E-Ep-J100 - Job Aid - Ee's - Rev 1.0

Electrical Procedure
Job Aid
E-EP-J100 - Electrical System Study
Revision: 1.0
This document contains information proprietary to Cargill, Inc. and shall not be reproduced, transferred to other documents or disclosed to others for any
purpose other than for which it is furnished without the prior written permission of Cargill, Inc.
Plant System and Controls PS&C Doc ID E-EP-J100
Job Aid Rev. 1.0

Electrical System Study Project
Table of Contents
I. REVISION HISTORY ..................................................................................................................................................... 4
II. DOCUMENT APPROVAL .............................................................................................................................................. 4
III.PURPOSE ................................................................................................................................................................... 4
IV. SCOPE ........................................................................................................................................................................ 4
V. REFERENCES............................................................................................................................................................... 5
SUPPORTING DOCUMENTATION ................................................................................................................................................ 5
INDUSTRY STANDARDS ............................................................................................................................................................ 5
VI. GLOSSARY.................................................................................................................................................................. 6
GLOSSARY ............................................................................................................................................................................. 6
ABBREVIATION ....................................................................................................................................................................... 8
PERSONAL QUALIFICATION REQUIREMENTS ............................................................................................................... 9
PERSON CONDUCTING THE ELECTRICAL SYSTEM STUDY ................................................................................................................... 9
PERSON REVIEWING THE ELECTRICAL SYSTEM STUDY ...................................................................................................................... 9
CARGILL TRUSTED INTEGRATOR................................................................................................................................................. 9
GOVERNANCE ......................................................................................................................................................................10
APPLICABLE STANDARDS .......................................................................................................................................... 11
SHORT CIRCUIT CALCULATION ................................................................................................................................................11
IEC regulated countries ..........................................................................................................................................11
NEC - North America...............................................................................................................................................11
ARC FLASH HAZARD ANALYSIS ................................................................................................................................................11
NFPA70E .................................................................................................................................................................11
ISSA .........................................................................................................................................................................11
TOOLS TO BE USED FOR THE STUDY .......................................................................................................................... 12
WORKFLOW ............................................................................................................................................................. 13
STUDY REQUIREMENTS ............................................................................................................................................ 14
SCOPE OF THE STUDY ............................................................................................................................................................14
DATA COLLECTION AND VERIFICATION ......................................................................................................................................15
MODEL OF THE ELECTRICAL NETWORK ......................................................................................................................................17
LOAD FLOW OR POWER FLOW STUDY (LFS)..............................................................................................................................18
SHORT CIRCUIT STUDY (SCS) .................................................................................................................................................19
PROTECTION SYSTEM STUDY (PSS) .........................................................................................................................................20
STABILITY AND DYNAMIC STUDY (SDS) ....................................................................................................................................21
ARC FLASH HAZARD ANALYSIS (AHA) ......................................................................................................................................22
PARAMETERS FOR THE SHORT CIRCUIT CALCULATION ..................................................................................................................23
PARAMETERS FOR THE PROTECTION SYSTEM STUDY ...............................................................................................................23
PARAMETERS FOR THE ARC FLASH CALCULATION ...................................................................................................................24
NFPA70E .................................................................................................................................................................26
ISSA .........................................................................................................................................................................27
VERIFICATION..................................................................................................................................................................29
Voltage profile ........................................................................................................................................................29
Electrical equipment (Circuit Breakers, Switchboard/Switchgear) ........................................................................29
Transformers ..........................................................................................................................................................32
LV Cables ................................................................................................................................................................32
HV Cables................................................................................................................................................................34
RECOMMENDATIONS ........................................................................................................................................................34
CONTENT OF THE REPORT ........................................................................................................................................ 36
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SUMMARY ..........................................................................................................................................................................36
Load flow and Short Circuit Study: .........................................................................................................................36
Protection System Study:........................................................................................................................................36
Arc Flash Hazard Analysis:......................................................................................................................................36
Stability and dynamic study ...................................................................................................................................36
STRUCTURE OF THE ELECTRICAL NETWORK:................................................................................................................................36
Description..............................................................................................................................................................36
Single line................................................................................................................................................................37
SCOPE OF THE STUDY AND ASSUMPTIONS ..................................................................................................................................38
Scope ......................................................................................................................................................................38
Standard .................................................................................................................................................................38
Tools .......................................................................................................................................................................38
Operational Modes.................................................................................................................................................38
Network Loads ........................................................................................................................................................38
Applied Protection scheme .....................................................................................................................................38
Protection data .......................................................................................................................................................40
INPUT DATA ........................................................................................................................................................................40
RESULT FOR THE LOAD STUDY .................................................................................................................................................40
RESULT FOR THE SHORT CIRCUIT CALCULATION ...........................................................................................................................40
VERIFICATION (VOLTAGE DROP, OVERLOAD AND SHORT CIRCUIT) ...................................................................................................41
Voltage Profile ........................................................................................................................................................41
Electrical equipment (Circuit Breakers, Switchboard/Switchgear ) .......................................................................41
Transformers ..........................................................................................................................................................43
LV Cables.................................................................................................................................................................43
HV Cables................................................................................................................................................................44
RESULTS FOR THE PROTECTION SYSTEM STUDY ..........................................................................................................................44
Selectivity Charts HV faults (phase and earth fault) -existing setting ...................................................................45
Selectivity Charts HV faults (phase and earth fault) -proposed setting ................................................................45
Selectivity Charts LV faults (phase and earth fault) -existing setting....................................................................45
Selectivity Charts LV faults (phase and earth fault) -proposed setting .................................................................46
STABILITY AND DYNAMIC STUDY .............................................................................................................................................46
ARC FLASH HAZARD ANALYSIS............................................................................................................................................46
RECOMMENDATIONS ........................................................................................................................................................47
ARC FLASH LABELS ............................................................................................................................................................48
NFPA70E – NEC version ..........................................................................................................................................48
NFPA70E – IEC version............................................................................................................................................48
ISSA .........................................................................................................................................................................48
7. DELIVERABLES.......................................................................................................................................................... 49
APPENDIX A – SAMPLE WORKFLOW ................................................................................................................................ 50
APPENDIX B1 – SELECTIVITY CHART HV FAULT ................................................................................................................. 51
APPENDIX B2 – SELECTIVITY CHART HV EARTH FAULT ...................................................................................................... 52
APPENDIX B3 – SELECTIVITY CHART LV FAULT.................................................................................................................. 53
APPENDIX C – PROTECTION AND SELECTIVITY PHILOSOPHY ............................................................................................. 54
APPENDIX D – SAMPLE LABELS FROM CARGILL SITES ....................................................................................................... 56
...............................................................................................................................................................................................56

Job Aid Rev. 1.0

I. Revision History
Revision Description Date Author Status
A Initial version for discussion 06.04.2017 A. Lehr Draft

B Content added to the outline 28.09.2017 A. Lehr Draft
Updated arc flash labels and split verification part from
C section 6 into requirement (5.5) and reporting (6.7). 22.10.2017 A. Lehr Draft
Rev for F2F meeting in Houston.
D Discussion during F2F meeting in Houston 22.11.2017 D. Voss Draft
Incorporation of input from EMEA EBPO and small
E 15.12.2017 A. Lehr Draft
group review
After review by external companies – final version for
F 02.01.2018 A. Lehr Draft
approval
1.0 Approved after COE call 16.04.2018 A. LEHR Approved
II. Document Approval
Revision Approver Position Signature Date
A. Lehr Corporate Electrical Lead 16.04.2018

1.0
Leader Plant systems and
J. Davison 16.04.2018
Controls
III. Purpose
The purpose of this job aid is to give guidance on the content of the electrical system study, which is required
by the electrical procedure of the plant systems and controls (PS&C) policy.
The Intended audience of this document is as follows:
1. Cargill employees accountable for the electrical installation of a Cargill operated site
2. Cargill or 3rs party subject matter experts (SME) for electrical design, operation and maintenance
3. Electrical integrators executing electrical studies for Cargill
IV. Scope
The scope of this document includes all parts of the electrical system study as detailed by the electrical
procedure. These are:
• Load Flow or Power Flow Study (LFS)
• Short Circuit Study (SCS)
• Protection System Study (PSS), also known as Selectivity Study
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• Stability and dynamic study (SDS)

• Arc flash hazard analysis (AHA)
V. References
Supporting Documentation
The following documents are referenced in this job aid:
Revision Reference Title Date Modified Purpose

Document issued by the EMEA LP
organization. References to basic
protection philosophy regarding, safety,
- 050.06.002_BP Protection System Study -
selectivity and back up protection.
Guideline for protection setup on various
different electrical equipment.
organization. This document gives further
- 050.06.002_BP Electrical System Study - detailed requirements for Electrical
Systems Studies executed by the EMEA
Build Project organization.
organization. The operating manual
Operating Manual “Electrical System
1.0 24.11.2017 describes the fundamentals and the
Study”
assumptions for standardization of the
different calculations and verifications.
Industry Standards
The following industry standards and guidelines have been referenced in the preparation of this job aid:
Revision Reference Title Date Modified Purpose

EN-IEC 60909-0 Short-circuit currents in
Recommended standard for the Short
2016 three-phase a.c. systems Part 0: -
Circuit Calculation
Calculation of currents
ANSI/IEEE 399 - Recommended Practice for
Industrial and Commercial Power System - -
Analysis (brown book)
ANSI/IEEE 242 - Recommended Practice for
Protection and Coordination of Industrial - -
and Commercial Power Systems
NFPA 70E – Standard for Electrical Safety in
2015 - Reference for the Arc Flash Calculation
the Workplace

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ISSA –Guideline for the selection of

personal protective equipment when Recommended standard for the Arc Flash
2011 -
exposed to the thermal effects of an Calculation
electric arc – ISBN 978-3-937824-08-6
IEEE 1584 - Guide for Performing Arc-Flash Recommended standard for the Short
2002 -
Hazard Calculations Circuit and Arc Flash Calculation
IEEE 1584.1 - Guide for the Specification of
Scope and Deliverable Requirements for an
2013 -
Arc-Flash Hazard Calculation Study in
Accordance with IEEE Std 1584
IEEE C37.20.7 – Guide for Testing Metal- Exception that arc flash energy limitation is
2017 Enclosed Switchgear Rated Up to 38 kV for - not required when arc resistant switchgear
Internal Arcing Faults is installed.
IEC 61641 - Enclosed low-voltage
Exception that arc flash energy limitation is
switchgear and control gear assemblies –
2014 - not required when arc resistant switchgear
Guide for testing under conditions of
is installed.
arcing due to internal fault
IEC 62271-200: High-voltage switchgear
and controlgear - Part 200: AC metal- Exception that arc flash energy limitation is
2011 enclosed switchgear and controlgear for - not required when arc resistant switchgear
rated voltages above 1 kV and up to and is installed.
including 52 kV
VI. Glossary
Glossary
Terminology Definition
Load Flow or power flow Analysis of the power systems in normal steady-state operation
study (LFS) and different potential switching states obtaining information
of the magnitude of the voltage at each bus, and the real and
reactive power flowing in each line.
Short circuit study (SCS) Determination of the short-circuit current available at each
component of the electrical system in normal steady-state
operation and different potential switching states to ensure the
ability of the component to withstand and/or interrupt the
current and to provide the required data for protection system
study.
Protection system study Determination of the protective device settings to minimize
(PSS) hazards to personnel and equipment while allowing the least
disruption of power service.
This is also known as Coordination, Selectivity or Discrimination
Study
Stability and dynamic study Calculation of voltage dips for motor starting and
(SDS) determination of the ability of the electrical system’s
synchronous machines to remain in step with one another
following a disturbance.

