand Gloves – Size 9,
UMC no- 5775A0005 c) Hand Gloves - Size 10, UMC no- 5775A0004 d) Arc Face shield of 12 Cal/Cm2,
UMC no- 5323A0012
7. Training and communication requirement: Training on Electrical safety to be given to all
Tata Steel (OPR and Non-OPR) and contractors employees working in electrical area every year
and record for the same shall be maintained.

8. Audit requirements: Each department should audit, compliance with this standard as part of
its EHS audit program.

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SFT/PRO-04, Version-05 18th Apr’19

9.0 Annexure
Annexure-I
Hazard Risk Category Classification (Ref NFPA-70E table 3-3.9.1)

S No. Voltage level Task (Assumes equipment is energized Hazard/Risk

and work is done in the Flash protection category
Boundary
1 240V and Circuit breaker (CB) or Fuse switch 0
below (25kA operation with covers on.
short circuit CB or fuse switches operation with covers 0
current & off.
fault clearing
time 0.03 sec) Work on energized parts including voltage 1
testing
Remove install CB or fused switches 1
Removal of bolted cover (to expose bare, 1
energised parts).

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Opening hinged cover (to expose bare, 0
energised parts).

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2 >240V and Circuit breaker (CB) or Fuse switch 0
upto 600V operation with covers on.
(25kA short
circuit current o r
CB or fuse switch operation with covers off
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1
& fault
clearing time u e
Work on energised part including voltage 2
testing.

3
0.03 sec)
600V MCCs
DCB or fused switch or starter operation with 0
(65kA short enclosure door closed.
circuit current Reading a panel meter while operating a 0
& fault meter switch
clearing time
0.03 sec) CB or fused switch or starter operation with 1
enclosure door open.
Work on energized parts including voltage 2
testing
Work on control circuits with energised 0
parts 120V or below, exposed.
Work on control circuits with energised 2
parts >120V, exposed.

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Insertion or removal of individual starter 3

“bucket” from MCC.
Application of safety grounds after voltage 2
test
Removal of bolted cover (to expose bare, 2
energised parts).
Opening hinged cover (to expose bare, 1
energised parts).

4 600V CB or fused switch or starter operation with 0

Switchgear enclosure door closed.
(with power Reading a panel meter while operating a 0
circuit breaker meter switch
or fused
switches) CB or fused switch or starter operation with 1
(65kA short enclosure door open.
circuit current Work on energised parts including voltage 2
& fault testing
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clearing time Work on control circuits with energised 0
up to 1 sec)
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parts 120V or below, exposed.
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Work on control circuits with energised 2
parts >120V, exposed.

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Insertion or removal of CBs from cubicles 3

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doors open.
Insertion or removal of CBs from cubicles 2
Ddoors closed.
Application of safety grounds after voltage 2
test
Removal of bolted cover (to expose bare, 3
energised parts).
Opening hinged cover (to expose bare, 2
energised parts).
5 Other 600V Lighting or small power transformer(600V -
class (277V, maximum)
through 600V, Removal of bolted cover (to expose bare, 2
nominal energised parts).
equipment)
Opening hinged cover (to expose bare, 2
energised parts).

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Work on energised parts including voltage 2

testing
Application of safety grounds after voltage 2
test
Cable trough or tray cover removal or 1
installation
Miscellaneous equipment cover removal or 1
installation
Work on energised part including voltage 2
testing
Application of safety grounds, after voltage 2
test.
6 NEMA E2 Contactor operation with enclosure door 3
Motor closed
starters,
2.3kV through
7.2kV.
Reading a panel meter while operating a 0
meter switch
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open.
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Contactor operation with enclosure door 3

testing
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Work on energised part including voltage 3

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Work on control circuits with energised 0
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parts 120V or below, exposed.
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parts >120V, exposed.
Insertion or removal of starters from 3
cubicles doors open.
Insertion or removal of starters from 3
cubicles doors closed.
Application of safety grounds after voltage 3
test
Removal of bolted cover (to expose bare, 4
energised parts).
Opening hinged cover (to expose bare, 3
energised parts).

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7 Metal clad CB or fused switch operation with enclosure 3

switchgear, door closed.
1kV and
above
Reading a panel meter while operating a 0
meter switch
CB or fused switch or starter operation with 4
enclosure door open.
Work on energised parts including voltage 4
testing
Work on control circuits with energised 2
parts 120V or below, exposed.
Work on control circuits with energised 4
parts >120V, exposed.
Insertion or removal of CBs from cubicles 4
doors open.
Insertion or removal of CBs from cubicles 3
doors closed.

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Application of safety grounds after voltage 4
test

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Removal of bolted cover (to expose bare, 4
energised parts).

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Opening hinged cover (to expose bare, 3
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energised parts).

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Opening voltage transformer or control 4

8 Other
equipment
D power transformer compartments
Metal clad load interrupter switches, fused
or unfused switch operation, doors closed
3

1kV and
above
Work on energised parts, including voltage 4
testing.
Removal of bolted cover (to expose bare, 4
energised parts).
Opening hinged cover (to expose bare, 3
energised parts).
Outdoor disconnect switch operation 3
Insulated cable examination in manhole or 4
other confined space.
Insulated cable examination, in open area 2
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Annexure-II

Selection of ATPV for Jacket Fabric

Past Electric flash incidences (11 nos-Annexure-IV) were analysed for assessing the severity
of Electric arc for selection of Arc thermal protective value (ATPV) of the Jacket to be used
in LV system.
In all the above cases of Electric flash, the most severity of Electric arc was in case of fault at
RMBB2 which happened on dated 01.06.2013 and burn injury was 20% (highest in all above
cases). This fault was most severe fault in 415 volt, as the three phase fault happened at the
mouth of the 1600 kVA transformer (6.6 / 0.415 kV) which is connected in series with highest
rating of Power transformer in Tata Steel i.e.31.5 MVA (33/0.415 kV) at SP-3 and 80 MVA
(132/33 kV) at CRM. In this case the actual fault current in 415 volt side was 19 kA for 800
msec which corresponds to incidence energy (ATPV) of 5.69 cal/cm2 (refer for detail
calculation in Annexure-III). Although the calculated fault current (ETAP study) considering
zero line impedance comes around 35 kA in place of actual current of 19 kA. This shows that
actual fault current in this case was only 54% (19*100/35) of the calculated value.

