Beruflich Dokumente
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ANALYSIS
H. Wallace Tinsley III Michael Hodder Aidan M. Graham
Member, IEEE Member, IEEE Senior Member, IEEE
Eaton Electrical Eaton Electrical Eaton Electrical
130 Commonwealth Drive 4120B Sladeview Cres 13205 SE 30th St, Ste 101
Warrendale, PA 15086 Mississauga, ON L5L 5Z3 Bellevue, WA 98005
Abstract – Once an Arc Flash Analysis has been locations be lowered below 40 cal/cm2 in order for personnel to
performed for a facility, the quantification of the potential safety perform energized work on these locations.
incident energy has been completed. However, this is only Additional HRC thresholds are often desired in order to
the first step in establishing and implementing a complete minimize the cost of purchasing personal protective equipment
arc flash program. Labels must be applied to the equipment (PPE) for each employee. A summary of the NFPA 70E Hazard
and the information presented must be appropriately Risk Categories is shown in Table 1. Each HRC is associated
meaningful and instructive to qualified persons preparing with specific requirements for PPE.
to access the energized equipment. Arc Flash warning
Table 1: Hazard Risk Categories (HRC)
labels are only one type of arc flash documentation that
should be presented and available to facility personnel. A
Hazard Risk Incident Incident
comprehensive safety policy and corresponding training Category Energy From Energy
program should be developed and implemented to ensure (HRC)
2
(cal/cm )
2
To (cal/cm )
understanding and compliance with the procedures in
place to reduce the impact of a potential arc flash hazard. 0 >0 < 1.2
Lastly, a preventative maintenance program must be put 1 1.2 <4
into place to ensure that all electrical equipment, most 2 4 <8
importantly the protective devices, will react appropriately
during an arc flash event. 3 8 < 25
4 25 < 40
Index Terms – Arc Flash Analysis, Arc Flash Training, Arc
Flash Warning Labels, Maintenance Program When a facility decides to purchase clothing for HRC’s 1
through 4, the cost per employee is very high. In order to avoid
I. INTRODUCTION having to purchase clothing for each HRC, specific HRC
thresholds are often set. For example, one of the most common
Much has been written in recent years regarding the arc approaches is to limit the PPE to HRC’s 2 and 4. All employees
flash hazard and the importance of quantifying the incident requiring arc flash PPE are provided clothing that meets HRC 2
energy at all locations where work may be performed on and clothing that meets HRC 4. Using Table 1 as a reference,
energized equipment. This quantification is typically HRC 2 clothing would be required for all locations where the
2
accomplished by performing an arc flash hazard analysis calculated incident energy is less than 8 cal/cm . Likewise,
utilizing one of several calculation methods. However, the initial HRC 4 clothing would be required for all locations where the
arc flash analysis is only the first step in establishing and calculated incident energy is greater than or equal to 8 cal/cm2,
implementing a complete arc flash program. but less that 40 cal/cm2. Any locations with incident energy
2
levels above 40 cal/cm are deemed unsafe for energized work.
II. REVIEW OF STUDY RESULTS AND ENERGY Using the above-mentioned philosophy as a guideline, it is
REDUCTION APPROACH then common practice to attempt to set HRC thresholds for
each particular type of equipment within a facility. For
Upon completing the initial arc flash analysis, the next step example, in a 480 V distribution system it is often feasible to set
is to review the results of the study with the facility safety, the desired maximum threshold for all panelboards and motor-
maintenance and electrical staff. Prior to labeling the control centers (MCC) to HRC 2 and for all switchboards and
equipment, several items need to be addressed in order to switchgear to HRC 4.
“finalize” the arc flash analysis calculations. B. Incident Energy Reduction Approach
A. Determination of Hazard Risk Category (HRC) Thresholds Using the guidelines and HRC thresholds defined by the
It is the authors’ experience that the initial arc flash analysis facility personnel, the study engineer must then re-examine the
will usually reveal a number of work locations where the initial arc flash analysis and choose solutions to get each
2
calculated incident energy exceeds 40 cal/cm - the upper limit equipment location below the desired HRC threshold. This is
of HRC 4 set forth in the NFPA 70E Standard for Electrical accomplished using one of many incident energy reduction
Safety in the Workplace 2004 Edition. Due to arc blast pressure techniques. A summary of the most common techniques are
concerns, it is recommended that the incident energy at these listed below:
PRESENTED AT THE 2007 IEEE IAS PULP AND PAPER INDUSTRY CONFERENCE IN WILLIAMSBURG, VA: © IEEE 2007 - PERSONAL USE OF THIS MATERIAL IS PERMITTED.
