Arc Flash Analysis PDF

Arc Flash Analysis –
More Than Just

Labeling
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Arc Flash Analysis
In this session you will learn how an Arc Flash Analysis can help you
identify issues that may lead to an arc flash or blast. Arc Flash Analysis
i the
is th pathth to
t risk
i k reduction
d ti forf your electrical
l t i l technicians.
t h i i To
T help
h l reduce
d
the risk of an arc flash or blast, an Arc Flash Analysis includes:
– Electrical power systems analysis

– Recommended arc flash study training
– Sh t circuit
Short i it currentt analysis
l i
– Over current protective device coordination analysis
– Hazard analysis
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

ARC FLASH
• Electricity has become essential to modern life. Perhaps because it is

such a familiar part of our surroundings, it often is not treated with the
respectt it deserves.
d
Safety and health programs must address electrical incidents and the
variety of ways electricity becomes a hazard. In general, OSHA requires
[29 CFR 1926.416(a)(1)] that employees not work near any part of an
electrical power circuit unless protected.
protected
• Did you know? Approximately 350 electrical-related fatalities occur each
year.

Definition – Electrical Hazard
A dangerous condition such that contact or equipment failure can result

in electric shock, arc flash, or arc blast.

Arc Flash
• Causes of arc flash:

– Arc flash is caused by phase-to-phase or phase-to-ground faults, or contact
with
ith lilivee cond
conductors
ctors or equipment
eq ipment fail
failure.
re
• What is an “arc flash”
– when the energygy creates an arcingg fault, the arc creates a plasma,
p which has a
much lower impedance, or much higher conductivity than air.
– Also, the energy produced melts components, flooding the air with conductive
p
particles.
– Copper expands to 67,000 times its original volume when vaporized.
– The flash occurs instantaneously, releasing a huge amount of energy in a very
short period of time.

Arc Flash Hazards
• Arc Flash Hazards Include:

• Burns (Temps can reach 35,000 degrees)
• Thermal hazards
ha ards due
d e to plasma – molten metal expanding
e panding
• Acoustical Hazard – in excess of 160db (Air Raid Siren, Jet Engine, Fire Arm = 140db)
• Shock / Pressure (Blast) - 1000’s of lbs per sq. ft.
• Flying components due to broken panel components
– Material and molten metal is blasted away at speeds over 700 mph.
• Arc blasts release dangerous levels of heat energy, fire , molten materials, vaporized
solids that can be inhaled, flying shrapnel and the rapid expansion of air, all capable of
causing severe and sometimes fatal injuries.
• Arc
Arc-flashes
flashes can and do kill at distances of 10 ft.

Arc Flash - Burns
• Thermal impacts of arc flash temperatures

145 Degrees F Curable Burn
205 Degrees F Cell Damage
700 Degrees F Clothing Ignition
1,400 Degrees
g F Burning
g Clothing
g
9,000 Degrees F Surface of the Sun
35,000 Degree F Arc Terminal Temperatures
3rd Degree burns form when skin is exposed to 200º F

t
temperature
t forf less
l th 1/8th off a second.
than d

Terminology - Current Limiting
Understanding circuit breaker performance and fuse performance in light of

current.
A flflashh occurs att a lower
• Arc l currentt llevell due
d tto th
the iimpedance
d off th
the air.
i
• Circuit breakers and fuses are traditionally designed to disconnect very rapidly when
the current reaches a specific bolted fault value, while allowing a time delay when
current magnitude is at a lower value.
• Due to this design, greater incident energy is allowed to pass through the current
limiting device, when the current is at a lower value.
• New types of devices are being designed to reduce the incident energy.

Arc Flash Services – Why are they needed?
• Your facility may need an arc flash analysis to properly identify the risk
category.
– Why is this important?
“ OSHA requires that the proper PPE (Personal Protective Equipment) be worn
based on the risks that an employee is exposed to
to.”
If an employee is working on a panel where electrical energy is present, the

proper PPE is required
If an Arc Flash Hazard Analysis has not been completed, based on the OSHA
q
requirement, , the customer would have to wear PPE to p
protect against
g the
highest risk rating category in the panel.
Even wearing
g the most p
protective PPE for Arc Flash hazard reduction mayy not
be enough based on the cal/cm2

Arc Flash
• Arc Flash Hazard analysis

– determine system voltages and equipment class
– determines the amount of current that can flow
• Bolted fault current
• arc fault current
– determines the time required for the nearest circuit protective device to operate to
clear a fault.
• find protective device characteristics and arc duration
– select working distances
– calculate incident energy
– calculate the flash protection boundary

