Arc-Flash Hazard Evaluation

Provides Safer and More

Efficient Workplace

David Castor, P.E.

ESA, Inc
Hazards of Arcing Faults
Arcing faults release
dangerous levels of
radiant heat energy,
capable of causing
severe burns.
Fatal burns can occur up
to five feet from the arc,
with serious burns up to
ten feet away.
Clothing is ignited
several feet away.
Hazards of Arcing Faults – cont’d

Arcs spray droplets of molten metal

The vaporization of metal and heating
of the air produces blast pressure
waves that have thrown workers across
room and knocked them off ladders.
This explosion distributes the molten
metal produced by the arc over a large
area
Hazards of Arcing Faults – cont’d

Temperature of Arc Flash?

 Arc Terminals 35,000 deg F
 Plasma Region 22,000 def F
Compare with:
 Surface of the Sun 9,000 deg F
 Curable Burn (1/10 Sec.) 145 deg
 Cell Death (1/10 Sec.) 205 deg
 Burning Clothing 1,400 deg
 Metal Droplets 1,800 deg
 Clothing Ignition 700-1400 deg
Hazards of Arcing Faults – cont’d
Burn Injury – Probability of Survival

100
25% Body Burn
80 50% Body Burn
% Survival

60 75% Body Burn

40

20

0
20 - 29.9 30 - 39.9 40 - 49.9 50 - 59.9

Age Range, Years Revised: March 2002

Source: American Burn Association (1991-1993 Study)

Burn Injury Costs
Cost of treatment can exceed
$1,000,000/case
 Does not include litigation fees
 Does not include process loss
Treatment can require years of skin
grafting and rehabilitation
Victim may never return to work or
retain quality of life
Safety Codes Beginning to
Address the Hazard
Historically, NEC and other safety
codes have been primarily
concerned with protection from
fire, electrocution, and shock
hazard – arc flash hazards were not
addressed
This is changing – the 2002 NEC
contains requirements for warning
labels and NFPA 70E – 2003 and
IEEE 1584 – 2002, provide
guidance on implementing
appropriate safety procedures
OSHA Requirements
1991 – Arc Flash added as a hazard to
Title 29 CFR Subpart S for electrical
safe work practices
OSHA has NOT specifically addressed
Arc Flash requirement
OSHA 1910.132(d), and 1926.28(a).
The employer is responsible to…………
 Assess the hazards in the work place
 Select, have, and use the correct PPE
 Document the assessment
The Nature of Electrical Arcs
An arc is produced by flow of electrical
current through ionized air after an initial
flashover or short circuit.
Arcs produce some of the highest
temperatures known to occur on earth – up
to 35,000 deg F. This is four times the
surface temperature of the sun.
All known materials are vaporized at this
temperature.
Electrical Arcs - continued
As a conductor, arcs have substantial
resistance, with voltage drops of 75 to 100
volts per inch.
For a 480/277 V system, a 3 to 4-inch arc can
become “stabilized” and persist for extended
period of time.
Energy released is a function of fault current
magnitude and fault duration.
Arcs in enclosures, such as MCCs magnify risk
because radiant heat is reflected from
enclosure surfaces.
Reducing Risk from Arc-Flash
Acknowledge there is a hazard
Define the magnitude of the hazard
Address the hazard
 Avoid working on or near exposed energized
equipment
 Where exposure can not be avoided, implement
safety procedures to minimize dangers
 Ensure workers within danger zones are
appropriately protected with suitable PPE
Even Routine Maintenance Work Can
Entail Substantial Risk

Opening door on
MCC starter to check
voltage or replace
fuse
Hotstick operation of
fused cutouts
Replacement of
plug-in breaker on
panelboard
Requirements of 2002 NEC
Article 110.16 requires “field marking” of
potential arc flash hazard for panels likely to
be serviced or examined in energized
condition.
Also contains an FPN regarding proper
signage and an FPN referencing NFPA 70E.
These FPNs are not technically part of the
NEC.
NEC is generally not retro-active, so this
would apply only to new work.
Required Signs per NEC
 Requirements of NFPA 70E
NFPA 70E – “Electrical Safety Requirements
for Employee Workplaces”
Not a legal requirement at this point, but
voluntary adoption is becoming common to
provide a recognized third-party safety
process.
Has been adopted by over 200 companies at
this point – Consensus Standard.
OSHA may incorporate in near future.
Adherence to NFPA-70E satisfies OSHA
hazard assessment.
NFPA-70E Covers Electrical
Safety
NFPA-70E
National Consensus Standard