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Arc flash hazard analysis Determination of arc-flash incident energy levels and flash
(AHA) protection boundary distances based on the results of short-
circuit and coordination/selectivity studies.
Interconnection Station The interconnection station is the switchboard/switchgear in
(ICS) the plant which is directly connected to the public grid,
connecting the Cargill network to the public grid on the HV
level. This is sometimes also referred to as Utility Point of
Connection. Not all Cargill sites will have an ICS – some plants
might be fed directly on the LV side. See blow under ICP.
Main Distribution Station The main distribution station is the central HV
(MDS) switchboard/switchgear from which all sub distribution stations
are fed. In flat networks, HV motors and transformers are
directly fed from the MDS. Generators are usually connected to
the MDS. Sometimes the ICS and the MDS are integrated in one
panel.
Sub Distribution Station The sub distribution station is a HV switchboard/switchgear
(SDS) which is feeding HV motors and transformers. SDS are fed out
of MDS or connected to other SDS via ring lines or back up
connections. They are usually found in bigger plants which
have individual SDS per process areas (e.g. refinery, wet mill,
dry mill, power house, etc.)
Interconnection Panel (ICP) The interconnection station is the switchboard/switchgear in
the plant which is directly connected to the public grid,
connecting the Cargill network to the public grid on the LV
level. This is sometimes also referred to as Utility Point of
Connection. Not all Cargill sites will have an ICP – some plants
might be fed on the HV level or have the MCCs directly
supplied on the LV level by grid owned transformers. See also
above under ICS.
Main Distribution Panels Primary electrical LV switchboard/switchgear located
(MDP) downstream electrical distribution transformers, feeding
various secondary panels, MCCs or other electrical equipment,
such as PFC units, UPS, packet units, etc. They usually have
feeding breakers in the range of few thousand ampere.
Sub Distribution Panel (SDP) Secondary electrical LV switchboards, which are fed by UPS,
MCCs or MDPs. Typical examples are lighting distribution
panels, auxiliary power supply panels, UPS distribution panels.
They are located several levels downstream the distribution
transformers and usually have feeding breakers in the range of
400 … 64A.
Motor Control Center Electrical LV or HV switchboards, which contain mainly motor
(MCC) starter. Usually these panels are either directly fed by
individual transformers (in flat networks) or they are fed by
MDS/MDP. Very often MCCs are grouped by process areas.
MCCs can be combined with MDPs.
Inverse Definite Minimum Tripping characteristic of electrical protection devices, which
Time (IDMT) are time and current dependent. Also known as ANSI 51
(overcurrent protection function). IEEE and IEC recognize
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different standardized tripping curves, such as Normal Inverse

(NI), Very Inverse (VI) or Extreme Inverse (EI).
Definite Time (DT) Tripping characteristic of electrical protection devices, which
have a fixed time that is independent from the current. Also
known as ANSI 51 (delayed phase current over protection
function).
IS limiter IS limiters are fault current limiting devices that use explosive
devises (similar like the ones used in air bag systems) and
current-limiting fuses to interrupt the fault current within the
first quarter of a cycle before the current reaches its peak
value.
Abbreviation
Terminology Definition
CT Current Transformer
CHRC Cargill Hazard Risk Category
ISSA International Social Security Association
MDPR Maximum Demonstrated Production Rate
OEM Original Equipment Manufacturer
PDP Process Delivery Process
PPE Personal Protection Equipment
PS&C Plant Systems and Controls
SME Subject Matter Expert
TCC Time Current Curve
UPS Uninterruptable Power Supply
VFD Variable Frequency Drive
VT Voltage Transformer

Job Aid Rev. 1.0

Personal Qualification Requirements

Person conducting the electrical system study
The electrical study shall be conducted under the supervision and approval of an electrical engineer, specifically
trained and individually skilled in performing and interpreting electrical studies as detailed by this document.
The professional electrical engineer shall meet the following minimum requirements:
• Engineering degree (bachelor or master) in electrical engineering
• Full-time employee of an equipment manufacturer or an engineering firm
• A minimum of five years of practical experience in the execution of all individual parts of the electrical
studies
• In depth knowledge of the regionally applicable codes and standards as mentioned but not limited to
section Vb of this document
The engineering firm shall demonstrate the experience of their personnel by submitting names of at least ten
electrical studies which were conducted by the professional electrical engineer in the past years. On request of
Cargill an example of an electrical study conducted by the professional electrical engineer shall be submitted to
Cargill.
Person reviewing the electrical system study

The electrical study should be reviewed by a Cargill engineer (SME) unless the study is executed by a Trusted
Integrator. The Cargill engineer shall meet the following minimum requirements:
• Engineering degree (bachelor or master) in electrical engineering or approved equivalent
• In depth knowledge of the regionally applicable codes and standards as mentioned but not limited to
section Vb of this document
• In depth knowledge of Cargill’s Corporate Electrical procedure and its referring job aids
• Knowledge of the electrical installation under investigation in the electrical system study
This person is also referred to as electrical expert of Cargill (SME). Many Cargill sites will not have electrical experts
on site. Electrical experts are usually part of the central AEI teams of the Cargill enterprises, Cargill Engineering
Teams and the corporate Electrical COE.
Cargill Trusted Integrator

A Cargill Trusted Integrator is an engineering firm that is approved by Cargill for the execution of Electrical System
Studies in a certain geography. The Trusted Integrator needs to comply with all requirements as listed under 1.1.
The quality of work of the Trusted Integrator is review by Cargill Electrical SMEs before the Trusted Integrator status
is granted and on a regular base, at least every three years. A list of all Trusted Integrators is published on the PS&C
website.

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If a Cargill Trusted Integrator is used for the execution of the Electrical System Study, a review of the study as
mentioned under 1.2 is not required.
A Trusted Integrator approach can only be selected, if the Trusted Integrator was not involved in the detail
engineering of the electrical network on a site.
Governance
The Cargill Trusted Integrator status (1.3) is approved by the corporate Electrical COE.
Persons reviewing the electrical study (1.2) are approved by the corporate Electrical COE on corporate level or by
the Electrical or AEI leads of the relevant Cargill enterprises on enterprise level.

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Applicable standards
Short Circuit Calculation
Either of the two norms mentioned below shall be followed, depending if a country is following IEC norms or
NEC/IEEE. Countries which do not follow either of the two regulations shall select one of the two norms, provided
there is no legal obligation that prevents their use.
In case that none of the two listed norms can be applied, separate consultation with the Corporate Electrical COE is
required.
IEC regulated countries

The short-circuit calculation shall be performed in accordance with IEC 60909-0. This method is based on the
introduction of an equivalent voltage source at the short circuit location. The equivalent voltage source is the only
active voltage of the system. All other elements of the network are replaced by their internal impedances.
NEC - North America

The short-circuit calculation shall be performed in accordance with ANSI/IEEE 1584.
Arc Flash Hazard Analysis

The arc flash hazard analysis shall be executed according to one of the two standards mentioned below. The
preferred standard is NFPA70E, but there are some possible legal limitations that could drive the use of ISSA in
some countries.
NFPA70E
Arc Flash Hazard Analysis shall be done per the requirements set forth in NFPA 70E. The arc flash calculation shall
be performed according to the IEEE 1584 equations for systems or portions of systems which operate between
230V and 15kV and are presented in NFPA70E-2015, Annex D4.
ISSA
For regions where the use of NFPA70E is not permitted due to legal limitation, the Arc Flash Hazard Analysis shall be
done per the requirements set forth in the ISSA Guideline for the selection of personal protective equipment when
exposed to the thermal effects of an electric arc.

Job Aid Rev. 1.0

Tools to be used for the study

Cargill has evaluated several short circuit and arc flash calculation tools. The following tools are accepted to be used
to execute electrical system studies. The selection of the software is left to the Cargill enterprises:
Preferred Software for IEC Preferred Software for North America

regulated countries and countries following ANSI code
Load Flow or power flow study
Short Circuit Study Neplan, latest approved SKM Systems Analysis Power*Tools
Protection System Study revision for Windows (PTW), latest revision
Stability and Dynamic Study
• SKM Systems Analysis
Power*Tools for Windows
Neplan, latest approved (PTW)2, latest revision (≤ 15kV)
revision1 • ARCPRO Electrical Arc Hazard
Assessment software (> 15kV)
Notes:
1 Neplan has a known issue with calculations over different voltage levels; these need to be corrected manually
2 SKM is limited to the arc flash calculation according to NPFA70E up to 15kV only
The currently approved version of Neplan for the use in Cargill is v 5.5.7

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Workflow
It is essential to maintain a standardized workflow for the electrical system study in order to ensure that data is
correctly collected, the study is addressing all possible operational modes of the electrical network and all
recommendations are in line with Cargill’s requirements and well understood by the location. Below are some key
points:
• Basic information provided by the plant: This information is required by the engineering firm to evaluate
the required effort for the study and to enable them making an offer. This basic information will include the
plant single line and the operation mode, especially if the plant has more than one power sources (e.g. are
there any emergency couplings, are parts of the plant running on emergency power generators, is the own
power generation always running parallel with the grid or can the plant run in island mode, etc.). This
information needs to be supplied by the Cargill plant to the engineering firm.
• Detailed information: This information is required by the engineering firm to build the electrical model of
the plant and to evaluate the electrical equipment (e.g. generator and transformer datasheets, load lists,
breakers lists with type model and short circuit rating, trip units/protection relay models, setting of
protection relays, cable schedule, load list, etc.). This information needs to be supplied by the Cargill plant
to the engineering firm unless the Cargill plants orders the on-site data collection from the engineering
firm. If data cannot be verified as accurate from the existing plant documentation, then onsite collection by
a third party is required. This might require a de-energization of parts of the electrical network to retrieve
the information on site. Another way to gather the information is by cross reference with electrical testing
records.
• Discussion of the protection philosophy: The overall protection philosophy should be proposed by the
engineering firm to the plant, based on the requirements of the plant before the Protection System Study is
done. As part of the overall protection philosophy, selective time intervals, requirements for back up
protections, selectivity requirements, arc flash energy levels, etc need to be agreed. The overall protection
philosophy is usually a compromise between reliability (maximum selectivity) and safety (minimum arc
flash energies). It is required to have an electrical SME of Cargill included in the presentation.
• Draft report: The draft report is prepared by the engineering firm and shall be submitted for discussion with
electrical SME of Cargill, that review the report for approval. Most Cargill sites will not have electrical SME
on site which requires central electrical experts of the Cargill enterprises, electrical experts of Cargill
Engineering organizations or the corporate Electrical COE to be involved. The approval of the draft report
by one of the electrical SME of Cargill is an important step in the process.
• Presentation: The final, approved report is presented to the Cargill plant. The presentation shall include the
executive summary which is intended for the supervisors of that site as well as all detailed
recommendations which is intended for the local electrical team. The aim of the presentation is to transfer
the ownership of the report from the engineering firm to the location, to ensure all recommendations are
correct and understood by the local team and that the local team agrees to the recommendations and
commits to implement them. It is recommended to have an electrical SME of Cargill included in the
presentation.
• Delivery of the electrical model and the report: The final report and the electrical plant model shall be
delivered to Cargill and stored electronically, in a readable and editable format. Cargill claims all rights on
both, the report and the electrical model. Both are considered intellectual property of Cargill.
• All recommendations are added into Enablon for tracking purposes by the plant.
A recommended sample workflow is given in Appendix A.
Job Aid Rev. 1.0

Study requirements
Scope of the study
The electrical system study shall cover the complete electrical HV and LV network, starting from the grid connection
(ICS) and all internal permanent and temporary power generation sources down to the bus bars of all distribution
systems (e.g. motor control centers, lighting cabinets, heat trace cabinets, etc. – MCC/SDP).
The following circuits are not part of the scope:

• Branch circuits, such as motor cables less than 1000V, lighting cables or heat tracing cables
• Circuits less than 240V as per IEEE 1584
• Circuits fed by transformers of 125 kVA or less as per IEEE 1584
• Circuits fed by UPS systems
Separate calculations and/or measurements shall be available for these circuits to prove they are correctly
engineered and safely protected.
Temporary generators require special considerations, because the exact data of the generator that is going to be
hooked up to the network is unknown. The connection of such a generator will require an investigation, unless this
generator is shown on the single line diagram and minimum technical data is available. In this case an operational
scenario can be created for the generator feed, however it must be ensured by the site, that only generators that
comply with the technical requirements as assumed by the study are hooked up to the network.
The electrical system study shall cover all possible operation modes of the electrical network as this will impact all
parts of the study (load flow, short circuit, arc flash hazard). If a plant can be operated in different modes (e.g.
transformers running in parallel or separated, generators running parallel with the grid or in island mode, open
versus closed rings, parts of the plants supplied by emergency generators, coupling of diesel generators and steam
turbines during start up, etc.) all possible operation modes need to be investigated in the electrical study. The worst
case scenarios shall be used for evaluation of the equipment (maximum short circuit levels), the selection of the trip
settings (minimum short circuit levels) and for the Arc Flash Hazard Evaluation (current/time combination that
results in highest energy – this is not necessarily the maximum short circuit)
All investigated operation modes shall be mentioned in the electrical system study. In case that an operation mode
is deemed to be unsafe it shall be mentioned specifically in the electrical system study.
The verification of the star (earthing) point connections (connections between the neutral of the
transformer/generator and earth/ground) are part of the scope of the electrical study.
It is important to know the network earthing system, as the grounding has an impact on the short circuit calculation
and the protection setting. For solidly grounded networks, phase to phase and earth fault protection can usually be
combined in one protection function, while for isolated or high resistance grounded networks, separate calculations
and protection functions are required. The network earthing system shall be documented during the study.

