Arc Flash Awareness

Electrical Group – Mar. 2008

By Paul Cleary
 Introduction
• Who am I?
– Colt 5.5yrs
– Sarnia Office
– Currently on Nexen Project LLSP1
– EE in Canada, PE in US
 Introduction
• Objectives of presentation
– Awareness of hazards involved with arc flash
– Review legislative requirements
– Requirements of NFPA 70E
• Supplement to Arc flash study presentation
– Calculation methods of IEEE 1534
Part #1: Arc Flash Primer
 What is Arc Flash?
• Definition:
“An arc flash event is a type of electrical explosion that results from a low
impedance connection to ground or another voltage phase in an electrical
system.” – Wikipedia

Phase A

Ground
Typical Causes of “Low Impedance
Path”?
 During Maintenance
• Tool falling
• Electrician leaving equipment on bus bar
• Wrong insulation level for testing equipment used
• Human Error
 During Operation
• Insulation failure due to cracking (aging) or treeing (water ingress)
• Equipment malfunction due to defect
• Poor maintenance of equipment
• Human Error
 Arc Flash Example
• Real world example: 480V Arcing Test
 Arc Flash Example
• Real world example: Arcing Transformer
 Electrical Incidents - Statistics
Statistics
• US Department of Labour Bureau
– 1992-1999 Study of Incidents due to Electric Shock or Burn
– 2287 Fatal and 32,807 non fatal
– 38% non fatal classified as electrical burn

• Electricite de France
– 10 year study, 120,000 people
– 77% of all recorded electrical injuries due to electric arc

• What about Alberta?

 What about Alberta?
• Alberta Municipal Affairs & Housing: Statistics, Electrical Incidents in Alberta
 Alberta: Incident Examples
• Incidents are assorted. Sample from Alberta Municipal Affairs & Housing:
Statistics, Electrical Incidents in Alberta, 2006 Results:

Electricity Does not distinguish between: Occupation, Sex, Voltage

Experience…or Stupidity.
Arc Flash Hazards
 #1 Hazard: Shock
• During course of work, person may come in
contact or close proximity to live conductor
– Inadvertent contact
• Tool, hand, body part
– Ionize air and “jump”
• Potential difference between two points ->
current will flow
 #1 Hazard: Shock
• Magnitude limited by resistance
• Resistance of person dependent on number of
factors, major:
– Resistance of body
– Resistance of PPE (gloves, boots etc.)
 Hazard: Shock
• Current Magnitude & effects on the body:

Current Value Effect

1-8mA Sensation of shock, not painful, possible to let
go
8-15mA Painful Shock, let go threshold
15-20mA Painful Shock, cannot let go
20-25mA Painful shock, severe muscle contractions,
difficult breathing
100-200mA Ventricular fibrillation – change or disruption
to normal heart pattern
>200mA Severe burns & muscle contractions, chest
muscles clamp and stop heart

• Duration of exposure also a factor

 Hazard: Shock
• Amperage GFI’s set to?
• Amperage most industrial systems limit
ground fault current to?
• Typical Bolted Fault Value? 100’s-1000’s A
 #2 Hazard: Thermal
• Arc Energy = immense heat
• Can reach 35,000 deg F
– (4x hotter than sun surface!)
• Immense heat = disastrous effects on skin
NFPA 70E: Curable Burn
• Term used to ensure that employee exposed to arc
does not receive a burn causing irreversible skin
damage = Second Degree Burn
 Hazard: Thermal
• Thermal Effects on Skin:
First Degree Second Degree Third Degree

Effects Skin Outer Outer and Underlying Deep tissue layers

Layer Skin Layers

Pain Redness, Pain, Redness, White, blackend,

Swelling Swelling, Blistering chard skin, numb
 #3 Hazard: Pressure
Pressure Hazard
• Immense heat -> vaporization of material
– Vaporization of bus, breaker, metal bucket, parts of door, cabling

• Copper
– 1 in^3 CU (vaporized) -> 67,000 in^3 (or 39 cubic feet)
• Rapid expansion of solid to vapor takes place in
milliseconds – Creates a “Pressure Blast”
 Hazard: Pressure
• Example of Pressure Hazards:
– Based on a 20kA Fault
– Typical worker exposure area of 2-3 sq. feet

Distance Resulting Pressure

20 feet 60 lbs

5 feet 300 lbs

2 feet 600 lbs
1 feet 1000 lbs

Typical worker distance when operating PD?

