Improving Safety Through Arc Flash Technologies

Educational Session A:
Improving Safety
Through Arc Flash
Technology
John A. Kay, CET
Senior Product Specialist,
Medium Voltage Technologies
Copyright 2011 Rockwell Automation, Inc. All rights reserved. V11.7.1

1
Agenda
1. Arc Dynamics
2. What is arc resistance equipment all about?
3. Global arc resistant testing guides and standards
4. How these guides and standards affect what you specify
5. What are the key aspects to arc resistant product specs
6. How are arc resistant equipment designs tested
7. The role arc resistant products play in your safety program
8. Compliance to current NFPA-70E requirements
9. Whats on the horizon?
Copyright 2011 Rockwell Automation, Inc. All rights reserved.
NFPA 70E Defines an Arc Flash Hazard as.

..a dangerous condition associated with the
release of energy caused by an electric arc.
Flash Facts
Surface of the sun- 9,032F

Arc Flash core- 35,000F
Source- NASA, NOISH
Faults Exhibited in Electrical Circuits

Bolted Fault current flowing through bolted bus bars or other
electrical conductors.
A bolted fault test is standard for all MCCs, Switchgear and most
electrical designs
It is an electro-mechanical test, i.e. bus/cable bracing
Arcing Fault current flowing through air
Always lower current than bolted fault current
Voltage drop across the arc due to resistance within the arc
plasma
Specify bolted fault & arcing fault currents levels separately!
THEY ARE NOT THE SAME! IBF is always more than IAF
Arc Flash/Blast Dynamics
35,000 F
Shrapnel
Intense Light
Molten
Metals
Sound &
Pressure
Waves
Copper Vapors
Intense Heat
Expelled
(Expansion rate
67,000 times)
Characteristics of an Arc Flash

A conductive plasma, which has a much lower impedance and much
higher conductivity than air
Melts and vaporizes components - flooding the air with more
conductive particles
A large pressure wave is created by the expansion of the super heated
air and the vaporized materials
The flash occurs virtually instantaneously, releasing a huge amount of
energy in a very short period of time
The available short circuit current has a major influences on the
energy released in the arc* *-other factors also must be considered!
Dynamics Stages of Arc in an Enclosure

1
4
1 Compression
Pressure
2 Expansion
Current
3 Emission
4 Thermal
Arc Voltage
Typical Arc Pressure & Temperature Profile

Opening time of a 5 cycle
breaker (83 ms) NOT
including relaying latency
T&P
Total clearing time

with coordinated
overcurrent
protection
(up to 225 ms ) typical
Temperature [C]
>12,700 C
(>23,000 F)
2105 Pa
(~29 PSI)
Steel fire
(~1550C)
Pressure [Pa]
It, kA s
calories
Copper fire
(~1100C)
Cable fire
(~600C)
10
20
30
100
200 ms
t
Extensive damage to
equipment and critical
injury to personnel
>250 ms
How Long Can Arcing Occur?

The arc will continue as long as,
The voltage available is high
enough to sustain it
Current continues to flowing in
the arc plasma
There is fuel to feed the arc
materials that can provide the
ions necessary to sustain
current flow within an air
mixture
10
Arc Resistant Equipment

Arc Resistant is a term used to describe how a piece of equipment
resists the effects of an internal arc fault (relates to arc flash exposure)
The level of arc flash protection is defined by the level to which an arc
flash/blast is:
Extinguished or Controlled
Channeled away from personnel
Prevented from propagating
Testing must be performed to validate a level of resistance (protection)

Defined as the Arc Resistant Accessibility Rating
The equipment manufacturer is responsible to test to a given standard

or guide to validate a given accessibility rating.
The Accessibility Rating defines one of the performance
characteristics for arc resistant equipment.
11
Common Arc Testing Guides & Standards

EEMAC G14-1-1987 Procedure for Testing the Resistance of Metal-Clad
Switchgear under Conditions of Arcing Due to an Internal Fault
IEC 62271-200 AC Metal-Enclosed Switchgear and Controlgear for Rated
Voltages Above 1 kV and up to and Including 52 kV, Annex A - Internal Fault
IEC 61641-2008 Enclosed low-voltage switchgear and controlgear assemblies
Guide for testing under conditions of arcing due to internal fault
IEEE C37.20.7-2007 "IEEE Guide for Testing Metal-Enclosed Switchgear
Rated Up to 38 kV for Internal Arcing Faults
CSA C22.2 NO. 0.22-11 Evaluation Methods for Arc Resistance Ratings of
Enclosed Electrical Equipment
Many global guides and standards for AR equipment ..

