Arc flash

An arc flash is the light and heat produced as part of an arc fault,
a type of electrical explosion or discharge that results from a
connection through air to ground or another voltage phase in an
electrical system.

Arc flash is distinctly different from the arc blast, which is the
supersonic shockwave produced when the uncontrolled arc
vaporizes the metal conductors. Both are part of the same arc fault,
and are often referred to as simply an arc flash, but from a safety
standpoint they are often treated separately. For example, personal
protective equipment (PPE) can be used to effectively shield a
worker from the radiation of an arc flash, but that same PPE may An electric arc between two nails
likely be ineffective against the flying objects, molten metal, and
violent concussion that the arc blast can produce. (For example,
category-4 arc-flash protection, similar to a bomb suit, is unlikely to protect a person from the concussion of
a very large blast, although it may prevent the worker from being vaporized by the intense light of the
flash.) For this reason, other safety precautions are usually taken in addition to wearing PPE, helping to
prevent injury.[1] However, the phenomenon of the arc blast is sometimes used to extinguish the electric arc
by some types of self-blast–chamber circuit breakers.

Contents
Definition
Examples
Precautions
Switching
Live testing
Protecting personnel
Arc flash protection equipment
Reducing hazard by design
Fault current
Arcing time
Distance
Research
Standards
Notable incidents
References
External links

Definition
An arc flash is the light and heat produced from an electric arc
supplied with sufficient electrical energy to cause substantial
damage, harm, fire, or injury. Electrical arcs experience negative
incremental resistance, which causes the electrical resistance to
decrease as the arc temperature increases. Therefore, as the arc
develops and gets hotter the resistance drops, drawing more and
more current (runaway) until some part of the system melts, trips, or
evaporates, providing enough distance to break the circuit and
extinguish the arc.[2] Electrical arcs, when well controlled and fed
by limited energy, produce very bright light, and are used in arc A controlled arc-flash, produced in a
lamps (enclosed, or with open electrodes), for welding, plasma flashtube. Even though the energy
cutting, and other industrial applications. Welding arcs can easily level used is fairly low (85 joules),
turn steel into a liquid with an average of only 24 DC volts. When the low-impedance, low-inductance
an uncontrolled arc forms at high voltages, and especially where circuit produces a flash of
large supply-wires or high-current conductors are used, arc flashes 24,000,000 watts. With an arc
can produce deafening noises, supersonic concussive-forces, super- temperature of 17,000 K (30,100 °F),
heated shrapnel, temperatures far greater than the Sun's surface, and the radiation output is centered at
intense, high-energy radiation capable of vaporizing nearby 170 nanometers, in the far UV. The
materials. intense burst of radiation easily
penetrates the shade #10 welding
Arc flash temperatures can reach or exceed 35,000 °F (19,400 °C) filter which shields the camera.
at the arc terminals.[3] The massive energy released in the fault
rapidly vaporizes the metal conductors involved, blasting molten
metal and expanding plasma outward with extraordinary force.[3] A typical arc flash incident can be
inconsequential but could conceivably easily produce a more severe explosion (see calculation below). The
result of the violent event can cause destruction of equipment involved, fire, and injury not only to an
electrical worker but also to bystanders. During the arc flash, electrical energy vaporizes the metal, which
changes from solid state to gas vapor, expanding it with explosive force. For example, when copper
vaporizes it suddenly expands by a factor of 67,000 in volume.[4]

In addition to the explosive blast, called the arc blast of such a fault, destruction also arises from the intense
radiant heat produced by the arc. The metal plasma arc produces tremendous amounts of light energy from
far infrared to ultraviolet. Surfaces of nearby objects, including people, absorb this energy and are instantly
heated to vaporizing temperatures. The effects of this can be seen on adjacent walls and equipment - they
are often ablated and eroded from the radiant effects.