 #3 Hazard: Pressure
Pressure Blast
• Knock worker off feet
• Smash into wall, equipment etc
• May create additional hazards
 #4 Hazard: Auditory
Auditory Hazards
• Sudden pressure change -> Arc Blast
• Large “BANG”
• Tests show arc fault sound levels can exceed 160 dB
 Jumbo jet take off, 140dB
 Shotgun blast, 130 dB
 Hazard: Auditory
• Resultant damage to ear
– Hearing loss (temporary or permanent)
– Cilia – “Tiny Hairs” Breakage
– Rupture ear drum (membrane)
 #5 Hazard: Projectile
Projectile Hazard
• Resulting pressure blast and vaporization causes
ejection of materials
• Not all material vaporized
– Doors, parts, fragments of partially vaporized material

• Ejected material will move at very high speed

• Directed at person in front of arc flash
 #6 Hazard: Inhalation
Inhalation Hazard
• Breathing in vaporized materials
• “Surprise reaction” upon arc flash – Tendency to
gasp and draw air deep into lungs
• Dependant on timing of inhalation air now a mixture:
– Superheated gas
– Molten metal
– Toxins from burnt insulation, plastics
• Significant lung damage results
– Often not repairable
 Hazard Protection
• How do we prevent or at least limit the
damage caused by arc flash & shock?
– Legislation
– Standards
– PPE
– Warnings
– Procedures & Permits
 What about Legislation?
• Relevant Legislation
– Canadian Electrical Code CSA 22.1
– Alberta Occupational Health and Safety
– CSA Z462 (Soon to come – Electrical Safety in the
Workplace)
 CEC Requirements
• CEC 2-306
– Field Mark Warning of Arc lash and Shock Hazards
– Appendix ‘B’ References Industry Standards
• NFPA 70E
• ANSI Z535.4 – Labels and Product Safety Labels
• IEEE 1584
“Electrical equipment such as switchboards, panelboards, industrial
control panels, meter socket enclosures, and motor control centres that
are installed in other than dwelling units and are likely to require
examination, adjustment, servicing or maintenance while energized
shall be field marked to warn persons of potential electric shock
and arc flash hazards.”
 CEC Requirements
• Labelling meets intent of CEC

Generic Label
typical from
equipment
manufacturers
 CEC Requirements
• What CEC doesn't tell us?
– PPE, Shock & Arc Boundaries
– When an arc flash study is required
– Incident Energy levels
• However, industry standards are referenced in
Appendix B
• Good engineering practice and due diligence for
public safety warrants that we review &
implement were appropriate appendix B
standards (CYA)
 Legislation: Alberta OHS
• Part 18, Section 232
– Requirement for Flame Retardant clothing if worker may
be exposed to electrical equipment flashover.
– Clothing worn beneath be flame resistant