Developed by NFPA
at the request of
OSHA. Utilized to
augment the simple
1910 Sub Part S
requirements
OSHA and NFPA
OSHA has tasked the NFPA with
addressing both shock and arc
flash hazards in detail for OSHA
adoption (discussions PCIC
2003)
Evolution of NFPA 70E
1994 – NFPA-70E established a flash
protection boundary
2000 – NFPA-70E expands
requirements for flash protection
boundaries and personal protective
equipment (PPE)
2003 – NFPA-70E adopts IEEE-1584
for arc flash calculations (well,
almost)
NFPA 70E Concepts
70E defines a series
of boundaries
related to electrical
safety when working
on energized
equipment
We will discuss each
in turn.
Flash Protection Boundary
Serious injury due
to arc-flash burns
can occur within
this area unless
appropriate PPE is
used.
Anyone within this
area must wear
appropriate PPE
regardless of what
they are doing.
Arc Flash Boundary Defined
The distance from the arc source at
which the onset of a 2nd degree burn
occurs
1.2 Cal/cm2 > 0.1 Sec is considered a
second degree burn threshold
Medical treatment may still be required
if bare skin is exposed to this level of
flash. Full recovery expected.
Limited Approach Boundary
Defines a boundary
around exposed
live parts that may
not be crossed by
“unqualified”
persons unless
accompanied by
“qualified” persons.
May be closer than
flash boundary
Restricted Approach Boundary
Boundary near
exposed live parts
that may be crossed
only by “qualified”
persons using
appropriate shock
prevention
techniques and
equipment
Concern is shock
hazard
Prohibited Approach Boundary
A shock protection
boundary to be
crossed by only
“qualified” persons
using same
protection as if
direct contact with
live part is
planned.
Considerations For Work Near
Live Parts
Can the work be done with equipment
de-energized? This is always
preferred.
How are the various boundaries in NFPA
70E established?
How is the appropriate level of PPE
determined?
De-energizing Equipment
Determining Approach
Boundaries

Limited Approach
Restricted Approach
Prohibited Approach

ALL determined based only on

voltage level
Table 220.2(A)(1)
Determining Flash Protection
Boundary
Based on voltage, available short-circuit
current and predicted fault duration.
NFPA 70E provides THREE acceptable
methods of determining flash protection
boundary:
 Simplified Table 220.2(B)(2)©, 220.6(B)(9),
 Analysis based on NFPA 70E Annex B
 Analysis based on IEEE 1584
Simplified Table – NFPA 70E
220.2(B)(2)(C)

Arc Location System Voltage Flash Protection

Boundary
(Feet)

Arc in Air 200 to 1000 Volts 4

Arc in Enclosure 200 to 1000 Volts 10

Arc in Enclosure 1000 Volts and Up 20

NFPA 70E and IEEE 1584
Calcs
Both calculation methods attempt to compute
the expected arc-flash energy that would be
created by an arcing fault.
This is a worst-case calculation based on
expected fault current, arc length and fault
duration.
IEEE 1584 probably more accurate. NFPA
70E can be non-conservative in some
cases.
Determining PPE Level
Based on expected arcing fault energy
Again, NFPA 70E provides three options:
 Use “cookbook” table in the Standard
 Calculate based on NFPA 70E equations
 Calculate based on IEEE 1584 equations
Per NFPA 70E, Flash Hazard Analysis
must be documented by employer prior
to any work.
Arc Ratings
Arc ratings of PPE are based on the incident
energy level calculated for the worst-case
arcing fault that could occur where the work
is to be done.
Arc energy level is expressed in calories per
square centimeter, or cal/cm2.
This energy level is calculated for the
expected working distance for the task
involved.
Working Distance
Based on distance from
worker’s face and chest
area.
Emphasizes that this
standard is intended to
prevent death and
serious injuries, not
prevent all possible
injuries.
Can increase working
distance to decrease risk.
NFPA-70E, 2003 - PPE
Requirements
Category Energy Typical PPE
Level
1 4 cal/cm2 FR shirt and FR pants