Job Aid Rev. 1.0

Data Collection and verification

The following data is required to execute the Electrical System Study. The collection of the data is an important and
integral step of the electrical system study. Part of the data might be retrieved from the plant documentation (e.g.
public grid data). Other data might be collected from the plant documentation, however a field verification of the
data is required to ensure that the data is correct and up to date. Some of the data verification will require to de-
energize the system.
• Public Grid
o Nominal voltage in kV
o Nominal frequency in Hz
o Minimum and maximum short circuit power in MVA
o Minimum and maximum short circuit current in kA
o Minimum and maximum Earth fault current in A or kA
o Earthing method (e.g. isolated, reactance earthed, resistance earthed, compensated, solidly
grounded) and size of the earthing device, if applicable
o Ratio R/X
o Contractual data: Maximum available power, minimum requested power factor
o Minimum and maximum operational voltage as per local grid code
• Generators
o Rated voltage in kV
o Rated frequency in Hz
o Rated Current in A or kA
o Rated power in MVA or kVA
o Rated power factor (cos phi)
o Synchronous Reactance xd in %
o Transient Reactance x’d in %
o Sub-transient Reactance x’’d in %
• Transformers
o Type (oil or dry) and cooling method (natural, forced)
o Apparent power in MVA
o Vector group
o Short circuit impedance voltages uk and uR in %
o Rated voltage on primary and secondary side in V or kV
o Tap changer type and setting (e.g. ± 2.5/5% - current setting +2.5%)
o No load and short circuit losses P0 and PK in W or kW
o Protection devices fitted on the transformer (e.g. Buchholz relay, DGPT, temperature sensors in the
coil, top oil temperature sensor)
• Cables (HV and LV)
o Type (cable designation according to local standard, e.g. N2XSEY)
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o Number of cores – for single core connections indicate the laying conditions (e.g. trefoil, flat, flat
with distance) and grouping (e.g. phases individually grouped, groups with three phases and
neutral, etc.)
o Type and cross section of shield (if applicable)
o Type of armour (if applicable)
o Length (for IEC countries in m or km)
o No. of parallel cables
o Rated current in A
o Conductor cross section (for IEC countries in mm2)
o Conductor material (e.g. copper, aluminium)
o Insulation material (e.g. PVC, XLPE, oil impregnated paper)
o Sheath material (e.g. PVC, rubber)
o Laying conditions (e.g. no. of cables on the same cable tray, type of cable tray – slotted tray, ladder,
ambient temperature, laying in air or underground )
• Switchboards/Switchgear/MCC panels (HV and LV)
o Type and model of the switchboard/switchgear
o Rated frequency in Hz
o Rated main bus bar current in kA (ANSI continuous current)
o Rated short circuit current in kA/time (e.g. Icw 1 sec) (ANSI short time current rating, typically given
for 500 msec as symmetrical rms current)
o Rated peak short circuit current in kA (e.g. Ipk) (ANSI momentary current – 10 cycle rms current
including DC component)
• Protection Devices with existing settings (e.g. short circuit breaker and protection relays or short circuit
breaker with integrated trip unit)
o Type and model of the breaker
o Rated current in kA (ANSI continuous current)
o Rated short circuit current in kA/time (e.g. Icw 1 sec) (ANSI short time current rating, typically given
for 500 msec or 30 cycles as symmetrical rms current)
o Rated peak short circuit current in kA (e.g. Ipk) (ANSI close and latch rating – depending on year of
construction)
o Rated short circuit breaking current in kA (e.g. Ics and Icu) (ANSI circuit breaker interrupting duty)
o Rated short circuit making current in kA (e.g. Icm) (ANSI – not applicable)
o Number of poles
o Type and model of the protection relay or rather trip unit
o Overload protection type (IDMT, DT), range and setting for time and current. For IDMT add the
available trip characteristics (e.g. IEC-NI, IEC-VE, IEC-EI, IEEE-NI, IEEE-VI, IEEE-EI, i2t, i4t)
o Short time delayed range and setting for time and current
o Instantaneous short circuit release range and setting
o Earth fault protection range and setting for time and current
o CT (if fitted) with primary and secondary current, power and type/overloadability (e.g. 200/1A,
10P10) for phase current and core balance
Job Aid Rev. 1.0

• Motors (all HV and large LV as defined by this standard)

o Rated current in A
o Rated Power in kW or HP
o Power factor
o Efficiency
o Speed in rpm
o Ratio Starting Current – Rated Current
o Moment of inertia J in kgm2 or GD2
o Load during normal operation
o Ratio Breakdown Torque / Rated Torque
o Ratio Starting Torque / Rated Torque
o Starter type (across the line, soft starter, VFD)
• Power Factor Correction Units
o Rated Voltage in kV
o Rated Frequency in A
o Rated reactive power per stage in kVAr and number of stages (e.g. 8*50kVAr)
o Filter type, if fitted (e.g. 5,67% or 7%)
• Motor list per MCC
o List with all connected motors with rated voltage, rated current, rated power, efficiency and power
factor
o All VFD supplied motors to be marked individually
o Utilization (load factor) for the complete MCC or each individual motor
o Diversity factor for the complete MCC or each individual motor
• Consumer list with all thermal loads per switchboard (representing heat tracing, lighting, heating, etc.)
o List with all connected load with rated voltage, rated current, rated power factor
o Utilization (load factor) for the complete switchboard or each individual circuit
o Diversity factor for the complete switchboard or each individual circuit
• For existing plants only: Actual load measurement per transformer
o Measured Voltage in kV or V
o Measured Current in kA or A
o Measured power factor
Model of the electrical network

A model of the electrical network shall be built in the tool mentioned in section 3. The model shall show the
following parts of the electrical network:
• Network feeder (Some plants might have more than one connection to the public grid)
• Electrical panels (switchboard, switchgear, panel boards, motor control centres, etc.)
• Switching devices (circuit breakers)
• Protection devices (fuses, protection relays, trip units) including the relevant protection CTs
• Power Factor Correction units
• Generators, HV and LV, including temporary emergency generators if minimum technical data is known
Job Aid Rev. 1.0

• Power, Distribution and Block-Transformers

• HV motors shall be shown individually (>1000V)
• LV motors (≥200kW shall be shown individually; motors < 200kW can be shown as group of LV motors)
• Non motor loads (e.g. heat tracing, lighting, etc.). Loads ≥200kW shall be shown individually; loads <200kW
can be shown as group)
• Cables, external bus bars and overhead lines between the equipment mentioned above
Frequency drives need to be shown together with the motors, as VFD supplied motors will contribute to the load
flow, but not to the short circuit.
The load for the switchgear/switchboard shall be shown as follows (not every switchgear/switchboard will have all
four types of loads connected):
• Group of motors
• Group of motors supplied by VFD
• Thermal load
• PFC units
Note: Instead of motor groups, motors can also be shown individually.
For small plants it is preferred to have all equipment on a single drawing. For bigger, more complex systems, an
overview drawing is required showing the complete HV system, with individual drawings per substation/process
area.
Load Flow or Power Flow Study (LFS)

The load flow study shall document the flow of energy in the complete electrical network from the interconnection
station (ICS or ICP) down to the motor control centres (MCC) and sub distribution panels (SDP). The load flow shall
be determined for each individual branch of the network.
The purpose of the load flow study is to ensure that electrical equipment, such as transformers, cables, bus bars,
switches, fuses, current transformers and short circuit breakers are not overloaded and that an acceptable voltage
level is kept within the limits of the grid code. The correct modelling of the electrical load is also important for the
calculation of the contribution of the LV and HV motors to the short circuit current.
For the load flow study, the following electrical values shall be determined for all parts of the electrical network:
• Apparent power in [MVA] and % of nominal
• Real power in [MW]
• Reactive power in [MVAr]
• Current in [A] and % of nominal
• Voltage in [V] and % of nominal voltage
• Power factor
Job Aid Rev. 1.0

The load for the load flow study is taken from load lists (motor list, consumer list) assuming a utilization and
diversity factor. Since the loads in the electrical model are always an assumption (usually the size of motors is
known, but not the exact utilization and diversity factor) it is recommended to cross check and update the load flow
calculation of the plant with measured data.
For existing plants the calculated load flow shall be crosschecked with measured values. If detailed load lists cannot
be retrieved from the plant documentation for some switchgear/switchboard it is acceptable to take the load from
measured values. In order to get reliable and correct data it is required to measure data over a period of 30 days,
capturing high demand times (e.g. during peak season, cold weather condition for heat tracing, night time for the
lighting, MDPR trial run, etc.) with a sufficient resolution (min. one value per minute).
The load study shall be done without the consideration of power factor correction (PFC) units. The result of the load
flow study shall then be used to investigate the need and size of PFC units. If PFC units are required to operate the
electrical network within voltage and load limitations, a second load flow calculation shall be provided, including
the PFC units.
Short Circuit Study (SCS)

The short circuit study is the base of the protection system study and the arc flash hazard analysis. It is also
required to evaluate the integrity of the electrical installation to ensure that the electrical equipment is sufficiently
rated to withstand the thermal and mechanical effects during a short circuit.
The short circuit study shall calculate the maximum and the minimum short circuit in each branch of the network.
The earth fault current and earth leakage current needs to be calculated separately for isolated networks and high
resistance/reactance grounded networks. For these networks two sets of calculations and selectivity charts need to
be provided. For solidly grounded systems, the earth fault and the phase to phase fault are included in one set of
calculation and one set of selectivity chart.
The short circuit contribution of motors for the calculation of the maximum short circuit shall be taken into account
as prescribed by the relevant norm as mentioned in section 2.1. A group of LV motors can be represented by one
replaced LV motor for the calculation as described in section 5.3.
The following short circuit currents shall be calculated:
Maximum short-circuit currents

The maximum short circuit shall be calculated considering the contribution of motors for normal operation and the
worst case operation mode (e.g. running a generator in parallel with the grid or running transformers in parallel).
• Initial symmetric short circuit current Ik”max (Three phase symmetrical first cycle bolted short-circuit current
Isc sym and Total Asymmetrical rms current Isc tot)
• Peak short circuit current ip(Maximum first half cycle crest current Isc crest)
• Breaking short circuit current Ib (Calculated rms short circuit current interrupting duty or calculated total
asymmetrical rms short circuit interrupting duty)
Job Aid Rev. 1.0

• Thermal short circuit current Ith (Short Circuit currents at operating times for time delayed relaying devices)
The maximum short circuit current is usually the 3 phase short circuit current, however, close to the transformer
secondary side, the earth fault current or phase to phase short circuit current might reach higher values
Minimum short-circuit currents

The minimum short circuit current shall be calculated without contribution of motors for normal operation
considering the network earthing system and the worst case operation mode (e.g. running a generator in island
mode).
• Initial symmetric short circuit current Ik”min (Three phase symmetrical first cycle bolted short-circuit current
ISC sym and Total Asymmetrical rms current ISC tot)
The minimum short circuit current is usually the phase to phase short circuit for isolated and high resistance
earthed networks. For solidly grounded networks the minimum short circuit value depends on the fault location;
usually the single phase short circuit current (earth fault) has the lowest value while close to the transformer
secondary side, the phase to phase short circuit current might reach lower values.
Protection System Study (PSS)