Examples
One of the most common examples of an arc flash occurs when an incandescent light bulb burns out. When
the filament breaks, an arc is sustained across the filament, enveloping it in plasma with a bright, blue flash.
Most household lightbulbs have a built-in fuse, to prevent a sustained arc-flash from forming and blowing
fuses in the circuit panel.[2] Most 400 V and above electrical services have sufficient capacity to cause an
arc flash hazard. Medium-voltage equipment (above 600 V) is higher potential and therefore a higher risk
for an arc flash hazard. Higher voltages can cause a spark to jump, initiating an arc flash without the need
for physical contact, and can sustain an arc across longer gaps. Most powerlines use voltages exceeding
1000 volts, and can be an arc-flash hazard to birds, squirrels, people, or equipment such as vehicles or
ladders. Arc flashes are often witnessed from lines or transformers just before a power outage, creating
bright flashes like lightning that can be seen from long distances.[5]
High-tension powerlines often operate in the range of tens to hundreds of kilovolts. Care must usually be
taken to ensure that the lines are insulated with a proper "flashover rating" and sufficiently spaced from
each other to prevent an arc flash from spontaneously developing. If the high-tension lines become too
close, either to each other or ground, a corona discharge may form between the conductors. This is
typically a blue or reddish light caused by ionization of the air, accompanied by a hissing or frying sound.
The corona discharge can easily lead to an arc flash, by creating a conductive pathway between the lines.
This ionization can be enhanced during electrical storms, causing spontaneous arc-flashes and leading to
power outages.[6]

As an example of the energy released in an arc flash incident, in a single phase-to-phase fault on a 480 V
system with 20,000 amps of fault current, the resulting power is 9.6 MW. If the fault lasts for 10 cycles at
60  Hz, the resulting energy would be 1.6 megajoules. For comparison, TNT releases 2175 J/g or more
when detonated (a conventional value of 4,184 J/g is used for TNT equivalent). Thus, this fault energy is
equivalent to 380 grams (approximately 0.8 pounds) of TNT. The character of an arc flash blast is quite
different from a chemical explosion (more heat and light, less mechanical shock), but the resulting
devastation is comparable. The rapidly expanding superheated vapor produced by the arc can cause serious
injury or damage, and the intense UV, visible, and IR light produced by the arc can temporarily and
sometimes even permanently blind or cause eye damage to people.

There are four different arc flash type events to be assessed when designing safety programs:

Open air
Ejected
Equipment focused (Arc-in-a-box)
Tracking [7]

Precautions

Switching

One of the most common causes of arc-flash injuries happens when switching on electrical circuits and,
especially, tripped circuit-breakers. A tripped circuit-breaker often indicates a fault has occurred somewhere
down the line from the panel. The fault must usually be isolated before switching the power on, or an arc
flash can easily be generated. Small arcs usually form in switches when the contacts first touch, and can
provide a place for an arc flash to develop. If the voltage is high enough, and the wires leading to the fault
are large enough to allow a substantial amount of current, an arc flash can form within the panel when the
breaker is turned on. Generally, either an electric motor with shorted windings or a shorted power-
transformer are the culprits, being capable of drawing the energy needed to sustain a dangerous arc-flash.
Motors over two horsepower usually have magnetic starters, to both isolate the operator from the high-
energy contacts and to allow disengagement of the contactor if the breaker trips.

Circuit breakers are often the primary defense against current runaway, especially if there are no secondary
fuses, so if an arc flash develops in a breaker there may be nothing to stop a flash from going out of control.
Once an arc flash begins in a breaker, it can quickly migrate from a single circuit to the busbars of the panel
itself, allowing very high energies to flow. Precautions must usually be used when switching circuit
breakers, such as standing off to the side while switching to keep the body out of the way, wearing
protective clothing, or turning off equipment, circuits and panels downline prior to switching. Very large
switchgear is often able to handle very high energies and, thus, many places require the use of full
protective equipment before switching one on.[8]
In addition to the heat, light and concussive forces, an arc flash also
produces a cloud of plasma and ionized particles. When inhaled,
this ionized gas can cause severe burns to the airways and lungs.
The charged plasma may also be attracted to metallic objects worn
by people in the vicinity, such as earrings, belt buckles, keys, body
jewelry, or the frames of glasses, causing severe localized burns.
When switching circuits, a technician should take care to remove
any metals from their body, hold their breath, and close their eyes.
An arc flash is more likely to form in a switch that is closed slowly,
by allowing time for an arc to form between the contacts, so it is A 480 volt switchgear and
usually more desirable to "throw" switches with a fast motion, distribution panel, requiring category-
quickly and firmly making good contact. High-current switches 4 arc-flash protection.
often have a system of springs and levers to assist with this.[8]

