AF Solutions

V ESW Brasil 2011
Seminrio Internacional de Engenharia

Eltrica na Segurana do Trabalho
Innovative Techniques for

Mitigating Arc Flash Exposure
David Shipp
Eaton Corporation Electrical Sector
So Paulo 8 a 10 de novembro
Holiday Inn Parque Anhembi
ABSTRACT
As more and more industry addresses arc flash electrical

safety concerns, they are discovering high risk associated with
what used to be normal maintenance tasks. In many cases,
the excessively high arc flash incident energies make it so all
maintenance must be done with equipment de-energized not
always acceptable to the process industries. This paper will
address the multiple ways the authors have devised to
significantly lower arc flash incident energy exposure by new
system design and products, retrofits, retro-fills, equipment
modifications, alternate protection settings, etc. In most
cases, NFPA 70E Hazard Risk Category 2 or lower can be
obtained. Several real world examples will be discussed.
2011 IEEE The Institute of Electrical and Electronics Engineers, Inc. - Industry Applications Society - South Brazil Section
DEVELOPMENTS LEADING TO NFPA 70E

Large Hydro in Pacific NW
6.9kV Switchgear
Racking in Breaker
AF occurred
One worker injured
4+ years, $10+ million
NFPA 70E METHODS FOR SELECTING

PROTECTIVE CLOTHING AND PPE
NFPA 70E-2004 Table 130.7(C)(11) Protective Clothing Characteristics
Hazard
Risk
Category
Clothing Description (Typical number of

clothing layers is given in parenthesis)
Required Minimum Arc

Rating of PPE
[J/cm 2(cal/cm 2]
Non-melting, flammable materials (i.e.,

untreated cotton, wool, rayon, or silk, or blends
of these materials) with a fabric weight at least
4.5 oz/yd2 (1)
N/A
FR shirt and FR pants or FR coverall (1)
16.74 (4)
Cotton underwear conventional short sleeve

and brief/shorts, plus FR shirt and FR pants (1
or 2)
33.47 (8)
Cotton underwear plus FR shirt and FR pants

plus FR coverall, or cotton underwear plus two
FR coveralls (2 or 3)
104.6 (25)
Cotton underwear plus FR shirt and FR pants

plus multilayer flash suit (3 or more)
167.36 (40)
INTRODUCTION
Too Much PPE is Just
as Bad as Not Enough!
PROTECTIVE CLOTHING AND PPE FOR

ARC FLASH
Multi-Layering Testing
PROTECTIVE CLOTHING AND PPE FOR

ARC FLASH
Specialized Arc Flash Protective Equipment
Flash Suits / Switching Coats
Two-Layer Flash Suit,
ATPV = 42 cal/cm2
Use: Hazard/Risk Category 4
REDUCING ARC FLASH HAZARDS
Need a Total System

Solution Approach
SOLUTIONS THAT REDUCE ARC

FLASH INJURIES AND DAMAGE
Label Equipment & Train Personnel

Minimize Risk with Good Safety Practices
Reduce Available Fault Current
Faster Clearing Time
Move People Further Away
Redirect Blast Energy
Prevent Fault
ARC FLASH SOLUTIONS

Examples of Arc-Flash Solutions:
Bypass Isolation A.T.S.

Arc Flash Reduction Maintenance
System for new and old (Retrofit
Kits) installations (LV and MV)
Arc Resistant MV Motor Starters
MV and LV Arc Resistant Switchgear
Bus Differential Schemes
MV and LV Zone Selective
Interlocking
Current Limiting Reactors
LV/MV Remote Racking
Hi (or Low) Impedance Transformers
MV / LV HRG Systems
AF Power System Studies
Insulated Bus in Switchgear
Infra-Red Windows
Kirk Key Interlock Systems
MCC Bucket & Safety Switch Viewing
Windows
MCC Bucket Retrofits
Partial Discharge Systems
Infra-Red Sensors in Hi AF Areas
(Dont Have to Remove Covers)
AF Tested Current-Limiting MCCBs
Remote Monitoring, Control and
Diagnostics
LV/MV Remote Operators
Arc Mitigator Light Detection
Tripping (MV and LV)
AFL System (No Main 2ndary
Breaker)
10
Label Equipment
Train People
Wear PPE
11
Engineering Studies
Arc Flash Analysis
Arc Flash Studies
Standardized Data Collection
Templates
Power Systems Engineers
Labels, Training,
Recommendations
12
IEEE 1584-2002: Guide for Performing

