13 Personal Safety - S

Automation and Drives Automation and Drives
Personal Safety page 1 Siemens Industry 2012 - subject to modification

Personal Safety
with
Medium Voltage Drives
Table of Contents
Content Page
Safety Precautions ..................................................................................................................... 3
Electric Shock Hazards ............................................................................................................. 5
Arc Flash Hazards .................................................................................................................... 6
Areas and Boundaries ............................................................................................................... 7
PPE Levels ............................................................................................................................. 9
PPE Personnel Protective Equipment ...................................................................................... 10
Verifying the De-Energized Condition.......................................................................................... 12
Personnel Safety in Switching Operations................................................................................... 14
Components carrying Medium Voltage ( > 1000 V )..................................................................... 15
Components carrying Low Voltage ( < 1000 V )........................................................................... 16
Medium Voltage Circuit Breaker (at Input of VFD)....................................................................... 17
Grounding the VFD and its Environment..................................................................................... 20
External Main Power Verification................................................................................................. 21
One Source of Isolation for the Medium Voltage.......................................................................... 22
Two Sources of Isolation for the Medium Voltage........................................................................ 23
Isolating the Output (e.g. for Motors with long Lead Length)........................................................ 24
Isolating the Output (Motor with Bypass Capability)..................................................................... 25
Isolating the Output (Motor with Parallel Drives).......................................................................... 26
Parallel Drives on Synchronous Motor with Exciter...................................................................... 27
External Main Power Verification.................................................................................................. 28
General Safety Precautions......................................................................................................... 29
Mechanical Key Interlock (Standard)........................................................................................... 30
Mechanical Key Interlock (System Areva)................................................................................. 31
Electromechanical Interlock......................................................................................................... 32
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Safety Precautions ............................................................................................................
Electric Shock Hazards .......................................................................................................
Arc Flash Hazards ............................................................................................................
Areas and Boundaries .........................................................................................................
PPE Levels ..................................................................................................................
PPE Personnel Protective Equipment ...................................................................................... 10
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Table of Contents
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Safety Precautions
Numerous exposed connections present lethal voltages.
Only qualified individuals should install, operate,
troubleshoot and maintain the drive.
Verify that all power is off before you work on the
equipment.
Never touch anything within the drive cabinets
until verifying that it is neither thermally hot nor
electrically alive.
Never assume that by switching off the circuit
breakers all of the voltage is removed from inside
the cabinet.
Voltage is still present on the terminals of the input
circuit breaker.
There may be voltages present that are applied from other external sources.
www.safetysign.com
Safety Precautions
Always follow proper lock-out / tag-out procedures (lock-out / try-out)
before beginning any maintenance or troubleshooting work on the drive.