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Also fault level study was conducted for 429 numbers LV transformers (highest rating in TSL-
2000 kVA). The maximum calculated faults level (in kA) is 43 kA taking line impedances as

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zero ohm. Considering the actual fault current as 54 % of the actual fault current (as evident
from above example of RMBB2), the maximum fault current shall be 23 kA (54*43/100).

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The calculated arc energy corresponding to a fault current of 23 kA for the time of 800
msec (maximum tripping time of breaker) is 7.04 cal/cm2 (refer detail calculation in
Annexure-III).
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That is why we have chosen the Jacket fabric of rating 8.5 – 9 cal/cm2 which is 120% of the
required value.

Annexure-III
Calculation of ATPV for Jacket fabric
Electric arc intensity depends on Bus gap, distance of worker from the arc source, voltage, fault
current, duration of fault and number of phases involved in fault. The maximum incident energy
(ATPV) under different conditions due to three phase bolted fault was calculated with the help of
software “Flux.exe” and shown in given below table.

Bus Gap Worker Voltage (V) Fault amp Duration (sec) Calculated
(inch) distance (kA) Energy
(inch) (Cal/cm2)
1 18 440 19 800 5.69

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SFT/PRO-04, Version-05 18th Apr’19

1 18 440 23 800 7.04

12.3 34 33000 26.2 1000 32
Note
1) Bus gap has been considered as 1 inch (25 mm) based on the Tata Steel MCC specification
2) Worker's distance from the arc has been considered as 18 inch (reference IEEE Standard
1584-level of PPE with the intent to protect the worker from the thermal effects of the arc flash
at 18 inches from the source of the arc.)
3) Fault currents 19 kA and 23 kA for duration 800 msec have been considered based on the
actual fault current of RMBB2 and also study 429 nos. all LV transformer as explained in
Annexure-II
4) For 33 kV bus gap & workers distance taken from actual in Siemens AIS breaker model-3AH

Annexure-IV
Past Electric Flash incidences in LV system in TSL Jamshedpur Works

S No. Date Plant Incidence

1 10-10-07 LD1IEM Flash injury to Mr A K Mandal while attempting to replace
Contactor for CT in Live condition in Charging crane-2.
2 24-02-08 MM IEM
n
Flash injury to Mr M L Gope while working on Rake motor
o
si
contactor without switching off Breaker.
3 04-06-09 LD2 IEM
i
Mr N K Das flash injury while trouble shooting in the LT
v
re
circuit of Charging crane-3.
4 29-06-09 MM IEM 13-14% burn injury of Mr. D S Mishra while working on Iron

5 31-12-09 RPD IEM

f o rClad SFU of Havell’s make.
Mr PU Sundi narrowly escaped from Flash injury while

u e attending LC14 conveyor motor Electrical Problem, attended

first Aid at burn centre.
6 02-01-10 D
LD2 IEM Flash injury Mr Shankar Lal while Cleaning the Overload relay
in Aux hoist circuit of Slag Crane-1.
7 23.11.12 LD2 IEM Flash injury Mr D K Dikshit while trouble shooting in Havell’s
SFU to attend the 24V lighting problem at 33M Level. 7%
burn.
8 07.12.12 RMBB2 IEM Flash injury Mr Manoj Srivastava while trouble shooting in
Siemens MCC in Live condition. Burn-7% flash injury
impacted the eye & face.
9 01.06.2013 RMBB2 IEM Flash injury Mr B. Biswas of MSGE while attempting to Rack
out 415V Incomer-2 Breaker of RMLC#1A. 20% burn injury.
Safety goggles saved his eyes.
10 05.11.2013 LD2 IEM Flash injury Mr. A K Prajapati 3% burn injury in hands, while
working in Charging Crane2 his screw driver fell down on the
Live 415V terminations just below the relay on which he was
working.

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 SAFETY STANDARD –Electric Flash Suit Page 17 of 17
SFT/PRO-04, Version-05 18th Apr’19

11 09.07.2015 DBF IEM Burn injury in both hands of Mr. P K Dutta (approx. 7%) while
trouble shooting in star delta starter panel at OCP S/S and
admitted in BCU. MEG/INV/1661/15

12 19.11.16 MSG E LTI case of employee. During WRP half bus shut down, flash
occurred. Burn injury -5% (superficial burn).

13 18.05.18 LD#1 IEM LTI case of own employee, Burn-5%. Trouble shooting in 415V EE
SFU. The Door opened while switching off the Switch as Mechanical
interlock was defunct.

14 29.08.18 A-F BL FCE LTI Case of contractor employee. Burn-2-3% superficial. While
IEM checking the Contractor employee aged 56 years. shorted the cable
of Live side instead of after Fuse by the wire resulted in flash. Blue
Jacket was used. Safety goggle & hand gloves were not used.

o n
v i si
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f o
u e
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