Compliance to one does not mean compliance to the others!
12
Global Accessibility Types
IEC
Type A-Accessible to authorized Personnel

Type B-Accessible to general public
Type C-Pole top equipment
EEMAC
Type A-Front only

Type B-Front, back, sides
Type C-Front, back, sides, & compartmental
IEEE,
CSA
Type 1-Front only

Type 2-Front, back, sides
Suffix A-Used if no other suffix applies
Suffix B-Control compartment* (new in 2007)
Suffix C -Adjacent Compartments protection

13
IEEE Accessibility Type 1
Illustrative graphic only. Additional PPE may be required.

14
IEEE Accessibility Type 2
Illustrative graphic only. Additional PPE may be required

15
IEEE Accessibility Type 2B
LV Control
Compartment
Illustrative graphic only. Additional PPE may be required.

16
Other Arc Resistant Specifications

Arc Fault Current Level
The tested level of arcing current
Varies by equipment type, system voltage, manufacturer and global region
Typical values are 10kA, 25kA, 31.5kA, 40kA, 50kA, 60kA
Testing guides permit any level
Arc Duration
The time the arc was sustained for the test
Nominal is 0.10, 0.25, 0.5, 1 or 3 second ratings
Typically 0.5 seconds is used (suggested max. by IEEE)
Varies by vendor
Testing guides permit any time period
Testing guides permit any levels

17
Other Arc Resistant Specifications, cont

Mechanical Considerations
Top & Bottom exit/entry- dont assume both are available
Not all arc resistant controller suppliers can provide top exit!
Footprint could be bigger than non-arc resistant designs
Important for room layouts
Youll need more ceiling height
Gas plenums or chimneys?
Where are they located?
There are more things to take into account when installing

arc resistant equipment!
18
Plenum & Chimney Installation

Considerations
Where should the energy from an arc flash
be directed?
Within the building assumes an area can be made
inaccessible to personnel and no flammable
materials are present
Externally is generally preferred, implying that a
barrier be used to restrict the entry of weather
or vermin
If the arc gases are going to be released into a small control room
or building that houses the arc resistant equipment, it must be
designed to withstand:
Overpressure, up to 15-20 psi, on a transient basis
The effects of hot gases and flames as they are released into the room (i.e.
non-flammable construction materials are required)
Special ventilation may be required
19
Other Aspects to Consider

NEMA based Testing Guides dont fully cover LV MCCs!
IEEE C37.20.7-2007 now includes consideration for metal-enclosed Low Voltage
power circuit breaker switchgear
Standard is under review and revision currently
Difficult to find a consensus due to various manufacturers designs
Rockwell Automation has always used IEEE C37.20.7 as a guide for

testing both their LV & MV MCC
IEC products are tested to the appropriate IEC guide
Bulletin 2500 IEC LV MCC tested to IEC 61641-2008
Bulletin 7700 IEC MV MCC tested to IEC 62271-200
Flash Facts
OSHA Lockout/Tagout standard, which outlines the

MINIMUM requirements to control hazardous energy,
was the 5th most frequent cited violation from fiscal
year 2005 to 2009
Source- OHSA
20
How Are The Tests Completed?
LV MCC Prototype tests!

21
Test Setups Vary by Global Testing Guides

Generally
Flammable cotton indicators are placed vertically around the test unit as
follows:
Vertical indicators are placed 100 mm from the enclosure walls
From the floor to a height of 2 m (79)
Facing areas thought to be likely to emit gases
Indicators cover the area being evaluated, seams etc.