According to local regulations, an Energized Work Permit may be required.
Work with one hand, turn away, keep a distance.
Wear insulated or rubber safety shoes.
Wear safety glasses and hearing protection.
Use appropriate equipment for checking low voltage, medium voltage
www.safetysign.com
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Always follow proper lock-out / tag-out procedures
before beginning any maintenance or troubleshooting work on the drive.
According to local regulations, an Energized Work Permit may be required.
Work with one hand, turn away, keep a distance.
Wear insulated or rubber safety shoes.
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Safety Precautions
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There may be voltages present that are applied from other external sources
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Electric Shock Hazards
Voltages may drive a current through your body.
Depending on its amplitude, there may be various effects.
Arc Flash Hazards
Thermal
Arc flash temperatures can reach 20.000C (35.000F ); the surface of the
sun is 5000C (9000F); skin cell destruction after 1s at 70C (or 158 F);
incurable burns will occur after 0.1s at 96 C (205 F) for > 1.2 cal/cm
2
.
according to NFPA 70E: ArcFlashBoundaryDistance = (2.6 x MVAbf x t)
1/2
e.g. 4MVA transformer at 5% u
K
( 80MVAbf) and 0.2s: ArcFlashBoundaryDistance = 2 m (for <1.2 cal/cm
2
)
The emitted light is very intense and will damage the retina of the
unprotected eye, often permanently.
Pressure
Pressure wave up to 14.400 Pa (300lb/ft
2
) may cause appr. 227kg
(500lbs) thrust onto exposed body surface.
e.g. a 3 phase 20kA short circuit at 100V arc voltage for 0.2sec is equal to about 0.3kg TNT.
Auditory
Pressure levels can exceed 160dB; a gun blast is only 140dB or 200Pa,
e.g. only 1/10 of that pressure level. Irreversible damage to the ear will
occur at 120dB or more, which is only 1/100 of that level.
Projectile
Molten metal and broken parts will be ejected at high speed resulting in
severe burns and cuts.
Inhalation
Extremely hot air, molten metal and/or vaporized metal, as well as burning
insulation smoke and fumes will damage lungs and respiratory tract.
Large arc flashes are rare (5-10 per day in the US);
when they happen, they are life-changing events.
Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010
Released arc flash energy causes following hazards to health or life:
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Arc flash temperatures can reach 20.000C (35.000F ); the surface of the
sun is 5000C (9000F); skin cell destruction after 1s at 70C (or 158 F);
incurable burns will occur after 0.1s at 96 C (205 F) for > 1.2 cal/cm
according to NFPA 70E: ArcFlashBoundaryDistance = (2.6 x MVA
e.g. 4MVA transformer at 5% u
The emitted light is very intense and will damage the retina of the
unprotected eye, often permanently.
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Arc Flash Hazards
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Areas and Boundaries
Boundaries from NFPA70E
NFPA 70E 2012 Table 130.4(C)(a) shows
approach boundaries for various voltage levels.
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NFPA 70E 2012 Table 130.4(C)(a) shows
approach boundaries
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Boundaries from NFPA70E
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PPE Levels (Personal Protection Equipment)
104.6 (25)
Arc Rated FR Shirt and FR pants or FR
Coverall and Arc Flash Suit
3
167.36 (40)
Coverall and Arc Flash Suit
4
33.47 (8)
Arc rated FR shirt and FR pants or FR
Coverall
2
16.74 (4)
Coverall
1
N/A
Non-melting, flammable materials
(i.e. untreated cotton, wool, rayon, silk or
blends of these materials) with a fabric
weight of at least 4.5 oz/yd
2
0
Required Minimum
Arc Rating of PPE
[J/cm2 (cal/cm2)]
Clothing Description
(Typical number of clothing layers in
parentheses)
Hazard/
Risk
Category
NFPA 70E 2012, table 130.7(C)(16)
PPE Personnel Protective Equipment Protective Clothing
Protective Clothing (Flash Suit Cat. 4, 168J/cm
2
or 40cal/cm
2
*)
pants
jacket
Flash Hood
Safety Glasses
Hearing Protection
Safety Shoes
steel toed, leather upper
Electrical Hazard (EH shoes)
Rubber Gloves
class 2 / up to 17,500 VAC
leather gloves as second layer
to protect the rubber gloves
dont wear rings, watches etc.
Incident energy at 1/10 of a second
causing 2
nd
-degree burn to bare skin
underneath the PPE. Wear layers of
other cotton clothing underneath PPE
to reduce heat onto skin (but note that
this does not increase the arc flash
rating of the PPE).
70% of people who survive a major arc flash event
have to receive long term counseling, almost 60%
of those same people will have failed marriages.
Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010
*
DANGER
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PPE Personnel Protective Equipment
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PPE Personnel Protective Equipment Voltage Detector