Typical Arc Flash Program Process
1. General Training on Arc Flash Hazards

2. Push for Compliance – Corporate, Federal, Local Jurisdiction
3
3. Knowledge Building – determine scope of engagement desired
4. Arc Flash RFQ (Request for Quote)
5. Arc Flash Data Collection
6
6. Report Generation / Review Process
7. Label Generation / Installation –
1. Cabinet Specific Labels to the first Category device in the distribution chain (Transformers,
g , MCC’s,, Busses and floor level cabinets))
Switchgear,
2. Installation of Generic Category 0 Labels
8. More involved Arc Flash Training of employees
9. Mitigation
g decisions
10. On-going maintenance of the program, one line drawings and labels
11. Retraining as necessary
12. After 5 Years,, review the pprogram,
g , audit and update
p reports,
p , one lines and labels

Codes & Standards Associated with Arc Flash
• NFPA 70 – National Electrical Code (NEC)- 2008 Edition

• NFPA 70E – Standard for Electrical Safety in the Workplace - 2012
Edition
• OSHA 1910 Subpart S – Occupational Safety & Health Act, Electrical
Requirements
– 1910.301 – 308: Installation requirements
– 1910.331: Safety-Related Work Practices
– 1910.332: Training requirements
– 1910.333: Selection and use of work practices
– 1910.334: Use of equipment
– 1910-335: Safeguards
g for personnel
p protection
p
– 1910.399: Definitions
• OSHA will cite companies under the “General Duty Clause” for safety
concerns not connected to a violation of a specific OSHA standard:

OSHA -> to NFPA 70E
• OSHA bases its electrical safety mandates, found in Subpart S part 1910
and Subpart K part 1926, on the comprehensive information found in
NFPA 70E
70E.
• NFPA 70E is recognized as the tool that illustrates how an employer

might comply with these OSHA standards.
• The relationship between the OSHA regulations and NFPA 70E can be
described as OSHA is the “shall”
andd NFPA 70E th
the “how.”
“h ”

NFPA 70E-Std. for Electrical Safety
in the Workplace
• Initiated originally to give OSHA a document to enforce for

electrical safetyy
• OSHA will eventually adopt current version

– Today it may enforce NFPA 70E as an accepted practice.
• NFPA 70E- “Flash

Flash Hazard Analysis shall be done before
approaching equipment that has not been placed in a
electrically safe work condition”

Standards
• What is NFPA-70E?
– Discusses Hazards and rating method
– Discuss
scuss Standard
Sta da d requirement
equ e e t for
o risk
s reduction
educt o
• NFPA-70E 2012
– Labeling
– Safety Program
– Approach Boundaries
– Arc Flash Boundaries
– PPE Requirements

OSHA 29 CFR 1910
1910-333 Requires de-energizing unless doing so would

be infeasible or the hazard would be increased
1910-335 Requires the use of “appropriate” personal

protective equipment (PPE)
Implies that 70E can be enforced as a “safety practice”
Enforced by State & Federal OSHA Inspectors
22 States have their own State OSHA Rules & Inspectors
States may enact more stringent rules, but must enforce Federal
rules
l as a minimum
i i

NFPA 70E-2012
– Provides definitions and formulas to calculate Arc Flash and Shock

Hazard boundaries.
boundaries
– Provides default tables for Arc Flash levels and PPE required for
specific tasks.
– Mandates REQUIREMENTS for:

• Electrical Safety Program
• Live
Li workk permitsit
• Safe Work Practices (including PPE)
• Training Requirements

OSHA – General Duty Clause
• “Each employer shall furnish to each of his employees employment and

a place of employment which are free from recognized hazards that are
causing
i or are likely
lik l to
t cause death
d th or serious
i physical
h i l harm
h to
t his
hi
employees.”

HRC Tables – give guidance on what
PPE is required

HRC Tables –

HRC Tables –

Labeling Requirements
Switchboards, panelboards, industrial control panels, and motor control

centers that are in other than dwelling occupancies and are likely to
require
i examination,
i ti adjustment,
dj t t servicing,
i i or maintenance
i t while
hil
energized shall be field marked to warn qualified persons of potential
arc flash hazards.
The marking shall be located as to be clearly visible to qualified persons
before examination, adjustment, servicing, or maintenance of the
equipment.
equipment

Labeling Example
The minimum requirement (Brady Label)

Labeling Example
Large Petrochemical Company

Rockwell Automation Labeling Strategy
• We recommend that customer establish a labeling philosophy that is

consistent throughout the facility and supports their Electrical Safety
P
Program (NFPA 70E)
• Best practices include having a Category Level visible on each panel

where electricians may be performing work

Labeling

Electrical Distribution system

Arc Flash Risk ELIMINATION
Electrical Feeder Buss
Buss Disconnect
While working in Panel “A”

can you be exposed to arc
flash hazard if the disconnect
is OFF in panel A?
A
Floor Level Panel with Disconnect