Arc Flash Hazard Calculations
Provides guidance for the calculation of

incident energy and arc flash protection
boundaries.
It presents formulas for numerically

quantifying these values.
The IEEE 1584 Guide also includes an

Excel Spreadsheet Arc-Flash Hazard
Calculator which performs the actual
calculations using the formulas stated
in the Guide.
13
Personal Protective Equipment (PPE)
Cumbersome
Hot
Reduces Mobility
Increases Fatigue
14
Recommended Training
Arc-Flash Safety for electricians, technicians or
equipment operators whose employers have
already declared them to be "qualified" according
to OSHA rules but need to be recycled or be
updated with any new revision of NFPA 70E
Electrical and Arc-Flash Safety for electricians,
technicians and equipment operators who are not
"qualified" but who might be exposed to arc-flash
hazards
Understanding Arc Flash for engineers, safety
managers, consultants and electricians
15
Practical Methods for Reducing

Arc Flash Hazards
De-Energize Equipment versus Working It Live

unless increased hazards exist or infeasible due
to design or operational limitations.
Switching remotely (if possible)
Closing and tightening door latches or door bolts

before operating a switch.
Standing to the side and away as much as

possible during switching operations.
16
Practical Methods for Reducing

Arc Flash Hazards
Bad Exposed Back of Neck
Good All of Body Protected
17
INTRODUCTION
18
Reducing Arc Flash Hazards
Reduce Available Fault Current

(Reduce Incident Energy)
19
Reducing Incident Energy

Lowering Isc Does not
Always Lower Incident
Energy
Fuse vs Breaker
No 1 Single Answer
Must Do Arc Flash
Study
20
High Resistance Grounding (HRG)
HRG Units
Typically Under 5 Amps
Pulsing Contactor
Many Options
LV or MV
Does Not Preclude PPE
Lowers Probability of Accident
22
Reducing Arc Flash Hazards
Faster Clearing Time

(Reduce Incident Energy)
23
LV Circuit Breakers
Issues with IEEE 1584
SIMPLE method is based upon worst

case time of 4 manufacturers
time/current curves. VERY conservative!
ALTERNATE method requires
manufacturer specific time/current curve
input.
Concerns with ALTERNATE method too because circuit
breaker time/current curves are very conservative in their
instantaneous region.
Neither circuit breaker calculation method accounts for
their current-limiting effects.
Neither based on any actual circuit breaker test data.
24
MCCBs
Arc Flash Performance Comparison
Apply Current-Limiting Molded-Case Circuit Breakers
Incident Energy at
Bolted Fault Current
Min
Mid
Max
225 A MCCB with Thermal-Magnetic Trip Unit
Bolted fault current

2
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm )

2
3.4 kA 35 kA 100 kA
1
1.7
4.7
N/A
59.6
1.1
2.3
Measured Incident Energy (Cal/cm )

1200 A MCCB with Electronic Trip Unit
0.08
0.1
0.11
Bolted fault current
20 kA 35 kA 100 kA
1
3.5
9.4
N/A
Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm )

2
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm )

Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm 2)
2
Measured Incident Energy (Cal/cm )
218
1.86
3.5
1.2
5.8
1.64
N/A = Not Applicable

because it is outside the
range of the IEEE 1584
Generic Equation
1
IEEE 1584 Generic Equation

IEEE 1584 Using Time Current Curve Input
Tested Value
25
Comments about MCCB Application