“Use of flame resistant clothing

232(1) If a worker may be exposed to a flash fire or electrical equipment
flashover, an employer must ensure that the worker wears flame resistant
outerwear and uses other protective equipment appropriate to the hazard.
(2) A worker must ensure that clothing worn beneath flame resistant
outerwear and against the skin is made of flame resistant fabrics or natural
fibres that will not melt when exposed to heat.”
 CSA Z462
• Canadian version of NFPA 70E
– Currently no national standard exists in Canada for
Electrical Workplace Safety
• OSH and CEC somewhat lacking in guidance
• To be released shortly (late 2008)
• Voluntary, but most likely will be a legislated into
Canadian law as acceptance gained
• Read more at:
– http://www.elecleague.ab.ca/index.asp?view=news&news_id=418
 What about Standards?
• IEEE 1584
– Guide for performing Arc Flash study
• Methodology and Procedures
• Empirical based formulas 208V - 15kV
• Theoretical formula for >15kV
• Available on IHS
– Results identify energy exposure level, which
relate to PPE required to work on live equipment
 Standards
• NFPA 70E
– National Fire Protection Agency
– Legislated through OSH in US
– Standard for Electrical Safety in Workplace
• Safety Related Requirements
• Maintenance Requirements
• Installation safety Requirements
– More than just “arc flash”
Part #2: NFPA 70E
 NFPA 70E
• Major Components:
 NFPA 70E
• NFPA 70E -> Lots!
• Arc flash & electric shock -> Hazard Analysis
• Discussion today will focus on requirements
for Hazard Analysis
• Results of analysis are used to help determine
PPE required for task
 NFPA 70E
• Sections Related to Arc Flash & Shock Hazard
Analysis
• Article 110 – General Requirements
• Article 130 – Working on or Near Live Parts
• Appendix C – Limits of Approach
• Appendix D – Example calculation of arc boundary
 NFPA 70E: Working Live
• Requirement for Arc Flash & Shock Hazard
Analysis comes from the decision to work “live”
– NFPA 70E – 130.1 states,
– Hazard analysis for live parts >50V
– Energized Electrical Work Permit
• Work considered “Energized”
• Work performed by Written Permit ONLY!
• Working live defined as “Unsafe Condition”
– Safe Condition: Isolated, Locked, Tagged, Tested & Grounded
 Article 110 – Working on or Near
Electrical Conductors
• By Default: Live equipment shall be made
electrically safe work condition before
employee works on or near them.
• Working Live? -> Requirements
• #1 Justification
• #2 Must be a “Qualified person” to work
• #3 Perform Hazard Analysis
• #4 Have Permitting completed
 Article 130 – Working on or near live
parts
• 130.1 - Justification to work live?
– Additional or increased hazards present by
deenergizing
– Not feasible due to equipment design

NFPA 70E:
“Live parts to which an employee might be exposed shall be put
into an electrically safe work condition before an employee
works on or near them, unless the employer can demonstrate
that deenergizing introduces additional or increased hazards, or
is infeasible due to equipment design or operational limitations.”
 Article 130 – Working on or near live
parts
• Examples of Additional / Increased Hazards
– Interruption of life support equipment
– Deactivation of emergency alarm systems
– Shutdown of hazardous location ventilation
equipment
 Article 130 – Working on or near live
parts
• Examples of Infeasibility due to equipment
design
– Diagnostics or testing that can only be performed
with circuit energized
• i.e. Testing for voltage after deenergizing
– Work on circuits that perform an integral part of a
continuous process that would otherwise need to
be completely shutdown in order to do work on
one circuit or piece of equipment
 Article 130 – Working on or near live
parts
• Examples of unacceptable reasons to work
live
– Financial
• Its going to cost $100,000 to stop production for a day
– Convenience
 Article 110 – Working on or Near
Electrical Conductors
• 2nd Requirement to work live: Qualified Person
NFPA 70E:
“One who has the skills and knowledge related to the
construction and operation of the electrical equipment and
installations and has received the safety training on the hazards
involved”

– Has skills to
• Distinguish live parts
• Determine nominal system voltages
• Know minimum approach distances
• Use special techniques, PPE, shielding, insulated tools
• =Electrician or similar
 Article 110 – Working on or Near
Electrical Conductors
• Unqualified Person?
NFPA 70E:
“A person who is NOT a qualified person”

• = Engineer! (maybe)
 Aside on Permitting
• Requirement #3 - Work permit
– Essential to perform task
– Go through steps of Risk Evaluation
– Sign off by employee and employer
– Allows determination of overall risk by taking into
account such things as
• Proper SC rated equipment
• Maintenance record, has equipment been exercised lately
• Mechanical function and likelihood of failure
• Weather
• Operating Conditions etc.
 Safe Distances and Approach
Boundaries (Article 130)

• #4: Hazard Analysis (Article 130):

– Shock Hazard Analysis
– Arc Flash Hazard Analysis
• Analysis determines
– Approach distances to exposed live parts for
qualified vs. unqualified person
– Protective measures to be taken
– PPE to be worn
 Safe Distances and Approach
Boundaries (Article 130) Equipment