The protection system study (Coordination Study) is the base for the arc flash hazard analysis. It is also required to
ensure that all electrical equipment in the network is properly protected against overload condition and that
electric faults are detected and defective branches are switched off.
For each electrical protection device in the electrical network the following shall be verified:
• The electrical protection device protects the downstream equipment from thermal damage (e.g. cable, bus
bar, transformer, motor)
• The electrical protection device trips in case of a short circuit (phase to phase and earth fault)
• The electrical protection device does not trip during start up or planned and acceptable short time overload
conditions of the downstream equipment (e.g. motor start, transformer inrush current)
• Only the faulted part of the network will be disconnected from the network, keeping as much as possible of
the installation powered up (selectivity)
The electrical protection system study shall follow the protection philosophy of the location, which shall be
described in the electrical system study and which is location specific (e.g. requirement for backup protection,
selectivity versus minimization of arc flash energy). The electrical protection philosophy will always be a
compromise between maximum safety and equipment protection on one side and service continuity on the other
side.
For the Protection System Study the calculated minimum short circuit currents have to be compared with the
settings of the protection devices (short circuit breakers with protection relays/trip units, fuse characteristics). It
shall be checked whether and how fast the protection device will react in case of a failure. The results of the
Protection System Study shall be presented in selectivity charts in log-log scale (also known as TCC – Time Current

Job Aid Rev. 1.0

Curve). Each of them includes the incoming switch of the electrical panel together with all upstream protection
devices, which are in the scope of this study.
The following currents shall be shown on the selectivity chart (not every bullet point applies to every chart):
• Minimum short-circuit current on the HV side
• Maximum short circuit current on the LV side
• Minimum short-circuit current on the LV switchboard/switchgear including arc reduction factor
• The minimum current on the transformer primary side in case of a short circuit/earth fault on the
secondary side
• Nominal transformer LV current
• Transformer in-rush characteristic and thermal damage curve
• HV motor in-rush characteristic and thermal damage curve
• Nominal and start up current of the largest consumer (e.g. motor) connected to the switchboard
• Motor inrush current of the biggest motor connected to the system downstream
• Generator thermal damage curve
Guidance on the preferred protection philosophies which should be applied in the electrical system study is given in
Appendix C and in the engineering guidelines which are referenced in section Va.
Recommendations shall be made to optimize the safety and the reliability of the system.
Stability and Dynamic Study (SDS)

The stability and dynamic study is required to verify that the electrical system is able to switch on and off big
electrical consumers. It is required under the following situations:
• Plant is started up with (diesel) generators
• Parts of the plant need to run on emergency generators during a shutdown or rather power outage
• Plant is running in island mode with own power generation
• Switching of single suppliers which are bigger than 25% of the feeding transformer
The stability and dynamic study needs to be executed for individual loads (e.g. switching of a large, single motor).
During the study the following shall be evaluated:
• The electrical protection will not trip during the start due to the high start current (e.g. inrush current)
• The electrical equipment is able to cope with the starting current (no damage due to overload)
• Voltage level in the whole network remains within tolerances during the start
• Generators will not trip during the switching/starting
A result of the stability and dynamic study can be a list of restrictions (e.g. the motor can only be started if two
transformers are running in parallel or the motor can only be started with a soft starter or rather VFD).

Job Aid Rev. 1.0

Arc Flash Hazard Analysis (AHA)

The arc flash hazard analysis shall be done at all branches of the network, including all locations in the electrical
distribution system (switchboards, switchgear, motor-control centres, panel boards, busway and splitters) where
work could be performed on energized parts.
The Arc-Flash Hazard Analysis shall include all significant locations in 240 volt and 208 volt systems fed from
transformers equal to or greater than 125 kVA where work could be performed on energized parts.
The following values shall be calculated during the arc flash hazard analyse:
• The arc flash energy E in [cal/cm2] or [kJ] – preferred unit is [cal/cm2]
• The arc flash boundary DB in [cm] or [inch]
• The required level of PPE (either ATPV, category or class)
• Predicted arc fault current Ia in [kA]
Recommendations shall be made to achieve the following:

• Limitation the arc flash energy to the lowest possible values while still maintaining a minimum level of
selectivity
• Arc flash level should not exceed the following levels1:
o 8 cal/cm2 / 318 kJ (Class 2, for ISSA based design) for new installations where serviceable parts are
located or where devices require operation
o 40 cal/cm2 / 318 kJ (Class 2, for ISSA based design) - at any place in the system2
• Arc flash energy should never be based on the max allowed clearing time as determined by the code, but
always be based on the actual tripping time of a protection device, which has to act faster than the max
allowed clearing time.
Two separate sets of arc flash calculations shall be done for locations that have a maintenance mode integrated in
their electrical distribution system. The maintenance mode is a separate set of trip parameters which is
programmed in the electrical protection devices, which is activated by key switch and which is reducing the delay
time of the protection units to the minimum possible time in order to achieve maximum limitation of the arc flash
energy during maintenance works and operational tasks.
1 Note: The limitation of the arc flash energy to the levels described above is not required if arc resistant/arc proof
gear is used in line with IEC61641, IEC62271-200 (IAC Classes) or IEEE C37.20.7 and it can be ensured that operation
and maintenance is done with either all doors closed and latched or de-energized. This is typically the case for
modern, HV switchgear and for some LV main distribution systems.
2 Note: If the arc flash energy cannot be limited to the values given in the section above, alternative protection
methods must be implemented, such as remote racking, maintenance mode for the protection setting or work with
the bus de-energized.

Job Aid Rev. 1.0

Parameters for the Short Circuit Calculation

Voltage factors apply in line with applicable code for the determination of the maximum and the minimum short
circuit current.
In absence of individually discussed and agreed parameters, the following parameters shall be used as standard
values for the calculation of the short circuit currents:
• Time delay for the calculation of the breaking current Ib: 100 msec @ 50Hz or rather 84 msec @ 60Hz
• Time duration for determination of thermal short circuit current Ith: 1 sec
The parameter for the breaking current equals the delay of a 5 cycle breaker.
Parameters for the Protection System Study

For the calculation of the minimum short circuit currents on the LV network an additional reduction factor of 50%
shall be applied to the calculated bolted fault current to cover the additional impedance of the electric arc in case
of an arcing fault. To cover tolerances of the protection devices, an additional safety factor of 80% shall be applied.
Unless specified differently, the following reduction factors apply:
Protection Arc Reduction Safety Factor Total

device Factor Reduction
Factor
LV distribution Circuit Breaker 0.5 0.8 0.4
circuits Fuse 0.5 1.0 0.5
LV final Circuit Breaker 1.0 0.8 0.8
branches Fuse 1.0 1.0 1.0
HV Circuit Breaker 1.0 0.8 0.8
Fuse 1.0 1.0 1.0
Adequate time margins shall be considered between the protection devices to enable selectivity and back up
protection. The following standard values shall be used as guidelines:
• Between two HV breakers: 250 .. 300 msec
• Between two LV breakers: 100 .. 150 msec
A deviation from these guidelines is possible, if required by the installed equipment or due to limitations, e.g. given
by the public grid.

Job Aid Rev. 1.0

Parameters for the Arc Flash Calculation

The short-circuit calculations and the corresponding incident energy calculations for multiple system scenarios must
be compared and the greatest incident energy must be uniquely reported for each equipment location. Calculations
must be performed to represent the maximum and minimum contributions of fault current magnitude for all
normal and emergency operating conditions. The minimum calculation will assume that the utility contribution is at
a minimum and will assume a minimum motor contribution (all motors off). Conversely, the maximum calculation
will assume a maximum contribution from the utility and will assume the maximum amount of motors to be
operating. Calculations shall take into consideration the parallel operation of synchronous generators with the
electric utility, where applicable.
The incident energy calculations must consider the accumulation of energy over time when performing arc flash
calculations on buses with multiple sources. Iterative calculations must take into account the changing current
contributions, as the sources are interrupted or decremented with time. Fault contribution from motors and
generators should be decremented as follows:
a) Fault contribution from induction motors should not be considered beyond 5 cycles.
b) Fault contribution from synchronous motors and generators should be decayed to match the actual decrement
of each as closely as possible (e.g. contributions from permanent magnet generators will typically decay from 10
per unit to 3 per unit after 10 cycles)
When performing incident energy calculations on the line side of a main breaker (as required per above), the line
side and load side contributions must be included in the fault calculation.
Miss-coordination should be checked amongst all devices within the branch containing the immediate protective
device upstream of the calculation location and the calculation should utilize the fastest device to compute the
incident energy for the corresponding location.
For each equipment location with a separately enclosed main device (where there is adequate separation between
the line side terminals of the main protective device and the work location), calculations for incident energy and
flash protection boundary shall include both the line and load side of the main breaker.
Depending on the type of switchgear, up to three different values shall be given for a switchgear. This is depending
on the internal separation of the switchgear:
• _IN: Incoming compartment (protected by the breaker upstream)
• _BB: Bus bar compartment (protected by the incoming breaker)
• _OUT: Outgoing compartment (protected by the outgoing breaker)
The short circuit is the same for all three compartments, but the tripping time is different, as the tripping time
depends on the location of the fault. The picture below on the left side shows the typical section of a LV distribution
switchgear with separate feeder, bus bar and outgoing cable compartments (IEC form 4).

Job Aid Rev. 1.0

Left picture: Example of a LV switchgear with internal separation and three different arc flash energies. Right
picture: Example of a switchgear without internal separation – the complete switchgear has only one arc flash
energies, determined by the HV short circuit breaker upstream.

Job Aid Rev. 1.0

NFPA70E
Safe working distance (arc flash boundary) shall be based upon the calculated arc flash boundary considering an
incident energy of 1.2 Cal/cm2.
Delay time relay: In case the relay/trip unit is set to instantaneous trip a standard value of 20 msec shall be used as
relay response time.
Breaker opening time is set as standard for 70 msec as breaker response time unless actual opening times are given
by the manufacturer.
Total arcing time: Arc Flash calculations shall be based on actual overcurrent protective device clearing time.
• The total arcing time = Delay time relay + Breaker opening time (when short circuit breakers are used)
• Total Arcing time = Current retrieved from the TCC of the fuse at the calculated arcing current (for fuses);
the upper limit of the band shall be considered if the trip curve is given as a band.
Maximum clearing time will be capped at 2 seconds based on IEEE 1584-2002 section B.1.2. Where it is not
physically possible to move outside of the flash protection boundary in less than 2 seconds during an arc flash
event, a maximum clearing time based on the specific location shall be utilized.
Working distance (mm): The value as recommended by IEEE 1584, which is the sum of the distance between the
worker standing in front of the equipment and from the front of the equipment to the potential arc source.
Equipment Working distance [mm] Working distance [inch]

HV switchgear 910 36
LV switchgear 610 24
LV MCC and panelboards 455 18
Cable 455 18
Other To be determined in the field
Depending on actual situation the worker can get closer to the exposed conductive part. In these cases the distance
shall be determined individually form drawings or by measurements and the arc flash energy shall be calculated at
the lower distance.
Gap: Unless more detailed values are available, the following standard values shall be used in line with IEEE 1584:
Equipment Working distance [mm] Working distance [inch]

HV switchgear up to 15kV 152 6
HV switchgear up to 5 kV 104 4
LV switchgear 32 1.25
LV MCC and panelboards 25 1
Cable 13 0.5
Switchgear type: Arc in a box for electrical panels; on transformers with open terminals: Open Air.
Motor contribution: Considered for the calculation of the maximum short circuit as mentioned in section 5.5
Job Aid Rev. 1.0

PPE level: Cargill has defined the following table for PPE selection. The selection of the PPE can be done based on
the actual, calculated arc flash hazard energy or based on the PPE level. If the later method is used, the PPE shall be
selected to max the max. arc flash hazard energy of the PPE level.
Cargill Hazard Risk Calculated Arc Flash incident energy