Arc Flash Performance
Its important and necessary to have arc flash
application recommendations for MCCBs.
This is only a first step in making MCCB

recommendations for arc flash applications.
It is much easier for novice users to
understand the needed PPE, rather than a
caloric energy value.
26
LV Power Circuit Breakers
Unless a Low Voltage Power Circuit Breaker

operates in the Instantaneous trip mode, the
arc flash energy values will require Category
3 PPE or greater
Zone Selectively Interlocked LV Power Circuit Breakers

provide significantly lower Arc Flash energy values:
Testing confirms that a LV Power Circuit Breaker
(4000A maximum) require Category 2 PPE (8 cal/cm2)
with proper instantaneous settings
During maintenance it is recommended to temporarily adjust
the Instantaneous and Ground Fault (if available) trip
settings to their lowest value
27
High Speed Clearing

Bus Differential (87B)MV or HV
Zone Selective Interlocking a Control
approach / Form of 87B MV and LV
Arc Mitigator Light (Current) Detection

Systems for MV and LV Switchgear and
Controlgear
Current Limiting Fuses*
28
Zone Selective Interlocking (ZSI)

M1
Explanation:
SD=
0.5S
35kA fault current

F1
F2
SD=
0.3S
Without ZSI = 0.5 S:

43.7 Cal/cm2
Greater than Cat. 4 PPE
DANGER!
F3
SD=
0.3S
SD=
0.3S
With ZSI = 0.08 S:

7.0 Cal/cm2
Cat. 2 PPE
FR Shirt & Pants
29
Zone Selective Interlocking (ZSI)

Example:
An Off-Shore Oil Platform in the Gulf of Mexico

lowered their Incident Energy Exposure from
85 calories down to 12.7 calories by retrofitting
their 480 V Switchgear with ZSI.
30
Arc Flash Reduction Systems

Retrofit of LV PCBs
Breaker Mounted
Components
Door Mounted
Components
Indicating
Light
Harness
Lockout
DIGITRIP
Switch
Battery
Arc flash Reduction

Maintenance System
31

Retrofit of LV PCBs
An external over-ride switch and circuitry are
connected to a breakers trip unit, and is
adjustable between 2.5X - 10X.
When a person wants to perform maintenance,
they close the switch, which automatically overrides all of the delay functions, and causes the
breaker to trip without any intentional delay
whenever a fault is detected. Use its lockout
features for normal lockout tag-out procedures.
32

for LV PCBs
Upon completion of the maintenance, the lock is
removed, the switch is manually opened, and all
previous trip unit settings are again re-activated,
without need for recalibration.
33
Example: Existing Equipment
Overflow Sump Pump Location

Recommendation (Acceptable)
C0-5: XFMR protection
Main and FDR: Coordination
Hazard Risk Category

= HRC = Danger (>40 Cal.)
AF Current = 5.6kA
34

Example
Overflow Sump Pump Location
Recommendation (Good)
C0-5: TXMR protection
Main and FDR: Coordination
New Equipment (Better)
Replace C0-5 w/ DT3000
Replace FDR trip w/ DigiTrip RMS 610,
LSI trip unit.
Arc flash Reduction System (Best)
Replace C0-5 w/ DT3000
Replace FDR trip w/ DigiTrip RMS610,
LSI trip unit & Arcflash Reduction
Maintenance Switch.
Replace Main with Digitrip 610 LS & Arc
flash Reduction Maintenance Sw.
AF Current = 5.6kA HRC = 1 (< 4 cal/cm2)
35
Arc Flash Reduction Systems Example

for High Available Fault Current
High Avail Fault Current
Digitrip610 & Arc flash
Reduction System
Normal settings HRC=3
(10.7 cal)
With Arc flash Reduction
System: HRC= 1 (2.2 cal)
36

Retro fill Example
2000 A fuses supplying 480V
Glass Furnaces
Incident Energy =61 Cal /
HRC=Danger
Retro-filled fuses with LV
Power Circuit Breakers
35 cal with trip Unit/6 cal with
New Breaker + Built-in Arc
Flash Reduction System
37

Example of replacement of old LVPCB
38

Example of Integrated Trip Unit
Has 5 user-selectable levels of
protection to choose
maximum protection, while
avoiding nuisance tripping
Blue color LED indicating
Maintenance mode
Can be remotely activated
through IR communication
with PDA
39
Change to Electronic Trip Units