Horizontal indicators are placed at a height of 2 m (79) above the
mounting surface and parallel to the floor
Indicators extend beyond the switchgear by at least 300mm, 1000 mm typical
Each testing guide has slight changes to the electrical configurations
22
Typical Test Setup
23
Horizontal Indicators
24
MV Unit Under Test
25
A Successful MV Arc Test
26
Passing an Arc Test Generally Means:

Doors and covers do not open (bowing
allowed)
No parts are ejected from the equipment
The arc does not burn any holes in the
exterior of the tested structure (in the
applicable planes for the accessibility level)
150 mm2 (6 in2 ) 150 g/m2 Cotton test
indicators at a distance of 100 mm (4 in) must
not ignited or be perforated, (approximates
typical industrial
work clothes)
The grounding connections remain effective
Performance criteria varies by testing guide
27
Arc Resistant Equipment Considerations

Arc resistant equipment should been tested to a
relevant testing guide or standard
Certification Letter or Letter of Attestation should
be available to corroborate the claimed results
Not included in the existing Nationally recognized
testing standards for LV and MV motor controls
UL 845 Standard for Motor Control Centers does
not address arc fault performance
Specific performance criteria is mandated under bolted
fault, short circuit conditions for electric shock and fire
hazards
UL 347, for MV MCCs, also does not include content
related to arcing faults
28
Keeping it Arc-Resistant When I Use it

This requires that,
The equipment is properly installed in accordance with only the
manufacturers instructions
All* doors and covers be properly secured (*- for type 1B or 2B the LV controls
compartment door can be open)

If any door or cover is open to a medium voltage compartment, the equipment is not
in its arc-resistant condition and the level of protection to personnel will be
compromised!
Any exhaust vents must be free of obstructions

Extra care in cable installation
29
Where are These Standards Taking Us?
Enhanced Safety
CSA Z-462-2012
NFPA-70E-2012
NFPA-70E-2009
CSA Z-462-2008
NFPA-70E-2003
IEEE 1584-2001
NFPA-70E-2000
Arc resistant Switchgear-1990s
30
So Now What?
NFPA-70E is your guide
To understand your risk areas, you need to perform and maintain an arc
flash hazard study within your facility,
If you dont, you must adhere to the data and guidelines provided within NFPA-70E
regarding PPE, boundaries, etc.
Label electrical equipment, based on the study, to indicate,

The level of the arc flash hazard (incident energy)
The PPE requirements
The boundaries defined by NFPA-70E
Obtain and maintain the appropriate Personal Protective Equipment

(PPE)
Rockwell Automation can perform complete arc flash hazard
studies and provide risk mitigation solutions
31
So Now What?
You need to determine the extent of the risk- you may not require AR
equipment!
Your arc flash study will give you the facts!!!
It is the electrical system designer, constructor, and user/owner who are

responsible to define, manage and mitigate risks to a tolerable level
Develop, implement and train proper work place safety policies,
procedures and methods
Train the workers (both internal and contract)
You must actively update and audit the safety program in your facility
Rockwell Automation can assist you with these tasks!

32
So What is OHSAs Position on All of This

Industry consensus standards can be evidence that there is a hazard
for which that PPE is "necessary." While the NFPA 70E consensus
standard has not been adopted as an OSHA standard, it is relevant as
evidence that arc flash is a recognized hazard and that PPE is necessary
to protect against that hazard.
An flash hazard analysis shall be done in order to protect personnel
from the possibility of being injured by an arc flash. The analysis shall
determine the Flash Protection Boundary and the personal protective
equipment that people within the Flash Protection Boundary shall use
Failure to protect workers will result in OHSA prosecuting to

the fullest extent of the law, based on these premises
33
So What is OHSAs Position on All of This

Complacency is a major danger to anyone working around electrical
energy
Appropriate PPE should ALWAYS be used
Not only should OHSA and like standards be followed, but all
employers must adhere to the consensus standards- like NFPA-70E
Flash Facts
Electrical hazards are one of the top causes of

workplace deaths and violations of electrical
standards routinely top OSHAs list of cited
violations.
Source- OHSA
34
How can AR Equipment Help?