• Changing Existing Work Procedures: One of the maintenance switch is that the reduced settings are
lowest cost and most straightforward methods to only in place during maintenance and can be
reduce the incident energy exposure is to change switched back to the settings of the coordination
existing work procedures. One example of this study at the completion of the work task. Additional
would be changing the work location when contacts can be added to the maintenance switch
performing power quality measurements using a to monitor its status.
portable meter. Historically, measurements have
been performed by direct connection of the voltage •Retrofit / Replacement of Equipment: Retrofit or
and current probes to the primary circuit, where replace protective devices with devices that clear
incident energy can be relatively high. By taking faster at the respective arcing fault currents. This is
measurements utilizing the potential transformer often accomplished by changing fuse types, such
and current transformer circuits, one can as going from an RK5 fuse to an RK1 fuse or by
dramatically reduce the potential incident energy changing trip unit functions, such as going from a
exposure. Another example of procedure change trip unit that utilizes only the long time and
is to use a laser light beam for bus dimension instantaneous functions (LI) to a trip unit that
measurement on energized switchgear (see Figure utilizes long time, short time and instantaneous
1 below). (LSI) functions.
The study engineer should always attempt to accomplish the
incident energy reduction using the least-cost method first
(typically changing working practices or modifying existing
protective device settings). If these do not provide adequate
reduction, then more costly solutions such as device retrofit or
replacement may be required.
C. Revise Arc Flash Analysis
After determining the most appropriate incident energy
reduction methods for each location where the energy level is
too high, the initial arc flash analysis should be revised to
incorporate all changes. This updated arc flash analysis should
be used as the guide in upgrading and/or replacing equipment,
testing and setting all overcurrent protective devices,
purchasing PPE and printing arc flash warning labels for all
equipment locations where energized work may be performed.
The energy equation (Equation 1) from IEEE Std. Figure 2: Hazard Calculations at Multiple Working
1584-2002 may be simplified as shown by Equation 2 Distances
which has only three terms comprised of the energy,
calculated by the analysis, the working distance and
the distance factor used by the analysis calculation System Distance x
and everything else combined as represented by the
Equipment Type
Voltage (kV) Factor
letter “Y” in Equation 2.
0.208-15 kV Open Air or Cable 2
Equation 1
0.208-1 kV MCC and panels 1.641
⎛ t ⎞⎛ 610 ⎞
x
E = C f ∗ En ∗ ⎜ ⎜
⎟⎜ x ⎟⎟ 0.208-1 kV Switchgear 1.473
⎝ 0.2 ⎠⎝ D ⎠ 1-15 kV Switchgear 0.973
where:
2 Table 2: Distance Exponents for Distribution Equipment
E is incident energy in cal/cm
D is the working distance
x s the distance exponent • Settings Implemented Box: It may be desired that the
label include a method to track whether or not the
(The remaining constants and variables are defined in recommended settings in the study report were
IEEE Std 1584TM-2002, but are not required for this implemented in the field. This could be a blank line for
discussion.) the person’s initials and the date the settings were
implemented or some other method to allow the worker
Equation 2 who is referencing the label to determine if the settings
were indeed implemented.
( )
E Dx = Y D. Customized Labels for Special Cases
Once Y is determined, the working distance (D) may • Protective Devices with Multiple Settings: When a
be changed to suit a given job task. The distance protective device is capable of operating under multiple
exponent (x) is dependent on the equipment in settings or settings groups, it may be desirable to post
question and does not change. Table 2 shows the a special label that provides the hazard information for
distance exponents associated with various equipment both setting configurations. For example, if a
types. With Y, D, and x, a new energy is easily “maintenance switch (MS)” is installed to provide faster
determined. fault clearing time at a particular location, the hazard
without the use of the MS will be greater than when the
MS is engaged. It is important to direct qualified
persons to the location where the MS is to be engaged
and to warn of the hazard that is present when the MS
is not in use. Similar labels may be desirable when
overcurrent relays with selectable setting groups or
other MS configurations are used.
Below are a number of topics that should be included in Arc
E. Quantity of Labels Flash Hazard training:
It is common practice to provide one arc flash warning label • Review of the Arc Flash Hazard report results and
per equipment location studied. This label has generally been implementation of these results. For example,
located at the main protective device or incoming power maintenance procedures need to be re-evaluated
compartment. This label should contain sufficient information to to align with the results of the Arc Flash study and
describe the entire equipment location. A qualified person is it’s recommendations
responsible to properly apply the information to their job task(s). • Review of limits of the study scope of work. For
However, it has occasionally been requested that a label be example, the study may not have included the
placed on each “equipment compartment” with a benefit that the entire facility and there may be locations in the
worker does not have to find the main protective device or system that were not labeled yet.
incoming power compartment to find the arc flash warning label. • Review of the single line diagram contained in the
The major downside to this method is that “over-labeling” the Arc Flash Hazard report and the link between the
equipment leads to much higher and often unnecessary costs. single line and the Arc Flash Hazard labels.