Computer Room PDU
(Bypass Mode)
Thermal-Magnetic breaker
HRC = 4 Due to Long Time
Replaced with Electronic
Trip Breaker HRC = 1
40
Practical Methods for Reducing Arc

Flash Hazards
Multiple Settings Groups
Similar to LV maintenance
switch, only for MV applications
Used to reduce the trip delay of
medium-voltage relays while
maintenance is being performed
on equipment.
Requires relay with multiple
settings groups capability
41
Arc Flash Reduction using m-Processed

Relay with Group Settings
m-Processed
Relay
Indicating Light
Switch
42
Network Protectors
43
Network Protectors
44
Network Protectors
45
Network Protectors
46
Network Protectors
47
Network Protectors
48
Network Protectors
49
Substations without Main Secondaries

Any Exposure / Racking
Feeder Circuit-Breakers
Must be Cleared by Primary
Fuse
100 Cal Exposure
50

Arc Flash reduction by Retrofit
51

Primary Fuses Only:
594 calories
Primary Circuit-breaker Only:
289 calories
Primary Circuit-breaker + Arc
Flash Reduction System:
7.5 calories
52

Retrofill Primary Fuse with
Vacuum Circuit-breaker
Sense at 480V Transformer
side Trip Primary
Use Protective Relay with
Group Settings
Many Variations
Must Meet ANSI C37.59
53

54

55

Arc Flash solution for new installation
Safety by Design: Improved Unit Substation Design
Typical LV Unit Substation with Vacuum Breaker in MSB
(Medium Voltage Switch over Breaker) Assembly
CPT
LA
Line
CTs
Bkr
Load
Snubber
25H X 20W X 18 D, 330 lbs

ANSI C37.20 rated at 25 and
40kA
600, 1200 and 2000A ratings
Integral trip unit with linear trip
actuator
2-step stored energy
mechanism
56

Arc Flash solution for new installation
Safety
by Design: Improved Unit Substation Design
Substation One-Line
VCB
50
51
LV Swgr Elevation
ZSI
(3) 600:5 CT
50
51
(3) 3200:5 CT
(3) 3200:5 CT
ZSI
ZSI
XXPXXX-90PXXX-P1,P2,P3,P4
4-3/C, #500kcmil
600V, TC, XHHW-2, W/GND
XXPXXX-L1,L2,L3
CABLE TRAY
100 FEET
ZSI
ZSI
4-3/C, #500kcmil
XXPXXX-L1,L2,L3
CABLE TRAY
100 FEET
4-3/C, #500kcmil
XXPXXX-L1,L2,L3
CABLE TRAY
100 FEET
4-3/C, #500kcmil
XXPXXX-L1,L2,L3
CABLE TRAY
100 FEET
57
Light Detection System Arc Flash

reduction for MV Switchgear
58
Light Detection System Arc Flash

reduction for MV Switchgear
59
Move People Further Away
60
Arc Flash Reduction Remote Racking

of MV CB 5/15/27/38 kV Switchgear
Remain physically outside the flash protection boundary.

Therefore NO ARC FLASH HAZARD protection required.
61
Arc Flash Reduction Remote Racking

of MV CB 5/15/27/38 kV Switchgear
VS.
62
Arc Flash Reduction Remote

Switching (Chicken Switch)
Without
With
63
Arc Flash Reduction Remote

Operation of Isolation Switch
Accessory for Remote Operation of

Isolation Switch: Increased Operator
Safety.
Temporarily mounts to front of

Starter door equipped with mounting
provisions.
Operation by Control Station

connected to Motor Operator via 25foot Cable.
64
Arc Flash Reduction Motor Operated

Isolation Switch
65
Redirect Fault Energy
66
Arc Resistant Switchgear

Redirects Arc Energy and Particulates
67
5/15 kV Arc Resistant Switchgear

Arc Flaps
Control
Section
2000A or 3000A
breaker with Vent
VT drawer
1200A can be 1
high or 2 high
Manual Close/Open Push