The Voltage detector is used to verify that no voltage
is present on cables, terminals etc. (operating either
on contact or capacitive).
Voltage levels to check may be
Low Voltage
Medium Voltage.
Preferably use a type with
narrow tip to check the
voltage on individual cable.
Checking for medium voltage with a capacitive device,
use the LV-setting on the probe first to identify voltage
even from some distance.
conductor (Al, Cu)
conductive layer (XLPE)
insulation (XLPE)
conductive layer
(XLPE)
sheath
(Al, Cu)
XLPE:
cross linked
low density
polyethylene
protection
typical medium
voltage cable:
devices shown operate capacitive
Verifying the De-Energized Condition Voltage Detector
test probe shown:
KP Test 5
1kV to 36kV, from 10% to 110% of rated voltage at 50Hz
acc. to EN50110-1, IEC61243-1:2003 and IEC61243-1:2005
Manufacturer:
Pfisterer Kontaktsysteme GmbH & Co KG
Rosenstrae 44
73650 Winterbach/Germany
www.pfisterer.de
on contact
devices shown operate on contact
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on contact on co
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Verifying the De-Energized Condition
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The Voltage detector is used to verify that no voltage
is present on cables, terminals etc. (operating either
Voltage levels to check may be
Checking for medium voltage with a capacitive device,
use the LV-setting on the probe first to identify voltage
Verifying the De-Energized Condition Voltage Measurement
Depending on local regulations the de-energized
condition might be allowed to be tested by
capacitive voltage detection devices (Tic Tracer)
or the use of a
device working on contact
might be mandatory.
YOU can do better:
stand on the side of the door (not in front)
use one hand only to hold the probe
Basic rules for handling Voltage Detectors
- the Voltage Detector has to be selected for or set to the rated voltage to be checked
- the function of the Voltage Detector has to be checked on voltage before verifying the de-energized state
- the de-energized condition has to be checked on all three phases
- if possible, again check the function of the Voltage Detector on voltage
test probe shown:
DSP3 HS5 or DSP3 HS11
Manufacturer: Rudolf Tietzsch
Willringhauser Strae 18
85256 Ennepetal/Germany
www.tietzsch.de
Personnel Safety in Switching Operations
Any time you switch on the VFD or a Circuit Breaker a potential risk of malfunction is given.
For maximum safety, stand on the side and turn your head away.
(This precaution is strongly recommended when switching the device for the first time or after major repair work.)
Disconnect
(typically
no load isolator)
Circuit Breaker
(switches under load)
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Personnel Safety in Switching Operations
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- the Voltage Detector has to be selected for or set to the rated voltage to be checked
- the function of the Voltage Detector has to be checked on voltage before verifying the de-energized state
- the de-energized condition has to be checked on all three phases
Components carrying Medium Voltage ( > 1000 V )
Medium Voltage may be present at e.g.: input-, output terminals, cell connections, bus bars, transformer connections.
Medium Voltage / voltage from the input line: 2.2 kVAC 33.000 kVAC
Components carrying Low Voltage ( < 1000 V )
Hazardous Low Voltage (> 50 V) may be present at e.g.: contactors, miniature circuit breakers, power supplies,
terminals, transformers, control boards. Keep in mind to follow appropriate safety rules in Low Voltage circuits as well.
Low Voltage
control power: 120, 240, 480, 575 VAC (230, 400 VAC)
customer input control: 120, 230 VAC / 24 VAC, VDC / 0-10 VDC / 4-20 mA
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Components carrying Low Voltage ( < 1000 V )
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Medium Voltage Circuit Breaker (at Input of VFD)
Schematic of a Circuit Breaker
(racked out test position)
PH M
Example of a Circuit Breaker
(racked in operating position)
MV circuit breaker HV circuit breaker
other
load
Hands OFF,
Customer only !
Medium Voltage Circuit Breaker
Stationary section
(1) connection to common MV bus bar
(2) connection to feeder (e.g.: VFD)
Movable section (rear view)
(1) to common MV bus bar
(2) to feeder (e.g.: VFD)
1
2
1
2
Movable section (front view)
(3) optional fuses
(4) vacuum contactors
3
4
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racked in
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Example of a Circuit Breaker
operating position)
Access to rack the Circuit Breaker in or out without opening the
front door of the Circuit Breaker compartment (with metering and
protection devices)
Movable section of Circuit Breaker (shown in operating position;
test position is given with the Circuit Breaker racked out to front)
Grounding the VFD and its Environment
Transformer
(HV MV)
Earth Ground
Control Room
Power Input,
Circuit Breaker
V F D
M
Earth Ground
PH M