Open Door
Worker
“Exposed”
Live
Part

Arc Flash Limited Restricted Prohibited

Boundary Approach Approach Approach

Limited Restricted Prohibited

Qualified Yes Yes Yes

Unqualified Approach Boundary only No No
 Safe Distances and Approach
Boundaries (Article 130)
• Boundary Definitions
• Limited – Distance where a shock hazard exists
• Restricted - Distance where there is an increased risk of
Shock
Hazard shock due to electric arc over combined with
inadvertent movement
• Prohibited – Distance where work is considered the
same as making contact with live part
• Arc Flash Boundary - Distance at which person could
receive a second degree burn
 Safe Distances and Approach
Boundaries (Article 130)
• How to determine boundary distances for
Shock Hazard?
– Table 130.2(c) (Sample Below)
Nominal System Limited Approach Boundary Restricted Prohibited
Voltage Range (Phase- Approach Approach
Phase) Boundary Boundary
Exposed Moveable Exposed Fixed
Conductor Circuit Part

Less than 50V Not Specified Not Specified Not Specified Not Specified

50 to 300V 3.05m (10ft 0in) 1.07m (3ft 6in) Avoid Contact Avoid Contact

301 to 750V 3.05m (10ft 0in) 1.07m (3ft 6in) 304.8mm (1ft 0in) 25.4mm (0ft 1in)

751 to 15kV 3.05m (10ft 0in) 1.53m (5ft 0in) 660.4mm (2ft 2in) 177.8mm (0ft 7in)

15.1kV to 36kV 3.05m (10ft 0in) 1.83m (6ft 0in) 787.4mm (2ft 7in) 254mm (0ft 10in)
Arc Flash Hazard Analysis
 Determine Arc Flash Boundary
• Work within arc flash boundary requires
either
• Arc flash hazard analysis (as per IEEE 1584)
• Or use of NFPA 70E guidelines
 Arc Flash Boundary
• Warning about use of NFPA 70E guideline in
lieu of arc flash study:
– “Typical” SC & device operation times
– Application requires validation of assumptions
– Assumptions are listed in footnotes
– Guidelines not applicable for every application
 Arc Flash Boundary
• Contrast to Arc Flash Study IEEE 1584
– Engineering study specific to application
– Determines
• Arc Flash Boundary
• Exposure energy at working distance
• Level of PPE Required
• Recommendation: Use NFPA 70E tables in
conjunction with arc flash study
 Arc Flash Boundary
• Arc Flash Boundary with NFPA 70E Guide
• Section: 130.3(a)
– For <= 600V Applications
• If (Fault Level * Duration) <=300kAs
Then Boundary = 4ft
 Arc Flash Boundary
• Section: 130.3(a)
– For <= 600V Applications
• If Duration > 300kAs
Then Boundary = Dc

Dc= [2.65 x MVAbf x t ] 1/2

Dc= Distance in feet from an arc source for a second degree burn
MVAbf= Bolted fault capacity available at point involved
MVA = capacity rating of transformer
t= Time of arc exposure in seconds
 Arc Flash Boundary
• Section: 130.3(a)
– For > 600V Applications, Boundary defined
• At distance where incident energy at 1.2 cal/cm^2
• Or energy = 1.5 cal/cm^2 where < 0.1s clearing time

– Going to have to use Appendix D – Sample calc

– or IEEE 1584 calculation
 Arc Flash Task
• Once the boundary has been determined,
consider task for the worker
• NFPA 70E Guide, Table 130.7(c)(9)(a)
– In Lieu of full arc-flash study
– Specific conditions apply
– Might not be representative of actual plant
operating parameters -> Check footnotes!
– Interim Updates to table (see end of NFPA 70E)
Arc Flash Task: Example

Shock Hazard PPE

 Arc Flash PPE
• Determine PPE Level based on Hazard/Risk
Category
• NFPA 70E Guide, Table 130.7(c)(11)
– Based on Hazard/Risk Category, PPE can be
selected
– Remember: PPE Only protects for burns & shock.
Limited protection for other effects of Arc Flash
Arc Flash PPE: Example
 Arc Flash PPE
• PPE Clothing: Class 4 (40 cal/cm^2)
Cotton