Buttons
68
LV Arc Resistant Switchgear Testing

Test @ 65kA / 508V
Arc initiated in breaker
compartment
Plenum Design
March 2008 - PASS
Arc out-gassing through

plenum
No arc flash out of the

front of the gear
69
Prevent Fault
70
LV MCC Racking buckets with front

door closed
71
LV MCC Withdrawable units with

increased safety features
Racking Tool Receiver
Unit Latch
Internal Shutter Position

Open
Closed
Bucket Position
Connected
Test
Withdrawn
Handle Mechanism
Device Island
Start, Stop, Auto, Man
Breaker
Starter
72
LV MCC Withdrawable units with

increased safety features
Bucket Position:
Connected/Test/Disconnected
Stab Positive
Position Indicator:
With lockout tag out
hole
Racking Tool
Receiver: 3/8 Square
Internal Shutter
Position:
Open/Closed
Breaker Operator
Test Position Block:

Phase Voltage,
Control, voltage,
Ground
73
LV MCC Racking buckets with front

door closed
DC Motor Wireless Option

Attaches Easily
Minimal Torque Required
25 Foot Pendant Station
It should interfaces with other
Remote Racking Systems
74
Safety Related Solutions

Infrared Scanning Windows for LV/MV Assemblies
79
Continuous Thermal Monitoring

Monitoring connecting
joints on a PDU, utilizing
Plastic Bracket System
Monitoring Individual
Connections
80
QUESTIONS?
82
V ESW Brasil 2011
Seminrio Internacional de Engenharia

Eltrica na Segurana do Trabalho
Thank you!
David Shipp
Eaton Corporation Electrical Sector
So Paulo 8 a 10 de novembro
Holiday Inn Parque Anhembi

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V ESW Brasil 2011

Seminrio Internacional de Engenharia

Innovative Techniques for

As more and more industry addresses arc flash electrical

DEVELOPMENTS LEADING TO NFPA 70E

NFPA 70E METHODS FOR SELECTING

Clothing Description (Typical number of

Required Minimum Arc

Non-melting, flammable materials (i.e.,

FR shirt and FR pants or FR coverall (1)

Cotton underwear conventional short sleeve

Cotton underwear plus FR shirt and FR pants

Cotton underwear plus FR shirt and FR pants

PROTECTIVE CLOTHING AND PPE FOR

PROTECTIVE CLOTHING AND PPE FOR

REDUCING ARC FLASH HAZARDS

Need a Total System

SOLUTIONS THAT REDUCE ARC

Label Equipment & Train Personnel

ARC FLASH SOLUTIONS

Bypass Isolation A.T.S.

REDUCING ARC FLASH HAZARDS

IEEE 1584-2002: Guide for Performing

Provides guidance for the calculation of

It presents formulas for numerically

The IEEE 1584 Guide also includes an

Personal Protective Equipment (PPE)

Practical Methods for Reducing

De-Energize Equipment versus Working It Live

Switching remotely (if possible)

Closing and tightening door latches or door bolts

Standing to the side and away as much as

Practical Methods for Reducing

Bad Exposed Back of Neck

Good All of Body Protected

Reducing Arc Flash Hazards

Reduce Available Fault Current

Reducing Incident Energy

High Resistance Grounding (HRG)

Reducing Arc Flash Hazards

Faster Clearing Time

SIMPLE method is based upon worst

Bolted fault current

Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm )

Measured Incident Energy (Cal/cm )

Bolted fault current

Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm )

Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm )

Measured Incident Energy (Cal/cm )

N/A = Not Applicable

IEEE 1584 Generic Equation

Comments about MCCB Application

This is only a first step in making MCCB

LV Power Circuit Breakers

Unless a Low Voltage Power Circuit Breaker

Zone Selectively Interlocked LV Power Circuit Breakers

High Speed Clearing

Arc Mitigator Light (Current) Detection

Zone Selective Interlocking (ZSI)

35kA fault current

Without ZSI = 0.5 S:

With ZSI = 0.08 S:

Zone Selective Interlocking (ZSI)

An Off-Shore Oil Platform in the Gulf of Mexico