Category (CHRC) [cal/cm2]
0 < 1.2
1 1.2 ≤ … < 4
2 4≤ … <8
3 8 ≤ … < 25
4 25 ≤ … < 40
Dangerous 40 ≤
ISSA
Normalized Arc Power kp
The parameter kP is the normalized arc power and is mainly a function of the arc voltage UB = f (d; I"k; UrN; R/X) and
thus, a function of the electrode gap that is determined by the conductor spacing d and the construction of the
electric plant. Empirical equations for determining the arc voltage are given in special literature, and special
knowledge is required, among others, regarding the power equipment construction.
For a rough estimation without considering the switchgear geometry the maximum values of the kP-curves may be
used. The maximum values of the normalized arc power kPmax can be calculated by
k P max = 0,29  ( R / X ) −0,17
The following table shows these values for worst case consideration:
Maximum (extreme) values (EV)

R/X kPmax
< 0,1 0,45
0,1 0,43
0,2 0,38
0,5 0,33
1,0 0,29
2,0 0,26
≥ 2,0 0,25
A standard value of 0.25 can be used as normalization factor in absence of detailed (guided) values.
Arcing Time tk
The arcing or clearing time is determined by the upstream protection. Here the tripping time at minimum fault
current IkLB has to be considered.
Minimum fault current IkLB

Job Aid Rev. 1.0

As minimum fault current IkLB, the minimum three-phase s/c current Ik3pmin has to be considered reduced by the
expected arc reduction factor kB. As standard value, EV as per table below shall be selected:
EV GV DV
Maximum (extreme) values Guided values Detailed value
1,0 0,5 0,3 .. 1,0
Clearing time
The clearing time has to be taken from the TCC of the upstream protective device at IkLB. In case of tolerance ranges,
the upper time value shall be taken.
In cases where breakers with instantaneous protection function are used, the following clearing times shall be used
as standard:
Circuit breaker Instantaneous clearing time
LV ( ≤ 1000 V) 50 ms
MV (1000 V … 35 kV) 100 ms
HV ( > 35 kV) 150 ms
In case of tripping times above 1s, e.g. for circuits above 32A, the required clearing time by IEC 60364-4-41 as
protection against indirect contact would be 5s, it can be assumed that the person performing the work will move
away from the fault location latest after 1s and will increase the working distance significantly. Therefore the
tripping time shall be capped at 1s.
Transmission factor
The distribution of the arc and therefore the transmitted arc energy is depending to the configuration of the fault
location where the arc might occur. According to the literature, only three different configurations and therefore
three different transmission factors are considered:
Box volume = 1,6 l

Side and rear walls Only rear wall or bigger Arc is burning free/open
Limited volume volume for the arc burn Very big volume for the arc burn
kT = 1,0 kT = 1,5 …1,9 kT = 2,4
Unless specific details are given for the location a transmission factor of 1.0 shall be selected.
Working Distance
Working Distance a
The working distance ‘a’ is the distance between the arc and the body of the person working in the considered area.
For different work activities the lowest created distance has to be considered. Typical distances are 300 mm up to
600 mm. In cases where the working distance is unknown, a distance of 300 mm is a reasonable assumption which
normally will not be fallen below.

Job Aid Rev. 1.0

Verification
The verification section is an important and integral part of the electrical system study. In this section the voltage
profile of the electrical system is verified and the load of the electrical equipment is compared to the calculated
load. Additionally the rating of the electrical equipment is crosschecked with the calculated short circuit currents
and the overload protection settings are compared to the rated current.
The following equipment shall be verified:

• Circuit Breakers, Switchgear/Switchboard
• Transformers
• LV cables
• HV cables
Voltage profile
To ensure that the electrical equipment can be operated safely and reliably within its design limit it needs to be
ensured, that the voltage is kept within acceptable tolerances in the complete network under all possible
operational scenarios. The verification shall be done for all electrical switchboard/switchgear (ICS, MDS, SDS, MDP,
MCC, SPD) in the network.
For this verification the rated voltage of the equipment shall be compared with the calculated voltage under the
worst case operational scenario. Unless otherwise specified, the calculated voltage shall remain within the
following limits during normal operation:
• HV switchboard/switchgear (IS, MDS, SDS): 95% - 105 % of the rated voltage

• LV switchboard/switchgear (MCC, MDP, SDP) : 100% - 105% of the rated voltage
The additional safety margin for the LV switchboard/switchgear is to cover the additional voltage drop on the
motor cable. This will ensure that the terminal voltage on the motor is >95% of the rated voltage. Preferred voltage
at the motor terminal is 100%, which would require the MCC bus bar to be >102%, depending on the engineered
voltage drop of the motor cable.
Electrical equipment (Circuit Breakers, Switchboard/Switchgear)

Electrical switchboard/switchgear is composed out of bus bars and circuit breakers which are mounted in an
enclosure. The electrical rating of the switchboard/switchgear is determined by the electrical rating of the internal
components. In the model of the electrical network, the switchboard/switchgear is usually represented by the bus
bar, while the circuit breakers are shown individually. In this section of the study it shall be verified for both
internal components that they are capable to withstand the thermal and mechanical effects of a short circuit, that
they are sufficiently rated for the continuous operation and that they are not overloaded.
Overload verification
The load of the electrical equipment shall be calculated and verified as follows:
Load = I cal / Irated < 100%

Job Aid Rev. 1.0

With:
I cal : Calculated load current
Irated: Rated current of the equipment
Overload Protection Verification of switchboards/switchgear

The overload protection of all switchboards/switchgear shall be verified. A switchboard/switchgear is properly
protected against overload when the following condition is met:
Irswb > x * Irbreaker * stf
With:
Irswb: Rated Current of the main bus of the switchboards/switchgear
Irbreaker: Rated current of the feeding breaker
x: Overload Setting of breaker in p.u.
stf: Secure trip factor – describes the upper range of the trip tolerance of a protection device
Examples of secure trip factors according to IEC:

• Secure tripping factors for circuit breakers:
Protection device providing overload protection Conventional Conventional

non-tripping tripping
current current
CB with thermal o/l-protection acc. to IEC 60947-2 1,00∙In 1,20∙In
CB with electronic o/l-protection acc. to IEC 60947-2 1,05∙In 1,20∙In
CB with integrated thermal/magnetic release acc. to IEC 60947-2 1,05∙In 1,30∙In (IDMT)
1,10∙In (DT)
MCBs (Domestic breaker) acc. to IEC 60898 1,13∙In 1,45∙In
MCCBs (manufacturer specific; not defined in IEC) 1,05∙In 1,20∙In
• Secure trip factor of fuses
Range Conventional Conventional

non-fusing fusing current If
current Inf
In ≤ 4 A 1,50∙In 2,10∙In
4 A < In ≤ 16 A 1,50∙In 1,90∙In
16 A < In ≤ 63 A 1,25∙In 1,60∙In
63 A < In ≤ 160 A 1,25∙In 1,90∙In 1
160 A < In ≤ 400 A 1,25∙In 1,80∙In 1
400 A < In 1,25∙In 1,60∙In 1
1 The values are transferred 1 hrs-values as the IEC-values are rated for longer test duration.
Short Circuit Protection verification

To ensure that the electrical equipment (bus bars, circuit breakers) are sufficiently rated for the short circuit and
consequently can withstand the thermal and mechanical stress that occurs during a short circuit, an investigation
shall been done for each switchboard/switchgear. For this investigation a comparison of the calculated maximum
short circuit current with the rated short-circuit currents is required. It is necessary to fulfill all requirements below:

Job Aid Rev. 1.0

A. Requirements for switchboards/switchgear
Mechanical Withstand Capability: Ipk > ip AND
Thermal Withstand Capability: Icw > Ith if Icw is given for 1 sec
Icw² * tcw > Ith² * 1 sec if Icw is given for a different time (e.g. 3 sec)
B. Requirements for circuit breaker
Mechanical Withstand Capability: ICM > ip AND

ICU > ICS > Ib AND
Thermal Withstand Capability: ICW > Ith if ICW is given for 1 sec
ICW² * tCW > Ith² * 1 sec if ICW is given for a different time (e.g. 3 sec)
With:
Ipk = Rated Peak Withstand Current (ANSI momentary current – 10 cycle rms current including DC component)
Icw = Rated Short Term Withstand Current (ANSI short time current rating)
tcw = Rated Short Term Withstand Time
Icm = Rated Peak Withstand Current (ANSI close and latch rating – dep. on year of construction not applicable)
Icu = Rated Ultimate Breaking Current (ANSI circuit breaker interrupting duty – dep. on year of construction not
applicable)
Ics = Rated Breaking Current (ANSI circuit breaker interrupting duty – dep. on year of construction not
applicable)
Ip = Calculated peak short circuit current (ANSI maximum first half cycle crest current ISC crest)
Ib = Calculated breaking short circuit current (ANSI rms short circuit current interrupting duty or calculated total
asymmetrical rms short circuit interrupting duty)
Ith = Calculated thermal short circuit current (ANSI short Circuit currents at operating times for time delayed
relaying devices)
Notes:
• In cases where the thermal current is not sufficient, a verification of the Joule-integral with the calculated
breaking time toff is required. In this case the following equation shall be verified: ICW² * tCW > Ith² * toff . The
breaking time toff is the sum of the mechanical delay of the breaker and the tripping time of the protection
relay
• The maximum short circuit current flowing through the circuit breaker in case of a short circuit downstream
or upstream of the breaker has to be considered. As simplification it is acceptable to take the short circuit
current of the switchgear/switchboard to which the circuit is connected. This will lead to slightly higher
short circuit values as the breaker will never see the full short circuit current, but only the current reduced
by the contribution of its own branch.

Job Aid Rev. 1.0

Transformers
The thermal limits (i2t) of the transformers shall be verified based on the assumption that a transformer can
withstand its full short circuit current for 2 seconds and its full rated current without time restriction. It shall be
demonstrated that the HV protection upstream the transformer trips fast enough so that the thermal limit of the
transformer is not compromised in case of a short circuit.
Each transformer shall have a time/current protection device, that protects the transformer against an overload.
The overload protection of the transformer can be done on the primary or secondary side.
Further protection of the transformer, such as

• Temperature Sensors/temperature relays
• Thermal model of the transformer temperature in the HV relay
• Buchholz/DGPT
are not part of the electrical system study.
The calculated load shall be compared to the rated current of the transformer to ensure that the transformer is
correctly sized for continuous operation. The following condition shall be verified:
I cal ≤ Irated or rarther Load = I cal / Irated < 100%
With:
Irated: Rated current of the equipment
Overload and Short Circuit Protection verification:

The rated current of the transformer shall be shown on the selectivity chart together with the thermal damage
curve (i2t). On the selectivity chart it shall be demonstrated that the upstream protection device trips faster than
the transformer damage curve – the trip characteristic of the protection device shall be selective with the damage
curve of the transformer.
The overload protection is usually done on the LV side with the LV main incoming circuit breaker, but it is also
acceptable to do it with the HV circuit breaker.
LV Cables
The load of the cable shall be calculated and verified as follows:
Load = I cal / Irated < 100%
With:
Job Aid Rev. 1.0


Irated: Rated current of the cable
Overload protection verification

The overload protection of the LV cables shall be verified. A cable is properly protected against overload, if the
following condition is met:
Ircable * r * n > x * Irbreaker for protection with short circuit breakers
Ircable * r * n > x * Irfuse * sft/1.45 for protection with fuses
With:
Ircable: Rated Current of the cable
r: Reduction factor (depending on the ambient and laying conditions)
n: amount of parallel conductor
Irbreaker: Rated current of breaker
Irfuse : Rated current of the fuse
x: Overload Setting of breaker in p.u. (I> in p.u.)
sft: Secure trip factor in p.u.
Note: For cables protected with fuses, the secure trip factor as mentioned in section 5.12.2 needs to be taken into
account. This is not necessary in case short circuit breakers are used, because the secure trip factor of short circuit
breakers is within the overload tolerance of the cable.
For all cables, a reduction factor of 0,79 can be assumed unless more details are available. This equals the following
installation method:
• Multi core cables laid in air
• Ambient temperature 30 °C – Red. Factor 1.0
• Installation on cable ladders with 6 circuits without distance – Red. Factor 0.79
Short Circuit protection verification