FR
FR
 Arc Flash PPE
• PPE Level 3 (25 cal/cm^2)
Cotton

FR
FR
 Arc Flash PPE
• PPE Level 2 (8 cal/cm^2)

FR Cotton

Cotton

FR
 Arc Flash PPE
• PPE Level 1 (4 cal/cm^2)
 Arc Flash PPE
Leather

• Feet/Eyes/Hands

Insulated Boots
“Green Triangle”
“Ohm Symbol”

Ear canal type

Insulated
 Arc Flash PPE
• Many other types of PPE available with
various ratings
• Higher levels of PPE have their own issues
• Difficult to work
• Decreased dexterity
• Hot inside & uncomfortable
• Longer to perform work
• May lead to human error while working
 PPE & Work Task
• PPE selection Not always “Cut and Dry”
• Lets take a look at possible complications
 Example of PPE Selection
Door open/closed
• Example 2400V Breaker Operation w/ closed door
(assume criterion meets requirements to use NFPA
tables)
• Is PPE, Analysis & Permits required?
• Art. 130.1 – If worker exposed to “Live Parts”?
NFPA 70E:
“Live Part: (Exposed) Capable of being inadvertently touched or
approached nearer than a safe distance by a person. It is
applied to parts that are not suitably guarded, isolated, or
insulated.”

– Door closed -> no exposure to live parts -> PPE and work permit not required?
 Example of Engineering Judgement:
Door open/closed
• Depends: table 130.7(c)(9)(a) lists multiple tasks for
switching with Doors Open & Closed
>1kV

600V
 Example of Engineering Judgement:
Door open/closed
• Interpretation of the term “Suitably Guarded” for worker
exposure to a Live Part
• What about Arc Flash Study (IEEE 1584 method)
– Study always assumes Door Open
– Not task specific
– Value returned dependant on working distance
• (18” common)
– Hazard/Risk Level higher or lower than NFPA table
• Depends on operating & study parameters
• No easy answer either way
 Example of Engineering Judgement:
Door open/closed
• In selecting PPE, judgement must be made as part of
Hazard and Risk Analysis giving consideration to:
– Likelihood of equipment failure
– Task
– Is equipment properly rated for available fault level
– Maintenance and Exercise record for equipment
– Results from IEEE 1584 method
– NFPA Tables
• Risk Low? -> Possible reduction in PPE
 NFPA 70E Labeling
• Section 400.11 identifies labeling
requirements
• (Surprise) Essentially the same as CEC
– “…equipment…shall be field mark to warn
qualified persons of potential arc flash hazards”
 NFPA 70E Labeling
• Typical industry accepted warnings on label
• Shock Hazard
– Voltage Level
– Limited, Restricted, Prohibited Approach Boundaries
– PPE to minimize electric shock
• Flash Hazard
– Flash Protection Boundary
– Incident Energy cal/cm^2
– Required PPE within boundary
NFPA 70E Labeling
Part #3: Conclusion
 Conclusion: General
• How arc flash occurs
• Hazards
• Statistics
• Injuries can be sever
• Burns
• Loss of limbs
• Fatal
 Conclusion: General
• Preventative Measures
– Do not work live!
– If live work MUST occur, follow NFPA 70E
– At Design stage (not discussed in presentation)
• Ways to limit fault levels, PD duration
• Arc resistant gear
• Remote switching
• Light sensitive relays
• Etc.
 Conclusion: NFPA 70E
• NFPA 70E (Canadian Equivalent coming soon)
• Guide for Electrical workplace safety
• Arc & Shock only part of a larger picture
• Referenced in Appendix of CEC
• Core components:
 Conclusion: IEEE 1584
• IEEE 1584
• Fits into NFPA70E, Arc Hazard Analysis
• Calculates exposure level & reccomends PPE Specific to
equipment & operating conditions
• (SC level, breaker type, max/mins, opening time etc.)
 Conclusion: PPE
• When determining PPE to ware
– Perform Risk Evaluation
– Perform Hazard analysis
• Use table 103.7(C)(9)(a) as a reference in conjunction
with arc flash study
– Complete permitting
– Do not just rely on equipment labelling
Conclusion