Live testing

When testing in energized high-power circuits, technicians will observe precautions for care and
maintenance of testing equipment and to keep the area clean and free of debris. A technician would use
protective equipment such as rubber gloves and other personal protective equipment, to avoid initiating an
arc and to protect personnel from any arc that may start while testing.[9][10][11]

Protecting personnel
There are many methods of protecting personnel from arc flash
hazards. This can include personnel wearing arc flash personal
protective equipment (PPE) or modifying the design and
configuration of electrical equipment. The best way to remove the
hazards of an arc flash is to de-energize electrical equipment when
interacting with it, however de-energizing electrical equipment is in
and of itself an arc flash hazard. In this case, one of the newest
solutions is to allow the operator to stand far back from the
electrical equipment by operating equipment remotely, this is called
Play media
remote racking.[12]
A video describing the dangers of arc
flashes and measures that can be
taken to reduce risk to workers
Arc flash protection equipment

With recent increased awareness of the dangers of arc flash, there

have been many companies that offer arc flash personal protective equipment (PPE), such as suits, overalls,
helmets, boots, and gloves.

The effectiveness of protective equipment is measured by its arc rating. The arc rating is the maximum
incident energy resistance demonstrated by a material prior to breakopen (a hole in the material) or
necessary to pass through and cause a 50% probability of second degree burns.[4] Arc rating is normally
expressed in cal/cm2 (or small calories of heat energy per square centimeter). The tests for determining arc
rating are defined in ASTM F1506 Standard Performance Specification for Flame Resistant Textile
Materials for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and
Related Thermal Hazards.
The selection of appropriate PPE, given a certain task to be performed, is normally handled in one of two
possible ways. The first method is to consult a hazard category classification table, like that found in NFPA
70E. Table 130.7(C)(15)(a) lists a number of typical electrical tasks by various voltage levels and
recommends the category of PPE that should be worn. For example, when working on 600 V switchgear
and performing a removal of bolted covers to expose bare, energized parts, the table recommends a
Category 3 Protective Clothing System. This Category 3 system corresponds to an ensemble of PPE that
together offers protection up to 25 cal/cm2 (105 J/cm2 or 1.05 MJ/m2 ). The minimum rating of PPE
necessary for any category is the maximum available energy for that category. For example, a Category 3
arc-flash hazard requires PPE rated for no less than 25 cal/cm2 (1.05 MJ/m2 ).

The second method of selecting PPE is to perform an arc flash hazard calculation to determine the available
incident arc energy. IEEE 1584 provides a guide to perform these calculations given that the maximum
fault current, duration of faults, and other general equipment information is known. Once the incident
energy is calculated the appropriate ensemble of PPE that offers protection greater than the energy available
can be selected.

PPE provides protection after an arc flash incident has occurred and should be viewed as the last line of
protection. Reducing the frequency and severity of incidents should be the first option and this can be
achieved through a complete arc flash hazard assessment and through the application of technology such as
high-resistance grounding which has been proven to reduce the frequency and severity of incidents.

Reducing hazard by design

Three key factors determine the intensity of an arc flash on

personnel. These factors are the quantity of fault current available
in a system, the time until an arc flash fault is cleared, and the
distance an individual is from a fault arc. Various design and
equipment configuration choices can be made to affect these factors
and in turn reduce the arc flash hazard.
Example of IED equipped with arc
protection
Fault current

Fault current can be limited by using current limiting devices such as current limiting breakers, grounding
resistors or fuses. If the fault current is limited to 5 amperes or less, then many ground faults self-extinguish
and do not propagate into phase-to-phase faults.