Can be a part of the overall protection strategy
MV arc resistant equipment can reduces the hazard/risk category to
Level 0
The lowest level defined by NFPA-70E!
For LV MCCs see Article 130.7/(C)(15)(a)- no reduction at this point
May simplify your safety program

Select an accessibility type that best suits you requirements e.g. Type
2B
Always refer to NFPA-70E for details!
Arc resistant equipment reduces the hazard/risk category

to Level 0- the lowest level defined by NFPA-70E
35
How Can Rockwell Automation Help?

7.2kV NEMA & IEC MCCs
15kV IEC MCCs
LV NEMA MCC
LV IEC MCC
ArcShield & ONEGear Arc resistant LV and MV MCCs

36
What Else is on the Horizon
Light/current based arc detection systems- available now!

Personal arc detection sensors- available now!
Arc clamping devices- available now!
Pre-emptive arc detection technologies
In develop stages
Predicts immanent failures
Still doesnt address the human factor.but..
Human-Machine Interaction Bioengineering

Safety in Design
Understanding, more thoroughly, the interaction of humans
Future Technologies For the Future

37
Other Ways We Can Help

On Site Training including Arc Flash Training
On site data collection, Arc Flash Analysis, Protective Device
Coordination Studies, Short Circuit Analysis and Arc Flash Labeling
Category Mitigation Services (Design and Engineering)
Written Program Services
Electrical Work Permit Services
Ongoing support for the updating of site electrical diagrams and the
labeling of new panels
Reporting using industry recognized software tools
Rockwell Automation is your partner in machine safety!

38
Key Points and Take Aways!!!!
You must have a up to date and maintained safety program

You should have a maintained arc flash study of your facilities
You must have your equipment properly labeled
You must have the necessary PPE available based on your study
Arc resistant equipment can be a critical part of your overall safety
program
Arc resistant equipment can vary dramatically between vendors
Certification guides and standards continue to evolve
Guides and standards are behind the technological improvements
Rockwell Automation is your partner in creating a comprehensive

safety program compliant to NFPA-70E!
39
Questions

40

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Educational Session A:

Copyright 2011 Rockwell Automation, Inc. All rights reserved. V11.7.1

NFPA 70E Defines an Arc Flash Hazard as.

Surface of the sun- 9,032F

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Faults Exhibited in Electrical Circuits

Arc Flash/Blast Dynamics

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Characteristics of an Arc Flash

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Dynamics Stages of Arc in an Enclosure

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Typical Arc Pressure & Temperature Profile

Total clearing time

How Long Can Arcing Occur?

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Arc Resistant Equipment

Testing must be performed to validate a level of resistance (protection)

The equipment manufacturer is responsible to test to a given standard

Common Arc Testing Guides & Standards

Many global guides and standards for AR equipment ..

Global Accessibility Types

Type A-Accessible to authorized Personnel

Type A-Front only

Type 1-Front only

Suffix C -Adjacent Compartments protection

IEEE Accessibility Type 1

Illustrative graphic only. Additional PPE may be required.

IEEE Accessibility Type 2

Illustrative graphic only. Additional PPE may be required

IEEE Accessibility Type 2B

Illustrative graphic only. Additional PPE may be required.

Other Arc Resistant Specifications

Testing guides permit any levels

Other Arc Resistant Specifications, cont

There are more things to take into account when installing

Plenum & Chimney Installation

Other Aspects to Consider

Rockwell Automation has always used IEEE C37.20.7 as a guide for

OSHA Lockout/Tagout standard, which outlines the

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

How Are The Tests Completed?

LV MCC Prototype tests!

Test Setups Vary by Global Testing Guides

Indicators cover the area being evaluated, seams etc.

Each testing guide has slight changes to the electrical configurations

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Typical Test Setup

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

MV Unit Under Test

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

A Successful MV Arc Test

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Passing an Arc Test Generally Means:

Arc Resistant Equipment Considerations

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Keeping it Arc-Resistant When I Use it

compartment door can be open)

Any exhaust vents must be free of obstructions

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Where are These Standards Taking Us?

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Label electrical equipment, based on the study, to indicate,