There is also a possibility of an assumption that all • Include references from NFPA 70E-2004 in the
compartments may have the same hazard level when in reality, training program. Perform training for interpretation
compartments may have different hazard levels. and compliance with NFPA 70E-2004.
• Carry out training in the use and care of the specific
F. Printing and Applying Labels
PPE that will be used at the site.
• Printing Materials: Careful attention should be paid to • Include hands on training for donning and wearing
the quality and durability of the labels selected for all applicable PPE. Photos of a person wearing the
application. For clean, contained environments, labels correct PPE for each hazard category also provides
printed by an ink jet or laser jet printer may suffice. a good training aid. An example of this is shown in
These labels, however, may fade, smear, and lose Figure 3.
adhesion if exposed to direct sunlight, rain, cleaning
solvents, spills, oils, etc. For these environments, high
adhesion vinyl labels should be printed with a thermal-
transfer printer. Depending on the printer selected,
lamination may be required to protect the labels from
exposure to excessive wear.
• Installation of Labels: The general recommendation for
installing arc flash labels is to position them as close
as possible to the main protective device or incoming
power supply, at a height from the floor that allows the
labels to be clearly visible to most personnel. It is
important for the label placement to be standardized
throughout the facility so that qualified persons are
trained to refer to a specified location on the equipment
and are not required to search for haphazardly placed
labels.
• “Standard” HRC levels – determined during the The authors thank W. S. Vilcheck for his sponsorship,
review of study results stage. For example, in advice, and encouragement.
many cases, a choice of HRC 2 for everyday work
wear will make sense. IX. REFERENCES
• Questions such as: What does each employee
require? How many sets of PPE does each [1] Electrical Safety Requirements for Employee Workplaces, NFPA 70E-
employee need? Do all employees get the same 2004 ©NFPA.
PPE? Do some employees only get HRC 2 while [2] IEEE Guide for Performing Arc-Flash Hazard Calculations, IEEE Std
others may need HRC 4 as well? Should HRC 4 1584TM-2002.
PPE be issued on an individual basis or should it [3] National Electrical Code, NFPA 70
be purchased in a few sizes and put in a central
location where it is most likely needed?
• Other items to consider when evaluating PPE X. BIOGRAPHIES
include:
o Cost Wally Tinsley received a BSEE in 2001 from Clemson
o Quality University in South Carolina. Mr. Tinsley is currently employed
o Comfort - lightweight, breathable, etc. as a Power Systems Senior Engineer by Eaton Electrical where
o Wear Life he is a study engineer with a stated emphasis on arc flash
o Laundering methods - home or industrial analysis. Mr. Tinsley is the chairman of his group’s arc flash
o Coveralls versus shirt and pants committee and is responsible for the standardization and
o Flash suits versus layering to achieve improvement of arc flash analysis methods at Eaton Electrical.
HRC 4
Michael Hodder received a BASc in Electrical Engineering
VI. MAINTENANCE PROGRAM from University of Waterloo in 1977. Mr. Hodder is currently
employed as an Advisory Engineer with Eaton Electrical
Services and Systems, a Division of Eaton Corporation. He
Developing and sustaining a thorough maintenance program
presently performs power system studies and is a technical
is a crucial step in ensuring that the investment in an arc flash
trainer for Power System and Electrical Safety seminars. Mr.
program does not go to waste. A comprehensive maintenance
Hodder was previously employed by the Industry Services
program includes, at a minimum, the following three phases:
Division of Westinghouse Canada Inc. where he was
1. Work Procedures: Maintaining and/or updating work responsible for power system studies, testing, commissioning,
procedures to comply with the Arc Flash standards and startup and maintenance of power system installations. Mr.
report recommendations Hodder is a member of IEEE and a registered Professional
Engineer in Ontario. He is the author of several technical
2. Equipment Maintenance: Routine testing and cleaning of publications.
electrical equipment is essential in ensuring that all
equipment, most importantly the overcurrent protective Aidan M. Graham received the BSEE in 1998 and MSEE in
devices, will react appropriately during an arc flash 1999 from the University of Nevada, Reno. Mr. Graham is
event. currently employed as the Western Zone Team Leader for the
Power Systems Engineering Group at Eaton Electrical Services
3. Arc Flash Study: Updating and re-running the arc flash and Systems, a division of the Eaton Corporation. His core
analysis due to changes to the power distribution system responsibility is the management of all power system
is crucial to maintaining accurate arc flash calculations engineering business in the Western US. Mr. Graham is a
and arc flash warning labels. These system changes Senior Member of the IEEE and is a Registered Professional
can include modification to the utility distribution system Engineer in the State of Washington and Oregon. He is author
or equipment changes internal to the customer facility. of several technical publications.