Arcing time

Arcing time can be reduced by temporarily setting upstream protective devices to lower setpoints during
maintenance periods, or by employing zone-selective interlocking protection (ZSIP). With zone-selective
interlocking, a downstream breaker that detects a fault communicates with an upstream breaker to delay its
instantaneous tripping function. In this way "selectivity" will be preserved, in other words faults in the
circuit are cleared by the breaker nearest to the fault, minimizing the effect on the entire system. A fault on a
branch circuit will be detected by all breakers upstream of the fault (closer to the source of power). The
circuit breaker closest to the downstream fault will send a restraining signal to prevent upstream breakers
from tripping instantaneously. The presence of the fault will nevertheless activate the preset trip delay
timer(s) of the upstream circuit breaker(s); this will allow an upstream circuit breaker to interrupt the fault, if
still necessary after the preset time has elapsed. The ZSIP system allows faster instantaneous trip settings to
be used, without loss of selectivity. The faster trip times reduce the total energy in an arc fault discharge.
Arcing time can significantly be reduced by protection based on detection of arc-flash light. Optical
detection is often combined with overcurrent information.[13] Light and current based protection can be set
up with dedicated arc-flash protective relays, or by using normal protective relays equipped with an add-on
arc-flash option.

One of the most efficient means to reduce arcing time is to use an arc eliminator that will extinguish the arc
within a few milliseconds. The arc eliminator operates in 1-4 ms and creates a 3-phase short-circuit on
another part of the system, typically upstream at higher voltages. This device contains a fast contact pin that
upon activation by an external relay, makes physical contact with the energized bus which then creates the
short circuit. The arc eliminator will protect a human if they are standing in front of the arc flash event and
the relays detect the arc flash by diverting the arc flash to another location, although the diversion may
cause a system failure at the location the short-circuit was diverted to. These devices must be replaced after
an operation.

Another way to mitigate arc flash is to use a triggered current limiter[14] or commutating current limiter
which inserts a low rated continuous current current limiting fuse that melts and interrupts the arc flash
within 4 ms. The advantage of this device is that it eliminates the arc flash at the source and does not divert
it to another section of the system. A triggered current limiter will always be "Current Limiting" which
means it will interrupt the circuit before the first peak current occurs. These devices are electronically
controlled and sensed and provide feedback to the user about their operational status. They can also be
turned ON and OFF as desired. These devices must be replaced after an operation.

Distance

The radiant energy released by an electric arc is capable of permanently injuring or killing a human being at
distances of up to 20 feet (6.1  m). The distance from an arc flash source within which an unprotected
person has a 50% chance of receiving a second degree burn is referred to as the "flash protection
boundary". The incident energy of 1.2 cal/cm^2 on a bare skin was selected in solving the equation for the
arc flash boundary in IEEE 1584.[15] The IEEE 1584 arc flash boundary equations can also be used to
calculate the arc flash boundaries with boundary energy other than 1.2 cal/cm^2 such as onset to 2nd
degree burn energy. Those conducting flash hazard analyses must consider this boundary, and then must
determine what PPE should be worn within the flash protection boundary. Remote operators or robots can
be used to perform activities that have a high risk for arc flash incidents, such as inserting draw-out circuit
breakers on a live electrical bus. Remote racking systems are available which keep the operator outside the
arc flash hazard zone.

Research
Both the Institute of Electrical and Electronics Engineers (IEEE) and the National Fire Protection
Association (NFPA) have joined forces in an initiative to fund and support research and testing to increase
the understanding of arc flash.[16] The results of this collaborative project will provide information that will
be used to improve electrical safety standards, predict the hazards associated with arcing faults and
accompanying arc blasts, and provide practical safeguards for employees in the workplace.