The short circuit protection of the LV cables shall be verified. In order to be able to withstand the thermal impact of
a short circuit, the following condition has to be met:
2
𝑖𝑘𝑚𝑎𝑥 ∗ 𝑡𝑜𝑓𝑓 ≤ 𝑘 2 ∗ 𝑆 2
𝑘 𝑠 ∗𝑆 2
the required shutoff time can be calculated to 𝑡𝑜𝑓𝑓 𝑟𝑒𝑞𝑢 ≤ 𝑖 2
𝑘𝑚𝑎𝑥
With:
Ikmax2: Max short circuit current (usually the three phase, initial short circuit current or thermal short circuit
current)
toff: Switch off time (mech. delay breaker tbreaker + trip setting of the relay t>>)
Job Aid Rev. 1.0

k: Material constant, depending on conductor and insulation material

S: cross section of the cable conductor in mm2
A sec
[k ] = 1
mm2
HV Cables
The verification of the HV cables shall follow the same structure as the one of the LV cables as given in the section
above.
Recommendations
All detected deficiencies and opportunities for improvement which are detected during the studies shall be
summarized in the recommendation section. Every recommendation shall be numbered, classified and prioritized
with a criticality rating. The criticality is linked to the classification.
Possible classifications are as follows:
PSET- protection setting inadequate

This recommendation indicates, that the current (or time) setting of the protection device is too high, which will
cause the protection device to trip too late or not at all. As a consequence, equipment or cables can be overloaded
and thermally destroyed, eventually resulting in arc flash events with consequential damage to equipment in the
vicinity of the fault. The selected PPE might become ineffective.
PSET - Protection Setting Inadequate - Criticality: HIGH (P1Si)
EQC – equipment capacity exceeded

This recommendation indicates that the equipment is operated outside of its design limits. Examples of this
category is equipment that is overloaded or not capable to carry, make or break a specific current under normal or
fault conditions. This classification shall be applied when the deficiency cannot be solved with a change in
protection setting. Resolving of this recommendation will typically result in replacement of the equipment or
installation of additional protection equipment upstream (e.g. IS limiter, current limiting fuse, etc.). Example for this
classification is a short circuit breaker that has insufficient short circuit rating.
EQC-1 - Insufficient breaking or making capability - Criticality: HIGH (P1E)

EQC-2 - Insufficient thermal or mechanical short circuit capability - Criticality: MEDIUM (P1E)
EQC-3 - Insufficient overload (thermal) capability - Criticality: LOW – MEDIUM (P2)
BKUP - back-up protection issue

Job Aid Rev. 1.0

This recommendation indicates that an equipment (e.g. electrical panel, cable, etc.) is only protected by one
protection device, which is sufficient according to the electrical code. However, a malfunction of this protection
device will result in the loss of protection, which could cause consequential damage to the equipment in case of a
fault. By following this recommendation a second layer of safety is engineered into the system, increasing the
overall fault tolerance of the system.
BKUP - Backup Protection Missing - Criticality: MEDIUM (P2)
SEL - selectivity issue

This recommendation indicates missing selectivity. This means that in case of a fault a whole area of the network is
switched off rather than the defective branch only. This might result in additional downtime due to the functional
loss of additional equipment and longer downtime, as the identification of the fault might take longer.
SEL - Selectivity Insufficient - Criticality: MEDIUM (P2)
ARC - recommendation to lower arc flash energy.

This recommendation indicates that the arc flash energy on the equipment is unnecessary high. The arc flash
energy is mainly influenced by the delay time of the protection device. A long delay time leads to a high arc flash
energy. By reducing the delay time a lower arc flash energy can be achieved, resulting eventually in lower PPE
requirement.
ARC-1 - Arc flash energy unnecessary high (>cat3/class2) - Criticality: HIGH (P1S)
ARC-2 - Arc flash energy unnecessary high (>cat2/class1) - Criticality: MEDIUM (P2)
ARC-3 - Arc flash energy unnecessary high (>cat1) - Criticality: LOW (P2)
OPT – Optimization
This recommendation is to clean up the setting, make the selectivity chart better readable/understandable by
simplifying the set up. In some cases it will allow for more starting current. This has no impact on selectivity itself.
OPT - Optimization of setting without direct impact - Criticality: LOW (P3)
Note: The classifications are different from the classifications which are used during in the electrical integrity
program and which follow the classification of the mechanical integrity program. The classification used in the
electrical study is selected to better describe the findings. Related classification of the electrical integrity program
are given in brackets (e.g. P1Si, P1E, etc.).

Job Aid Rev. 1.0

Content of the report

The electrical system study shall be documented with a written report. The section below describes the
recommended outline and content of the report. A template for the report is available on the PS&C website.
Summary
This section is a high level summary for management and should be 2 pages max – ideally it would fit on one page.
No details should be given in this section, but it should refer to the detail sections later in the document. The idea
of this section is to allow management to quickly see if major deficiencies have been noted during the execution of
the study. The summary should refer to the four different sections, which are part of the Electrical Study:
Load flow and Short Circuit Study:

Describe if major findings related to short circuit and overload protection exist. Mention if electrical equipment
data was not available or if assumptions had to be made to show that the outcome of the study might not be
conclusive. Describe if electrical equipment was found to be insufficiently rated for short circuit and/or load.
Protection System Study:

Describe if there are major findings related to missing selectivity, as this could impact the plant reliability and if
there are opportunities to improve the protection settings, e.g. by the implementation of backup protection.
Describe if trip settings were identified that do not guarantee a safe trip under all possible fault conditions.
Arc Flash Hazard Analysis:

Describe if there are major findings related to the arc flash study; a major finding is identified by high arc flash
energy, where no PPE exists or rather where the arc flash risk is unnecessary high as it can be lowered with the
exiting protection system. Mention if assets were excluded from the study to indicate that the study is not
complete.
Stability and dynamic study

Describe if there are practical limitations for starting of motors in relation to the operational modes.
Structure of the electrical network:
Description
Give a verbal description of the electrical network and describe how it is operated (e.g. redundant feeding – one
line in standby, internal ring connections open/close, internal emergency connections open/closed, couplings
open/closed, generators only in standby/emergency, running in parallel with the grid versus island mode, etc.)
Describe the network feeding part on the public grid side and describe which data was available and which data had
to be assumed (e.g. are there two redundant feeding lines or is it a ring connection, can the plant be supplied from

Job Aid Rev. 1.0

different transformers on the HV side, are there and short circuit limiting devices, such as reactors or IS limiters,
etc.)
Describe the network earthing system for the LV and the HV side (e.g. isolated, high resistance or reactance
grounded, low resistance grounded/bolted to the ground). Describe where and how every section of the electrical
network is earthed/grounded. This is especially important for installations that can be fed from different sources
(island operation with generator or running off the grid).
Single line
Add a simplified single line of the plant to the report, showing only the main breakers, substations, ring lines and
emergency coupling lines to provide an overview of the network especially for understanding the different
operation modes. See example below:
Inst. 342044K
Kabel 2 (3x150 Al)
Kabel 4 (3x150 Al)

Kabel 3 (3x95 Cu)
Kabel 1 (3x95 Cu)

50/10 kV OSWN
50/10 kV OSWN
50/10 kV OSWN
50/10 kV OSWN
Line in operation
Line not in operation
G Gasturbine
9 MW
To Igma To Igma
MDS + Utility, 1MVA, app. 30A
3*1*630/70mm2 Al, XLPE 150mm2 Al 150mm2 Al
Inst. 342044F
Refinery, 1.6MVA, app. 55A
A-plant, 4MVA, app. 130A

OFF
B-plant, 5MVA, app. 225A
Load out, 1MVA, app. 1A
Public Grid – 3*1*630mm2 Al Protein, 3MVA, app. 75A
condensatorbank
13
389m, 150mm2 Al
21m, 150mm2 Al
205m, 150mm2 Al 11m, 150mm2 Al
Inst.342044B Inst.342044E Inst.342044A Inst.342044H
Kast I Kast II
11 12 13 14 15 16 17 K01 K02 K03 K04 K05 11 12 13
11 12 13
OFF
10C 7 8 14
9 10A 10B 6
119m, 150mm2 Al OFF

OFF
209m, 150mm2 Al
Inst.342044D Inst.342044C
Kast I Kast II
Kast I Kast II Kast III
11 12 13 15 16 17 18 11 12 13 14 15 16 17 18 19 20 21
OFF OFF
4 5 1 2 3
OFF
OFF OFF OFF OFF
x m, xxx mm2
x m, xxx mm2
12m, 150mm2 Al
32m, 150mm2 Al
523m, 150mm2 Al
All possible operational modes (network configurations) shall be listed and described in this section. A reference
number shall be given to each possible operational mode (e.g. OM1, OM2, etc.) to enable easy and consistent cross
referencing from the following sections of the report.

Job Aid Rev. 1.0

Scope of the study and assumptions
Scope
List what is in scope of the study and what is not in scope of the study. The scope should be in line with section 5.1
of this document but can go beyond this or fall behind it if commonly agreed between Cargill and the engineering
firm.
Standard
List to which standard the study was performed. The selection of the standard shall be in line with section 2 of this
document.
Tools
List the tool with name and version that was used to create the study. The tool selection shall be in line with section
3 of this document.
Operational Modes
Describe which operational modes were taken into account for the study and which one were not. Describe which
operation mode delivers the worst case result for maximum and the minimum load flow and short circuit.
Network Loads
Describe how the load of the plant has been modelled for the study. E.g. were single motors modelled, were
motors grouped to a single replacement motor, which diversity factors were assumed on the motor list, how was
actual measured load current transferred back into the modelled load and how was the load split between motor
load and thermal load.
Applied Protection scheme

List here the applied general protection scheme for the study as shown on the example below:

Job Aid Rev. 1.0

HV network structure LV network structure with HV backup
HV network structure LV network structure
Setting unknown NA
HV main incomer
t>> 1.5 sec NA
HV MDS feeder time selectivity with HV ring feeder
No protection NA
HV MDS incomer
t>> 0.7 sec NA
HV Ring Feeders time selectivity with HV transformer
feeder
Only for SDS AH NA
HV SDS incomer t>> 0.4 sec.
time selectivity with HV transformer
feeder
t>> 0.4 sec (t>> 0.3 sec when possible)
HV transformer Feeders (t>> 0.05 sec when possible) Backup for LV breaker;
fastest possible reaction Additional DT stage necessary
t>, I> to protect transformer against

overload (In and i 2t)
NA Feeding MDP:
LV Main Incoming Breakers t>> 0.1 sec
selectivity with LV main Out
Feeding MCC (no sub panels):
t>> 0.05 sec
Reduce Arc Flash Energy
General:
I>> below 50% Ikmin
Ensure trip in Arc Flash event
I> below Ir of transformer
t> to allow starting of biggest motor
being selective with the HV transformer
feeder
NA I> below Ir of cable including a reduction
LV Main Outgoing Breakers factor for laying condition
NA t> to allow starting of biggest motor
MCC Main Breakers being selective with the LV Main
Incoming Breakers

Job Aid Rev. 1.0

Protection data
Describe which library of the tool mentioned under 6.3.3. was used for the protection devices. Add information
retrieved from OEMs if new protection devices were modelled for the study that are not included in the existing
library of the tool or which curves were used from the library instead.
Input data
A list with all data as detailed in section 5.2. The data can be printed in the report or in an Excel list as appendix to
the report. A standardized report template for the input data is available on the PS&C website.
Important note: Sometimes data is missing (e.g. min short circuit from the gird, exact cable length, etc.), which is
required to execute the calculations. In these cases data is assumed and this data shall be properly marked in the
report as being assumed (e.g. by use of a different font and a different colour, e.g. italic red)
Result for the load study

Only relevant and calculated values shall be given in this tabulation. Results shall be given for all operation modes
which are in the scope of supply. It might be necessary to give various tables for the different operation modes in
case they cannot be combined by worst case scenarios.
• For all transformers in the electrical network the following numbers shall be calculated:
o Apparent power in [MVA] and % of nominal (based on loading without cross flow fans and other
auxiliary cooling systems)
o Real power in [MW]
o Reactive power in [MVAr]
o Current in [A]
o Power factor
• For all connections in the electrical network (bus bars, cables, circuit breaker) the following numbers shall
be calculated:
o Current in [A] and % of nominal (based on max continuous rating)
• For all (switchboard/switchgear) the following numbers shall be calculated:
o Voltage in [V] and % of nominal
If the study shows that PFC units are required to maintain the voltage level in the system and to prevent overload
of the distribution system, a second tabulation shall be provided taking into consideration the PFC units.
Result for the short circuit calculation

Only relevant and calculated values shall be given in this tabulation, which means that only absolute minimum and
maximum values are required, as only these will be used further in the report for the protection setting in the
power system study, the arc flash hazard analysis and the equipment verification.