How do I get to a point of having
a good program?
• Key elements:
• Training for Arc Flash Awareness of employees and training for
“qualified” electrical technicians
• Havingg a pprocedure and requiring

q g the pproper
p PPE based on the level of
Arc Flash Hazard exposure (categories 1 – 4) – this will be in the
“Written Electrical Safety Program”
• Having an Electrical Work Permit Program
• Labeling of the Cabinets where arc flash hazards exist
• Updating the program as the system changes

Safety Program
Employer shall implement an overall Electrical Safety Program that

directs activity appropriate for the voltage, energy level, and circuit
conditions (NFPA 70E)
conditions.
– Awareness and Self-Discipline
– Electrical Safety Program Principles
– Electrical Safety Program Controls
– Electrical Safety Program Procedures
– Hazard/Risk Evaluation Procedure
– Job
J b Briefings
B i fi
Typical Procedures and documents Required
– Electrical Safety Procedure
– Hazard/Risk
H d/Ri k Evaluation
E l ti Procedure
P d
– Lockout / Tagout Procedure
– Job Briefing
– Energized Electrical Work Permit

Energized Electrical Work
• Parts may only be worked on in a “live” condition if the employer can

demonstrate that deenergizing them:
– Introduces additional or increased hazards
– Is infeasible due to equipment design or operational limitations. This includes
performing
pe o g diagnostics
d ag os cs and
a d testing.
es g
–
• Definition: Safe State:
• A state in which the conductor or circuit part to be worked on or near
has been:
– disconnected from energized parts
– locked/tagged in accordance with established standards
– tested to ensure the absence of voltage
– gro nded if determined necessary
grounded necessar

Energized Electrical Work Permit
Live Work Permits

• Energized
g Electrical Work Permit – If live pparts are not pplaced in a
electrically safe work condition, work to be performed shall be
considered energized electrical work and shall be performed by
WRITTEN PERMIT ONLY ONLY. (Sample Annex J)
• Exemptions
p to Work Permit – Work pperformed byy qqualified ppersons
related to testing, troubleshooting, and voltage measuring shall be
permitted to be performed without a permit provided Safe Work Practices
and PPE in accordance to Chapter 1 are provided and used used.

Approach Boundaries
There are four different types of approach boundaries in

the standard:
– Limited Approach Boundary
• Unqualified persons must be escorted
– Restricted Approach Boundary
• Unqualified
q ppersons not allowed
– Prohibited Approach Boundary
• Safe work practices required by qualified persons
– Flash Protection Boundary
• Arc flash protection required

Definition – Flash Protection Boundary
An approach limit at a distance from exposed live parts within which a

person
pe so cou
couldd receive
ece e a seco
second-degree
d deg ee bu
burn if aan eelectrical
ect ca aarcc flash
as
were to occur.
– Personal Protective Equipment (PPE) and/or Arc Resistant Clothing (AR) are
required when working within the Flash Protection boundary.

Flash Protection Boundary
• For systems that are 600 volts or less, the Flash Protection Boundary is
4.0’ - meeting criteria.
• Systems over 600V must have the flash protection boundary calculated
for the specific application.
application (Annex D)
– The Flash Protection Boundary is the distance at which the incident
energy equals 5 J/cm2 (1.2 cal/cm2).

Approach Boundaries

Personal Protection Equipment
Hazard Risk
Hazard Risk Hazard Risk Category 4
Hazard Risk Hazard Risk
Category 0 Category 1
Category
g y2 Category 3

Arc Flash Services
• Arc Flash Analysis:

– Data collection to perform the Arc Flash Analysis, Protective Device Coordination
Studies Short Circuit Analysis
Studies,
– Data collection to include:
• Panel ID
• Incoming electrical source identification
– Source
– Wire Dia
– Wire length
g
• Branch circuit protective device details
– Types of device
– Device data
– Device settings
• Outgoing cable data
– Destination
– Wire Dia

Hazard / Risk Category 0
Protective Clothing, Nonmelting or Untreated Natural Fiber (i.e.,

untreated cotton, wool, rayon, or silk, or blends of these materials)
with
ith a Fabric
F b i Weight
W i ht off att LLeastt 44.55 oz/yd2
/ d2
• Shirt (long sleeve)
• Pants (long)
Protective Equipment
q p
• Safety glasses or safety goggles (SR)
• Hearing protection (ear canal inserts)
• Heavy duty leather gloves (AN)

Hazard / Risk Category 1 – (4 Cal/Cm2)
Arc-Rated Clothing, Minimum Arc Rating of 4 cal/cm2

• Arc-rated long-sleeve shirt and pants or arc-rated coverall
• Arc-rated face shield (see Note 2) or arc flash suit hood
• Arc-rated jacket, parka, rainwear, or hard hat liner (AN)
Protective Equipment
• Hard hat
• Heavy duty leather gloves
• Leather work shoes (AN)