Standards
OSHA Standards 29 CFR, Parts 1910 and 1926. Occupational Safety and Health
Standards. Part 1910, subpart S (electrical) §§ 1910.332 through 1910.335 contain
generally applicable requirements for safety-related work practices. On April 11, 2014,
OSHA adopted revised standards for electric power generation, transmission, and
distribution work at part 1910, § 1910.269 and part 1926, subpart V, which contain
 requirements for arc flash protection and guidelines for assessing arc-flash hazards, making
reasonable estimates of incident heat energy from electric arcs, and selecting appropriate
protective equipment (79 FR 20316 et seq., April 11, 2014[17]). All of these OSHA standards
reference NFPA 70E.
The National Fire Protection Association (NFPA) Standard 70 - 2014 "The National
Electrical Code" (NEC) contains requirements for warning labels. See NEC Article 110.16 &
NEC Article 240.87
NFPA 70E 2012 provides guidance on implementing appropriate work practices that are
required to safeguard workers from injury while working on or near exposed electrical
conductors or circuit parts that could become energized.
The Canadian Standards Association's CSA Z462 Arc Flash Standard is Canada's version
of NFPA70E. Released in 2008.[18]
The Underwriters Laboratories of Canada (http://www.ulc.ca/)'s Standard on Electric Utility
Workplace Electrical Safety for Generation, Transmission, and Distribution CAN/ULC S801
The Institute of Electronics and Electrical Engineers IEEE 1584 – 2002 Guide to Performing
Arc-Flash Hazard Calculations.[19]

Arc flash hazard software exists that allows businesses to comply with the myriad government regulations
while providing their workforce with an optimally safe environment. Many software companies now offer
arc flash hazard solutions. Few power services companies calculate safe flash boundaries.

Notable incidents
In a notable industrial accident at an Astoria, Queens Con Edison substation on December 27, 2018 a
138,000 volt coupling capacitor potential device failed which resulted in an arc flash which in turn burned
aluminum, lighting up the sky with blue-green spectacle visible for miles around. The event was
extensively covered in social media and LaGuardia Airport temporarily lost power, but there were neither
deaths nor injuries.[20][21]