Job Aid Rev. 1.0

It might be necessary to give various tables for the different operation modes in case they cannot be combined by
worst case scenarios.
Currents shall be given for all fault locations in the network.

• Maximum short-circuit currents: All currents as detailed in section 5.5 in [kA]
• Minimum short-circuit currents: All currents as detailed in section 5.5 in [kA] (recommended to report both,
two phase and earth fault current and mark the lower of the two in bold)
• Operational scenario in which they occur
Fault location 3 phase 2 phase 1 phase

max min min
IEC Ik’’ ip ib Ith1sec Ik’’ Ik’’

Operational Operational
IEEE ISC sym ISC crest ISC sym ISC sym
Scenario Scenario
Switchboard/Switchgear kA kA pk kA kA kA kA
Verification (voltage drop, overload and short circuit)

In this section, the protection of the electrical equipment shall be verified to demonstrate that the installation is
properly protected against overload and short circuit.
Voltage Profile
A table shall be created to compare the calculated voltage for all electrical panels in the network with the rated
voltage and the allowed voltage tolerances as defined in section 5.12.1.
Voltage Profile Rated Values Tolerances Calculated values Operational

Scenario
Ur U U
Switchboard/Switchgear kV ±x% kV %
The following color code applies:

Black – The calculated voltage is within the given tolerance
Red + Italic – The calculated voltage exceeds the given tolerance
Electrical equipment (Circuit Breakers, Switchboard/Switchgear )

A table shall be created which compares the rated current of the equipment with the calculated load current:
Load check Rated Values Calculated values Operational

Scenario
Ur Ir Ical Load

Job Aid Rev. 1.0

Circuit Breaker,
kV kA kA %
Switchboard/Switchgear

Black – The calculated current Ical is lower than the rated current Ir (Load < 90%)
Orange + Italic – The calculated current Ical is close to the rated current Ir (Load between 90 and 100%)
Red + Italic – The calculated current Ical is higher than the rated current Ir (Load > 100%)
Overload protection verification
A table shall be created which compares the rated current of the equipment with the setting of the protection
device upstream:
Overload protection Switchboard/switchgear

Protection Device
Rated Values
Ur Ir Type Ir I> setting stf Itrip

Switchboard/Switchgear kV kA ACB/MCCB/Fuse kA p.u. p.u. kA
With: Itrip = Ir * I> setting * stf

Black – The calculated trip current Itrip is lower than the rated current Ir of the switchboard
Red + Italic – The calculated trip current Itrip is higher than the rated current Ir of the switchboard
Short Circuit Protection Verification
Tables shall be created which compares the rated values of the switchboard/switchgear and circuit breakers with
the calculated short circuit values.
Operational
Short Circuit Protection Rated values Calculated Value
Scenario
Ur Icw Ipk Ik”max Ith @ 1sec Ip
Switchboard/Switchgear kV kA/xsec kA kA kA kA
Operational
Short Circuit Protection Rated values Calculated Value
Scenario
Ur Icw Icm Icu Ics Ik”max Ith @ 1sec Ip
Circuit Breakers kV kA/xsec kA kA kA kA kA kA
The following color code applies for these table:
Black – The rated values are above the calculated values – the equipment is sufficiently rated

Job Aid Rev. 1.0

Blue + Italic – The rated values are unknown but because of the small short circuit currents (< 10kA) or
because the switchboard/switchgear is protected by current limiting devices (fuse, MCCB)
no problems are assumed
Orange + Italic – The rated values are unknown – the equipment could not be checked
Red + Italic – The rated values are below the calculated values – the equipment is not sufficiently rated
Transformers
Overload verification:
A table shall be created which compares the rated current of the transformer (without additional cooling) with the
calculated load current:

Scenario
Ur Ir Ical Load
Transformer kV kA kA %

LV Cables
A table shall be created which compares the rated, reduced current of the cable with the calculated load current:

Scenario
Ur Ir Ical Load
Cable kV kA kA %
Note that this table uses the reduced current of the cable, taking into account the reduction factor due to laying
condition, ambient temperatures and number of parallel conductors.

Overload protection and short circuit protection verification

A table shall be created which compares the rated values with the protection setting.

Job Aid Rev. 1.0

Overload and Cable data Calculated Protection device data Req.

short circuit short Time
protection circuit
value
Overload Short Circuit

Type S k- Ir r n Ired cable Ikmax Ir I> I> t>> tbreaker/fuse toff toff req
factor cable breaker/fuse
- A√sec/
Cable mm2 A p.u. p.u. A A p.u. A sec sec sec Sec
mm2
With formulas as given in section 5.12.4:

Ired cable = Ir cable * r * n
I> [A] = Ir breaker/fuse * I> [p.u.]
toff = t>> + t breaker/fuse
toff req = k2 * s2 / ikmax2

Black – Both conditions below are met, which means that the cable is protected
Red + Italic – One of the conditions below is not met
Condition 1 (overload): Ired cable is bigger than I> (in A)

Condition 2 (short circuit): toff < toff requ
HV Cables
The verification of the HV cables shall follow the same structure as the one of the LV cables as given in the section
above.
Results for the Protection System Study

The results of the power system study shall be displayed in form of selectivity charts. The content of the selectivity
chart shall be as described in section 5.6 (tripping curves of the protection devices, nominal currents, minimum and
maximum short circuit currents, thermal damage curves and inrush currents).
Each selectivity chart shall be clearly labelled with the complete title, referring to the switchboard/switchgear
which it represents. All currents and protection devices shall be unambiguously labelled with clear reference to the
single line diagram.
The settings of the protection devices shall be labelled on the selectivity chart. Selectivity charts which show
protection devices from different voltage levels shall show current scales for both voltage levels across the bottom.
Branches which have the exact same equipment and protection setting can be represented by the same selectivity
chart – it is not necessary to duplicate the charts in this case. This is referred to as selectivity path.
The selectivity path shall be shown on the single line, as shown in the example below:
Job Aid Rev. 1.0

Separate selectivity charts shall be provided for LV and HV faults to ease the reading of the selectivity charts. The
HV transformer feeder shall be included in the LV selectivity chart, as this switch should be set up to provide back
up for the LV main incoming breaker.
Separate selectivity charts shall be shown for the existing settings and – in case setting changes are proposed – for
the proposed new settings.
Selectivity Charts HV faults (phase and earth fault) -existing setting

The selectivity chart shall contain a description of all values which are shown on the chart and a list of all identified
problems. Separate charts shall be provided for phase and earth faults.
See appendix B1 and B2 for examples
Selectivity Charts HV faults (phase and earth fault) -proposed setting

The selectivity chart shall contain a description of all values which are shown on the chart. Separate charts shall be
provided for phase and earth faults.
See appendix B1 and B2 for examples
Selectivity Charts LV faults (phase and earth fault) -existing setting

The selectivity chart shall contain a description of all values which are shown on the chart and a list of all identified
problems. For isolated and high resistance grounded networks, separate selectivity charts shall be provided phase
and earth faults. For solidly grounded networks (TN according to IEC) both can be combined on the same chart.
See appendix B3 for examples
Job Aid Rev. 1.0

Selectivity Charts LV faults (phase and earth fault) -proposed setting

The selectivity chart shall contain a description of all values which are shown on the chart. For isolated and high
resistance grounded networks, separate selectivity charts shall be provided phase and earth faults. For solidly
grounded networks (TN according to IEC) both can be combined on the same chart.
See appendix B3 for example
Stability and Dynamic Study

This section should describe all investigated equipment and operational modes. It should mention which
equipment can be operated or rather started in which operation mode and detail why an operation is deemed
impossible.

The results of the arc flash calculation shall be given in form of a table as outlined below. The example below shows
the version for the arc flash calculation according to NFPA70E. For a calculation according to ISSA the table shall be
adopted accordingly.
Arc Flash Evaluation according to IEEE 1584 - 2002/1004a / NFPA 70E - D.8
Plant: Author:
Date: Revision:
Bolted Required
Delay Breaker Total Predicted
Working Equipment Arc Flash Incident Incident Protective FR
Location Voltage Fault time opening arcing Ground Gap Arcing Energy Energy
Distance Type Boundry Clothing
(kV) Current relay time time (mm) Current
(mm) (m) (cal/cm 2) (J/cm 2) Category
(kA)1 (sec) (sec) (sec) (kA)
1 6_SDS_B 0.4 15.0 0.05 0.07 0.12 913 No SWG 153 0.66 3.29 0.7 3 Category 0
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Legend:
Equipment type: Category Explanation: Arc Flash Boundry:
MCC = Motor Control Center Category 0: Untreated Cotton Minimum distance from Arcing Point
SWG = Switchgear Category 1: FR Shirt & Pants where FR clothing is not required anymore
AIR = Open Air Category 2: Cotton Underwear + FR Shirt & Pants
Category 3: Cotton Underwear + FR Shirt & Pants + FR Coverall Calculated value
Ground Category 4: Cotton Underwear + FR Shirt & Pants + Multi Layer Flash Suit Parameter
Yes = Grounded Network Category Dangerous: No FR Category found Result short circuit study
No = High res or ungrounded
Remarks:

Job Aid Rev. 1.0

Recommendations
This chapter details all recommendations, such as changes of the protection settings, replacement of equipment,
changing the operational mode, etc. The reason for a recommendation shall be given together with the
recommendation and a classification and criticality as detailed in section 5.13.
The recommendations shall be given in form of a table:
No. Related Equipment Recommended Action Reason for the recommendation Classification Criticality
Circuit Breaker, Protection relays, e.g. change setting x from A to e.g. insufficient overload protection, device PSET, EQC, Low,
etc. B or replace by … will not trip al very low failure currents, etc. BKUP Medium,
SEL, ARC, High
OPT

Job Aid Rev. 1.0

Arc flash labels

Arc flash labels shall be provided in line with the section below, depending on the applied standard. Existing plants
can keep the current layout, but need to show the information as shown below. New installations are expected to
apply the layout below.
NFPA70E – NEC version
! WARNING Color: Orange (standard), Red (for

arc flash dangerous)
Nominal Voltage of the system Arc Flash and Shock Hazard: Appropriate PPE required per NFPA70E
Failure to comply can result in injury or death Cargill Hazard Risk Category (from
Limited Approach Distance (from Shock Hazard PPE is required to Cargill Hazard table in section 5.11.1)
table in NFPA70E) Boundaries 480 V AC open covers/doors, Risk Category
42 Inches Limited approach reset the overload or
Restricted approach distance (from 12 Inches Restricted approach operate the disconnect 2
table in NFPA70E) Arc Flash Hazard Refer to Cargill Enterprise Electrical
Designation of the
18 Inches 7.5 cal/cm2 Safety Program for a detailed list of PPE location/switchgear
Arc flash energy (calculated) 85 Inches Arc flash boundary for the Hazard Risk Category
Upstream Protection Device
Arc flash boundary (calculated) Location: Protection Device:
NFPA70E – IEC version

arc flash dangerous)
Nominal Voltage of the system Arc Flash and Shock Hazard: Appropriate PPE required per NFPA70E
Failure to comply can result in injury or death Cargill Hazard Risk Category (from
Vicinity Zone (from table in Shock Hazard PPE is required to Cargill Hazard table in section 5.11.1)
EN50110) Boundaries 400 V AC open covers/doors, Risk Category
300 mm Vicinity Zone DV reset the overload or
Life Working Zone (from table in No contact Life Working Zone DL operate the disconnect 2
EN50110) Arc Flash Hazard Refer to Cargill Enterprise Electrical
Designation of the
457 mm 7.5 cal/cm2 Safety Program for a detailed list of PPE location/switchgear
Arc flash energy (calculated) 1.57 m Arc flash boundary for the Hazard Risk Category
ISSA