MV circuit breaker HV circuit breaker
other
load
Hands OFF,
Customer only !
Correct grounding of the VFD has to be verified.
The grounding is required for reasons of safety and to ensure correct operation of filtering and protection devices.
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V circuit breaker
Hands OFF,
Customer only !
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Grounding the VFD and its Environment
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External Main Power Verification
- Switch off the power supply on all poles
- Verify the de-energized condition
- Ensure against unauthorized re-energizing (lock-out, tag-out)
- Ground and short circuit the power terminals on all poles
- Cover or fence off adjacent live components
Any work at the Medium Voltage sections of the VFD must be started only
after verification of the de-energized state of the external main power.
This rule applies both for the input power and for the motor connection.
The steps required and the sequence to follow depend on site conditions and
on the configuration of the VFD.
A choice of typical arrangements will be explained in the following in detail.
In general, the Five Safety Rules apply any time and have to be observed.
One Source of Isolation for the Medium Voltage
Step 1 - the Vacuum Contactor must be
in the de-energized state;
this is the dropped out position.
Step 2 - the Vacuum Contactor should then
be racked out (with door closed)
and locked in that position.
Step 3 - verify that no power is present
at the VFD
Step 4 - install grounding cables.
Step 1
Step 2
Step 4
Vacuum
Contactor
V F D
Step 3
location (room)
other than VFD
GND
GND
using an appropriate voltage tester, which
has been tested for functionality itself.
Step 2
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Vacuum
Contactor
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One Source of Isolation for the Medium Voltage
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- Ground and short circuit the power terminals on all poles
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Two Sources of Isolation for the Medium Voltage
Step 3
Vacuum
Contactor
Disconnect
location (room)
other than VFD
V F D
Step 1 - open Vacuum Contactor
Step 2 - rack out the Vacuum Contactor and
install lock on Vacuum Contactor
Step 3 - open Disconnect
+ through the viewing glass, verify
that contacts are open
+ open the door and verify
that no power is on the output
+ install lock on Disconnect
at the VFD
Step 5 - for additional safety,
install grounding cables
viewing glass
Step 1
Step 2
Step 4
Vacuum Contactor: - manual operation or
- remote control
Disconnect: - manual operation only
Isolating the Output (e.g. for Motors with long Lead Length)
Step 1a.1- the Vacuum Contactor has to be
in the de-energized state;
Step 1a.2- rack out the Vacuum Contactor
and lock it in that position.
Step 1b - open Disconnect, verify that contacts
are open and lock it in that position
(most have grounding connections)
at the VFD motor terminals
Step 3 - install grounding cables at VFD
terminals T1, T2, T3 to ground.
Step 1a.1
Step 2
Step 1a.2
Vacuum
Contactor
V F D
Disconnect
viewing glass
Step 1b
Motor
V F D
Motor
Step 3
either or
Vacuum Contactor: - manual operation or
- remote control
Disconnect: - manual operation only
Step 3
As general rule the input has to be isolated and
grounded as per information on pages 18 or 19!
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Step 3
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Isolating the Output (e.g. for Motors with long Lead Length)
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page 23
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erify that no power is present
- for additional safety,
nstall grounding cables
Isolating the Output (Motor with Bypass Capability)
Step 1 - the Vacuum Contactor of the VFD
must be in the de-energized state;
Step 2 - rack out the Vacuum Contactor of
the VFD and lock it in that position.
at the VFD.
Step 4 - install grounding cables at VFD
Step 1
Step 3
Step 2
V F D
Vacuum
Contactor
V F D
Bypass
Vacuum
Contactor
Motor
Step 4
Isolating the Output (Motor with Parallel Drives)
Step 1 - the Vacuum Contactors of both VFDs
must be in the de-energized state;
Step 2 - rack out both Vacuum Contactors
and lock them in that position.
at the output of either of the VFDs.
Step 4 - install grounding cables at both VFDs
on terminals T1, T2, T3 to ground.
Step 1
Step 3
Step 2
Step 4
V F D 1
Vacuum
Contactor
V F D 1
V F D 2
Vacuum
Contactor
V F D 2
Motor
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V F D 1
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Isolating the Output (Motor with Parallel Drives)
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page 25
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nstall grounding cables at VFD
Parallel Drives on Synchronous Motor with Exciter
V F D 1
Vacuum
Contactor
V F D 1
Motor
V F D 2
Vacuum
Contactor
V F D 2
Power Crid 33.000 kV
Exciter 2
A
C