References
1. Safe Work Practices for the Electrician by Ray A. Jones, Jane G. Jones -- Jones and Bartlett
Publishing 2009 Page 40
2. "The Great Internet Light Bulb Book, Part I" (http://donklipstein.com/bulb1.html#wbs).
Archived (https://web.archive.org/web/20130910060844/http://donklipstein.com/bulb1.html#
wbs) from the original on 2013-09-10. Retrieved 2013-11-12.
3. KM Kowalski-Trakofler, EA Barrett, CW Urban, GT Homce. "Arc Flash Awareness:
Information and Discussion Topics for Electrical Workers (https://www.cdc.gov/niosh/mining/
userfiles/works/products/videos/arcflash/afa.pdf) Archived (https://web.archive.org/web/2017
0829135448/https://www.cdc.gov/niosh/mining/userfiles/works/products/videos/arcflash/afa.
pdf) 2017-08-29 at the Wayback Machine". DHHS (NIOSH) Publication No. 2007-116D.
Accessed January 10, 2013.
4. Electrical Safety in the Workplace By Ray A. Jones, Jane G. Jones -- National Fire
Protection Agency 2000 Page 32
5. Electrical Injuries: Engineering, Medical, and Legal Aspects By Robert E. Nabours,
Raymond M. Fish, Paul F. Hill -- Lawyers & Judges 2004 Page 96
6. Electric power generation: Transmission and distribution By S. N. Singh -- PHI Limited 2008
Page 235--236, 260--261
 7. Hoagland, Hugh (August 3, 2009). "Arc Flash Training & PPE Protection" (http://ohsonline.c
om/Articles/2009/08/03/Arc-Flash-Training-PPE.aspx?p=1). Occupational Health & Safety.
Archived (https://web.archive.org/web/20120722215403/http://ohsonline.com/Articles/2009/0
8/03/Arc-Flash-Training-PPE.aspx?p=1) from the original on 2012-07-22. Retrieved
2011-02-22.
8. ARC Flash Hazard Analysis and Mitigation by J. C. Das -- IEEE Press 2012
9. Electrical Safety Handbook 3E By John Cadick, Mary Capelli-Schellpfeffer, Dennis Neitzel --
McGraw-Hill 2006
10. High Voltage Engineering and Testing By Hugh McLaren Ryan -- Institute of Electrical
Engineers 2001
11. "Archived copy" (http://www.hse.gov.uk/pubns/indg354.pdf) (PDF). Archived (https://web.arc
hive.org/web/20171031131057/http://www.hse.gov.uk/pubns/indg354.pdf) (PDF) from the
original on 2017-10-31. Retrieved 2017-10-14.
12. J. Phillips. "[1] (http://www.ecmag.com/?fa=article&articleID=11275) Archived (https://web.ar
chive.org/web/20110710165947/http://www.ecmag.com/?fa=article&articleID=11275) 2011-
07-10 at the Wayback Machine". Electrical Contractor. U.S. Accessed April 20, 2010.
13. Zeller, M.; Scheer, G. (2008). "Add Trip Security to Arc-Flash Detection for Safety and
Reliability, Proceedings of the 35th Annual Western Protective Relay Conference, Spokane,
WA" (http://www.selinc.com/WorkArea/linkit.aspx?LinkIdentifier=id&ItemID=3547). Archived
(https://www.webcitation.org/6IHcF9BLR?url=https://www.selinc.com/WorkArea/DownloadA
sset.aspx?id=3547) from the original on 2013-07-21. Retrieved 2009-11-30.
14. "Current Limiting Protector" (http://www.gwelec.com/current_limiting_system.html). Archived
(https://web.archive.org/web/20160627211101/http://www.gwelec.com/current_limiting_syst
em.html) from the original on 2016-06-27. Retrieved 2016-06-14.
15. '1584 IEEE Guide for Performing Arc-Flash Hazard Calculations.' IEEE Industry
Applications Society. September 2002
16. "IEEE/NFPA Collaborative Research Project" (http://standards.ieee.org/esrc/arcflash/index.h
tml). Archived (https://web.archive.org/web/20070729223522/http://standards.ieee.org/esrc/a
rcflash/index.html) from the original on 2007-07-29. Retrieved 2007-07-03.
17. "OSHA final rule revising its electric power standards" (https://www.osha.gov/FedReg_osha
_pdf/FED20140411.pdf) (PDF). Archived (https://web.archive.org/web/20140518205012/http
s://www.osha.gov/FedReg_osha_pdf/FED20140411.pdf) (PDF) from the original on 2014-
05-18. Retrieved 2014-05-18.
18. CSA Electrical Safety Conference (http://www.csa.ca/news/Workplace_Electrical_0507.pdf)
Archived (https://web.archive.org/web/20070928230836/http://www.csa.ca/news/Workplace
_Electrical_0507.pdf) September 28, 2007, at the Wayback Machine
19. IEEE 1584 Working Group website (http://grouper.ieee.org/groups/1584/index.html)
Archived (https://web.archive.org/web/20070608034115/http://grouper.ieee.org/groups/1584/
index.html) June 8, 2007, at the Wayback Machine
20. Daly, Michael (December 28, 2018). "The Real Reason the Sky Turned Turquoise in NYC
The glow was generated by burning aluminum when one small bit of decidedly earthly
Queens became momentarily hotter than the sun" (https://www.thedailybeast.com/heres-why
-the-sky-turned-turquoise-in-nyc). The Daily Beast. Archived (https://web.archive.org/web/20
181229160834/https://www.thedailybeast.com/heres-why-the-sky-turned-turquoise-in-nyc)
from the original on 2018-12-29. Retrieved 2019-01-01.
21. Haddad, Patrick (December 31, 2018). "Con Ed: New York 'transformer explosion' actually
an arc flash" (https://www.powertransformernews.com/2018/12/31/con-ed-new-york-transfor
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w-york-transformer-explosion-actually-an-arc-flash/) from the original on 2019-01-01.
Retrieved 2019-01-01.

External links
Arc Flash Awareness video available on YouTube (https://www.youtube.com/watch?v=j2XH
aIOMtYw) or from NIOSH (https://www.cdc.gov/niosh/mining/works/coversheet1839.html)
Arc Flash Guide (http://cdn.thomasnet.com/ccp/30155299/171931.pdf)
Arc protection system example YouTube (https://www.youtube.com/watch?v=a28X4lQYrFo)

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