Hazard / Risk Category 2 (8 Cal/Cm2)
• Arc-Rated Clothing, Minimum Arc Rating of 8 cal/cm2

g
• Arc-rated long-sleeve shirt and ppants or arc-rated coverall
• Arc-rated flash suit hood or arc-rated face shield and arc-rated
balaclava
• Protective Equipment
• Hard hat
• Safety glasses or safety goggles
• Heavy duty leather gloves
• Leather work shoes
• Arc-Rated Clothing Selected so That the System Arc Rating Meets

the Required Minimum Arc Rating of 25 cal/cm2
• Arc-rated long-sleeve shirt (AR)
• Arc-rated pants (AR)
• Arc-rated
Arc rated coverall (AR)
• Arc-rated arc flash suit jacket (AR)
• Arc
Arc-rated
rated arc flash suit pants (AR)
• Arc-rated arc flash suit hood
• Arc-rated gloves
g

• Protective Equipment
• Hard hat
• Leather work shoes

Safety Services
• Rockwell Automation is committed to providing our customers with the proper evaluation of
their electrical systems in terms of Arc Flash Services
– RA’s overall approach for Arc Flash services is to:
• Collect the plant information with qualified, experienced professionals
• Physically trace circuits where required
• Provide required PPE for the on-site RA Data Collection professionals
• Collect Data without interrupting production or minimizing impact on production by collecting
data per the customers’ schedule (3rd shift, weekends, shutdowns, etc.)
– Rockwell Automation will be there to support our customers’ current AND future arc flash services
and training needs (Updating one-line drawings as the electrical distribution system changes,
providing training to keep the employees current, mitigation, etc.)
– Training is by qualified master electricians who have hands on experience and are experienced at
providing classes at the college level
– RA applies the labels to the cabinets to insure that the proper labels are applied to the proper
panels (some companies leave label application up to the customer)
– Rockwell Automation can support your customers’ needs in the US, Canada and other countries

Risk Reduction Techniques
Guide lines for reducing the risk of arc flash

- Identify all possible sources of electrical energy
- Disconnect energy
- When possible, visually verify device is open
- Perform Lock out Tag out
- Test voltage on each conductor for verification
- Apply
A l grounding
di ddevices
i to
t release
l stored
t d energy or contain
t i induced
i d d voltage.
lt
Avoid Arc Flash incidents by

y PREVENTION

Services & Support
Global Support. Local Address. Peace of Mind.
Increase Mean Time Between Failures

Decrease Mean Time To Repair
Maximize Improve maintenance knowledge
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p systems
y pperformance
Improve equipment reliability
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Optimize
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Reduce assets
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Improve Avoid downtime costs
Financial Reduce operational costs
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Thank You!
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Arc Flash Analysis –

More Than Just

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

– Electrical power systems analysis

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

• Electricity has become essential to modern life. Perhaps because it is

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 3

A dangerous condition such that contact or equipment failure can result

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 4

• Causes of arc flash:

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 5

• Arc Flash Hazards Include:

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 6

• Thermal impacts of arc flash temperatures

205 Degrees F Cell Damage

700 Degrees F Clothing Ignition

9,000 Degrees F Surface of the Sun

35,000 Degree F Arc Terminal Temperatures

3rd Degree burns form when skin is exposed to 200º F

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 7

Understanding circuit breaker performance and fuse performance in light of

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 8

If an employee is working on a panel where electrical energy is present, the

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 9

• Arc Flash Hazard analysis

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 10

1. General Training on Arc Flash Hazards

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 11

• NFPA 70 – National Electrical Code (NEC)- 2008 Edition

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 12

• NFPA 70E is recognized as the tool that illustrates how an employer

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 13

• Initiated originally to give OSHA a document to enforce for

• OSHA will eventually adopt current version

• NFPA 70E- “Flash

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 14

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 15

1910-333 Requires de-energizing unless doing so would

1910-335 Requires the use of “appropriate” personal

Implies that 70E can be enforced as a “safety practice”

Enforced by State & Federal OSHA Inspectors

22 States have their own State OSHA Rules & Inspectors

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 16

– Provides definitions and formulas to calculate Arc Flash and Shock

– Mandates REQUIREMENTS for:

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 17

• “Each employer shall furnish to each of his employees employment and

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 18

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 19

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 20

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 21

Switchboards, panelboards, industrial control panels, and motor control

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 22

The minimum requirement (Brady Label)

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 23

Large Petrochemical Company

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 24

• We recommend that customer establish a labeling philosophy that is

• Best practices include having a Category Level visible on each panel

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 25

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 26

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 27

Electrical Feeder Buss