o
r

D
C
Exciter 2
Contactor
Exciter 1
Exciter 1
Contactor
A
C

o
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D
C
Fied Suppy
In this application the common field
supply is provided by connecting the
exciters in parallel with each other.
If even only one exciter contactor is
closed, power is present on the
output of each contactor.
To isolate both the stator terminals
(fed via VFDs) and the rotor
terminals (fed via exciters) of the
motor, proceed as follows:
step 1 to 4
isolate both VFDs as shown on the
previous slide
step 5 to 8
isolate both exciter cabinets
(switch off, lock out/tag out, verify
power is off, ground)
Step
1 4
Step
1 4
Step
5 8
Step
5 8
Medium Voltage
Power has been removed on the input and isolated state has been verified
Wait 10 minutes for the system to discharge capacitors
If a cell is to be handled
verify that no input voltage is present on the cells
(various cell AC input voltages: 480, 630, 690, 750,1375, 600; measure phase-to-phase only)
verify that no voltage is present on the bus capacitors
(DC voltages as high as AC voltage x 1.413 can exist: 678, 890, 974, 1060, 1943, 930)
Control Voltage (two sources)
Verify that the voltmeter operates before shutting the control power off
Shut the control power (disconnect) off
Verify that power has been removed on all three phases on bottom side of disconnect
Shut the power off upstream of the drive
Verify that power has been removed on all three phases on top side of disconnect
Lock out and tag out both sources (in the drive / upstream of the drive)
Customer Input Control
Before removing or replacing boards
shut off the customer control input power to the boards
verify that power has been removed and is secure
Be cautious not to short input wires to the control boards
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Power has been removed on the input and isolated sta
Wait 10 minutes for the system to discharge capacito
If a cell is to be handled
verify that no input voltage is present on the cells
(various cell AC input voltages: 480, 630, 690, 750,1375, 600; measure phase-to-phase only)
verify that no voltage is present on the bus capacit
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page 27
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isolate both VFDs as shown on the
isolate both exciter cabinets
switch off, lock out/tag out, verify
power is off, ground)
General Safety Precautions
Always turn the control power on before the medium voltage is applied!
Always turn the medium voltage off before shutting off the control power!
Never shut off the blower power and leave the main power on. This may cause the drive to
overheat and cause severe damage to the system.
Never run the drive with cabinet doors open. This reduces cooling to the drive.
Never connect or disconnect any meters, wiring or printed circuit boards while the drive
is energized.
Never store flammable material in, on or near the drive enclosure. This includes equipment
drawings and manuals.
Always be aware of electrostatic discharge (ESD) when working near or touching
components inside Drives.
(printed circuit boards contain components that are sensitive to static electricity.)
Mechanical Key Interlock (Standard)
K2
K2
K2
K2
K1
K2
DOOR INPUT SECTION 2
K2
DOOR INPUT SECTION 3D
K2
DOOR BYPASS SECTION 4B
K2
DOOR BYPASS SECTION 4D
KT 2
K1
L
INPUT CIRCUIT BREAKER
INPUT MV POWER
KT 2 assembly block
K2 K1 K2 K2
Step 1 - de-energize the Medium Voltage
Step 2 - remove K1
Step 3 - insert K1 into KT2 assembly block
Step 4 - remove K2 keys and open cabinets
to be worked on
Step 5 - verify in each cabinet that no voltage
is present (AC or DC voltages)
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Mechanical Key Interlock (Standard)
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page 29
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(printed circuit boards contain components that are sensitive to static electricity.)
Mechanical Key Interlock (System Areva)
(1)
33 kV
switchgear
Step 1 - disengage the 33 kV switchgear
Step 2 - take out the key (1) and insert it into the Areva key retention
Step 3 - disengage the vacuum contactor
Step 4 - take out the key (2) and insert it into the grounding assembly
Step 5 - engage the grounding system
Step 6 - take out the key (3) and insert it into the Areva key retention
Step 7 - take out key K1 and insert it into the VFD KT2 assembly block
Step 8 - remove K2 keys and open VFD cabinets to be worked on
(2)
(3)
K1
K1
V F D
Pre-charge
K2
K2
K2
K2
Circuit Breaker
Step 2
Step 6
Step 4
Step 1
Step 3
Step 5
Step 7
Electromechanical Interlock
1
1
Perfect Harmony Drives manufactured in Nuernberg / Germany
feature an electromechanical interlocking as a standard.
To open any cabinet door of a Medium Voltage section, the
assigned solenoid (2) has to release the door mechanism by
being energized. The solenoid is energized with control voltage
available and the feedback signal Circuit Breaker Open.
If a door should be opened by force, the assigned cabinet door
switch (3) trips the Circuit Breaker.
2 3
4
2
3
(1) Dummy-Screw to access the
Bolt of the Solenoid
(2) Interlocking Solenoid
(3) Cabinet Door Switch
(4) Control Section Door Switch
Door interlocking MUST NEVER be bypassed
with Medium Voltage switched on (C. B. = ON).
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Electromechanical Interlock
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page 31
remove K2 keys and open VFD cabinets to be worked on
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ake out the key (2) and insert it into the grounding assembly
ake out the key (3) and insert it into the Areva key retention
ake out key K1 and insert it into the VFD KT2 assembly block
remove K2 keys and open VFD cabinets to be worked on

13 Personal Safety - S

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13 Personal Safety - S

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Automation and Drives Automation and Drives

Personal Safety page 1 Siemens Industry 2012 - subject to modification

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