>class 2)
Nominal Voltage of the system Arc Flash and Shock Hazard: Appropriate PPE required per ISSA
Failure to comply can result in injury or death PPE class according to ISSA (Class
Vicinity Zone (from table in Shock Hazard PPE is required to PPE Class 1, 2 or No PPE available)
EN50110) Boundaries
400 V AC open covers/doors,
Life Working Zone (from table in

300 mm Vicinity Zone DV reset the overload or
operate the disconnect
1
No contact Life Working Zone DL
EN50110) Arc Flash Hazard Refer to Cargill Enterprise Electrical
Designation of the
300 mm 112.9 kJ Safety Program for a detailed list of PPE location/switchgear
Arc flash energy (calculated) for the Hazard Risk Category

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7. Deliverables
The engineering firm executing the electrical study shall supply the following deliverables during the execution of
the electrical study:
• A detailed list with all required data to build the electrical model and execute the study in case that they
are not requested by the site to collect the data themselves on site. The complete filled out list shall be
included as part of the report no matter who does the data collection.
• A proposal for a protection philosophy for the site in line with operational requirements given by the site
and general Cargill standards.
• A preliminary and a final report as detailed in this document – the report shall be available in colour paper
version and in electronic version (Microsoft Word). Cargill claims the full rights on the report.
• The electrical model of the plant as electronic file, including all required libraries for a working model.
Cargill claims the full rights on the electrical model. The model must be built on one of the tools specified
in this document. Intent is that the electronic file can be transmitted to another engineering firm, that
might be working on a project, and that they can load the model and run it without having to create
models and input data.
• A presentation of the results of the electrical study, explaining the overall result (executive summary) and
detailing all recommendations. The presentation can be made via video conference (e.g. Skype) or – as
option – as onsite face to face meeting.
• As option: Arc flash labels shall be provided for all locations listed in the Arc Flash Hazard Analysis.
Depending on the region, additionally individual labels shall be provided for each MCC drawer/bucket.
• As option: Engineering services to do the onsite data collection of all required data to execute the electrical
system study
• For greenfield plants, the study shall be executed in two parts: In the basic engineering phase of the project
(PDP 2b and 3), the model of the electrical network shall be build and the load flow study and short circuit
study shall be executed, to verify that the planned power distribution system can cope with the projected
load and to get the required rated data for ordering the electrical equipment (rated current and rated short
circuit currents). In the detailed engineering phase (PDP4) when the exact equipment is known (e.g. cable
type and length, circuit breaker types, trip units and protection relays, etc.) the rest of the study shall be
executed. The study must be finalized before the start-up of the plant.
• As option: Labels printed and placed on the switchgear
As standard, all deliverables shall be in English language. As option the delivery of the report additionally in local
language and do to the presentation in local language shall be given.

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Appendix A – Sample Workflow
COE Plant Engineering Firm

Explanation:
This workflow is a sample that can be adopted to the local
Trigger to start the Process:
1. New site (e.g. new
Start Process
situation and the locally selected engineering firm.
construciton or purchase)
2. Major changes (e.g. It shows important steps in the process, which sometimes
replacement of switchgear
and/or protection units,
Request for Request for
are left out:
brownfield, addition of
substantial load, etc.) Quotation Information - Discussion of the protection philosophy before the report
3. Regular 5y review cycle as
specified by the electrical is finalized
procedure
4. Major deficiencies Offer with - Approval of draft report by subject matter experts
detected in the existing Basic Information options:
electrical during an electrical A.) Data collection - Presentation of the report on site
inspection
B.) Presentation
on site
Site visit necessary to collect

detailed data?
No Yes
Order
Order w/o Site visit
include Collect detailed data
site visit
site visit
Collect detailed
Build Plant model
data
Calculation
(short circuit currents)
Proposal for
Discussion/Approval protection
philosophy
Draft report
(Discrimination, EQ
evaluation, ArcFlash)
Check/Approval
Adaptation/
Recalculation
Final report
(Input data, breaker
setting table, summary)
Presentation
(done by Engineering Firm – Depending on order via Skype or on site)
Upload Study and

plant model on
central repository
(Version Control)
End Process

Job Aid Rev. 1.0

Appendix B1 – Selectivity Chart HV fault

1000 s
10_IS_K_12/TU_MDS_F1
I>>=400A T=1,5s
In trafo
I>>=500A T=1,5s
10_MDS_F1_11/TU_SDS_C2
I>>=400A T=1,0s
I>>=1000A T=0,700s
10_SDS_C1_13/TU_Tra_1
100 s I=120A T=1,0pu
10/0,4_Tra_1
10,0 s
1,0 s
0,100 s
Ikmin SDS F line 2
Ikmin SDS F line 1
Ikmin Trafo HV
0,010 s
10,0 kV: 0,010 kA 0,100 kA 1,0 kA 10,0 kA
Fig.No.: Chart A - SDS C

Transformer 1 - 3

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Appendix B2 – Selectivity Chart HV earth fault

1000 s
I>>=400A T=1,5s
I>>=500A T=1,5s
10_SDS_AH/CB_incom er
I>=403A T=0,500s
I>>=4070A T=0,300s
10_SDS_AH/CB_incom er
100 s IE>=101A T=0,400s
Ik 10_IS_K_12/TU_MDS_F1
Ik 10_IS_K_16/TU_MDS_F2
10_MDS_F3_21/TU_SDS_AH
3*I0 10_SDS_AH/CB_incomer
I=401A T=1,4s
10,0 s
1,0 s
0,100 s
0,010 s
10,0 kV: 0,010 kA 0,100 kA 1,0 kA 10,0 kA 100 kA
Fig.No.: HV Earth Fault SDS AH

Job Aid Rev. 1.0

Appendix B3 – Selectivity Chart LV fault

1000 s
0,4_MCC_2/incom er
I>=1440A T=4,0pu
I>>=5760A T=0,100s
I>>=9600A T=0,050s
Ikmin HV
0,4_MCC_2/MCC_2-1
I>=400A T=1,0pu
Ikmin MCC 2
Ikmax MCC2
Ikmin MCC 2-1
Ikmax MCC 2-1

I>>=4000A T=0,020s
0,4_MCC_2-1
100 s I=320A T=0,500pu
IEC255-3 extrem ely inv erse
I=480A T=0,100s
10_SDS_C3_17/TU_Tra_2
I=120A T=1,0pu
10,0 s
1,0 s
0,100 s
In trafo
0,010 s
0,400 kV: 0,100 kA 1,0 kA 10,0 kA 100 kA 1000 kA
10,0 kV: 0,010 kA 0,100 kA 1,0 kA 10,0 kA
Fig.No.: MCC 2

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Appendix C – Protection and Selectivity Philosophy

This sections describes a standard protection philosophy that could be implemented in absence of a local
protection philosophy. This philosophy is designed for a radial network and is in use by many Cargill locations
world- wide. It however requires to have short circuit breaker protection on the HV side with a three stage
protection relay (switch B).
Current ranges
• Nominal current of the transformer (0)
• Min and max. current on the LV side (1) and (2)
• Min. current on the HV side (3) downstream outgoing breaker
• Min. current on the HV side (4) upstream outgoing breaker (for limited HV-networks the difference
between (3) and (4) can be neglected)
For the minimum currents the arc reduction factor and safety margin need to be taken onto account.
Green curve: Main HV switch (C): Two stages

• First stage: Trips on HV failure with one selective time interval – between min HV current (3) and max LV
current (2)
• Second stage: Overload protection for the HV system – set to switchboard nominal current with IDMT curve
Note: The instantaneous trip above the HV current (4) is not listed, as usually the two HV currents (3) and (4) will
be in the same range, hence this stage cannot be used.

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Blue curve: Transformer HV switch (B): Three stages

• First stage: Trips on HV failure instantaneously – between min HV current (3) and max LV current (2)
• Second stage: Trips on LV failure with one selective time interval (t3 – t2) – below min LV current (1),
providing backup to the Transformer LV switch (B) in case of a technical defect
• Third stage: Overload protection for the transformer – set to transformer nominal current (0) with IDMT
curve (usually EI); important to take into consideration the starting current of the biggest LV motor
connected to this transformer (orange curve) to avoid spurious tripping during motor start
Note: The dotted blue line shows an alternative set up which requires two stages only, but which results in longer
backup time as the backup is done with the IDMT stage
Red curve: Transformer LV switch (B): Two stages

• First stage: Trips on LV failure instantaneously – below min LV current (1)
• Second stage: Overload protection for the transformer – set to transformer nominal current (0) with IDMT
curve (usually i2t); important to take into consideration the starting current of the biggest LV motor
connected to this transformer (orange curve) to avoid spurious tripping during motor start
Note: The first stage can be set up for instantaneous tripping to reduce the arc flash energy on the LV
switchboard/switchgear. Alternatively it can be set up with a short time delay (t2 – t1) to improve selectivity with
outgoing breakers on the LV switchboard/switchgear, resulting in higher arc flash energies.
Orange curve: Indicates the motor starting current – for proper setup of the system, the starting current of the
biggest connected load to the LV switchboard/switchgear must be considered.

Job Aid Rev. 1.0

Appendix D – Sample labels from Cargill sites
• Category and ATPV of the PPE that must be worn to open this
panel
• People not wearing any PPE must keep this distance (1,07 m).
Unqualified people must be escorted by a certified
electrician.
• Only certified electricians are allowed beyond this point (0,3
m). People must wear PPE for shock hazard (insulating PPE)
WARNING • Category of the PPE that must be worn to open this panel (note
that no exact arc flash value is given to prevent relabelling upon
Arc Flash and Shock Hazard. Appropriate PPE Required per NFPA 70E
Failure to comply can result in injury or death
minor changes)
480 VAC Shock Hazard PPE required to open Cargill HR Category
• Limited Approach Boundary: Distance that unqualified persons
Boundaries covers/door, reset the
must maintain unless escorted by qualified persons and wearing
42 Inches
12 Inches
85 Inches
Limited approach
Restricted approach
Arc Flash Boundary
overload or operate the
disconnect 2 the right PPE (42” = 1.06 m).
Arc Flash Hazard: Refer to Cargill Corn Milling Electrical
• Restricted Approach Boundary: Only certified electricians are
4 - 8 cal/cm² at 18 inches Safety Program for a detailed list of PPE for
the HR Category
allowed beyond this point (12” = 0.3 m). People must wear PPE
Bus: (Enter Bus Name Here) Prot: (Enter Upstream Protective Device)
for shock hazard (insulating PPE)
• Arc Flash boundary: Distance at which the PPE indicated must be
worn when the panel is opened (85” = 2.16 m)
• Class of the PPE that must be worn to open this panel

• Minimum distance that must be obtained from any live part
inside the panel. Any work beyond this zone is considered life
work
• Minimum distance that should be obtained from any life part
inside this panel, unless the part is insulated/touch protected.
Special safety measures apply for any work in this zone.
If the arc flash energy is higher than the maximum available PPE class
as defined by IEC 61482-1-2, then the panel cannot be opened while it
is life.
In this case the definition of the Live Working Zone and the Vicinity
Zone is not necessary.

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Electrical Procedure

E-EP-J100 - Electrical System Study

Job Aid Rev. 1.0

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Revision Description Date Author Status

A Initial version for discussion 06.04.2017 A. Lehr Draft

II. Document Approval

Revision Approver Position Signature Date

A. Lehr Corporate Electrical Lead 16.04.2018

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• Stability and dynamic study (SDS)

Revision Reference Title Date Modified Purpose

Revision Reference Title Date Modified Purpose

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ISSA –Guideline for the selection of

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different standardized tripping curves, such as Normal Inverse

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Personal Qualification Requirements

Person reviewing the electrical system study

Cargill Trusted Integrator

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IEC regulated countries

NEC - North America

Arc Flash Hazard Analysis

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Tools to be used for the study

Preferred Software for IEC Preferred Software for North America

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The following circuits are not part of the scope:

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Data Collection and verification

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• Motors (all HV and large LV as defined by this standard)

Model of the electrical network

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• Power, Distribution and Block-Transformers

Note: Instead of motor groups, motors can also be shown individually.

Load Flow or Power Flow Study (LFS)

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Short Circuit Study (SCS)

The following short circuit currents shall be calculated:

Maximum short-circuit currents

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Minimum short-circuit currents

Protection System Study (PSS)

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