2 8 cal/cm2 FR shirt, FR pants, cotton underwear

3 25 cal/cm2 Two layers of FR clothing, cotton

underwear
4 40 cal/cm2 FR shirt, FR pants, multilayer flash suit,
cotton underwear
5 100 cal/cm2 Same as 4 but greater than 30 oz/yd2
Other PPE Requirements
Face Protection –
Face Shield and/or
safety glasses
Hand Protection –
Leather over rubber
for arc flash
protection
Leather work boots
– above 4 cal/cm2
Flash Hazard Analysis
NFPA 70E requires a flash hazard analysis be
done before “a person approaches any
exposed electrical conductor”.
Can be done using “cookbook” tables or by
two different calculation methods.
EasyPower allows either calculation method
to be used (plus additional options)
Advantages of Detailed
Calculations
More realistic risk
assessment
Increases compliance
by workers - compared
to overly conservative
blanket rules
Self-documenting for
Flash Hazard Analysis
Disadvantages - NFPA Table
Methods

Under Equal
18% 18%

Over
64%
Detailed Calculation Method
Develop Updated One-line
 Safety requirement
Data Collection
Create System Model – Analysis
Software
 Alternate – Hand or spreadsheet
calculations
Power System Studies
Modes of Operation
 Generation – on/off, Emergency Gen
 Tie Breakers, Alternate feeds
Short Circuit Calculations
 IEEE-141 Red Book
Protective Device Coordination
 IEEE-242 Buff Book
Arc Flash Calculations
 IEEE-1584
Short Circuit Requirements
Study Each Contingency
Min/Max Currents
Don’t forget maintenance or outage
conditions
Protective Device Settings
Do I need a Protective Device Study?
 Can I use ball park times?
PDC Settings to Maximize Process
Continuity?
PDC Settings to Minimize Arc Flash
Hazard?
Min/Max Currents – Effect on Incident
Energy
Arc Flash Requirements
Understand The Difference Between Let
Through Energy and Bus Energy
Hazard Labels
 Bus basis
 Individual protective device basis
Study Min/Max Currents – Effect on
Incident Energy – Worst Case
ArcFlash Summary
2000 Electrical burn accidents reported
each year
NFPA-70E Consensus standard – expect
adoption by OSHA
Arc Flash hazard is influenced by design
 Design Liability?
Expect continued refinements in
calculation methods
EasyPower ArcFlash
Uses existing EasyPower model
Completely integrated with Short Circuit
and Protection calculations
Provides for multiple calculation
methods
Flexible yet easy to use
 EasyPower PowerProtector
EasyPower eliminates hours of engineering time, prevents costly
mistakes, and is completely integrated -- with EasyPower and your
thought process.
TRUE WYSIWYG
GRAPHICS
help prevent
costly mistakes

SINGLE-LINE
DIAGRAM INSIDE
TIME CURRENT CURVE
PLOT WINDOW.
FULL PROTECTION
All the dynamic one-
MODELING --
line features are
differential, maintained.
overcurrent,
multifunction
relays, etc.

ADVANCED
TOTAL GRAPHICS
INTEGRATION prevent eye-
of all momen- numbing flicker
tary, interrupting, while dragging.
and relay short
circuit results. SET THE CURVES WITH AUTO-CLIPPING. COMPLETE INTEGRATION
YOUR MOUSE. You can see the trip with the one-line and
Tooltips show your exact times. protective devices.
settings as you drag.
 EasyPower ArcFlash
GRAPHICAL INTERFACE
HIGHLIGHTS DANGER
AREAS
where protective
clothing is required.

COMPLETE INTEGRATION
WITH POWER PROTECTOR
provides clearing times
based on your settings.

EASYPOWER ALLOWS
REAL-WORLD MODELS
of your protection
system.

SMART-CLICK REMOTE BRANCH INTERACTIVE SPREAD-SHEET EXPAND OR COLLAPSE

TECHNOLOGY. CALCULATIONS REPORT TO SEE MULTIPLE
Simply double-click from the fault allows you to change WORKING DISTANCES
any bus to instantly parameters for what-if
see hazard cases
requirements.
 EasyPower Arc Flash
CALCULATIONS:
IEEE-1584, NFPA-70E (2000),
NFPA-70E (2003), and ESA
Enhanced IEEE-1584
Proprietary Algorithms.

USER-DEFINEABLE
Equipment types (switch
gear, MCC, Panels, etc.)
and arc gaps.
Units: millimeters, meters,
inches, and feet.
Arc-flash boundary
energy.
Fault type: 3-Phase, Line to
Line, Line to Ground, and
Double Line to Ground
Option to include or exclude
buses from calculation.
Multiple working distances
for each voltage level.
Extensive library which
eliminates data entry
requirements so you are
up and running in
seconds.