Practical Approaches To Mitigating Arc Flash Exposure
Practical Approaches To Mitigating Arc Flash Exposure
Abstract - Increasing number of electrical system European codes and standards, currently do not
operators in Europe realize that the existing standards for specifically address the risks of arc flash, despite the fact
built-in equipment safety are not enough to prevent arc that arc flash is a risk. Accidents and near-misses in
flash hazards. The newest revisions of local standards for Europe proved that built-in equipment safety of electrical
operating an electrical installation, such as the Dutch installations and the intention to work on de-energized
NEN 3140, (based on EN 50110) are starting to provide equipment only is not always sufficient to prevent arc
guidance to reduce arc flash hazards. Not all equipment flash accidents. The next edition of EN 50110 will be more
in the field meets the latest standards, moreover Internal specific about arc flash hazards, by means of an
Arc Classification (IAC) does not consider risks informative appendix. Arc flash hazards are explicitly
associated with normal maintenance practices such as mentioned already in the latest NEN 3140, a Dutch
trouble shooting, testing and verification of de-energized standard for safe work on electrical installations based on
state of the electrical equipment. European standard EN 50110-1.
Arc Flash Hazard calculations can conveniently The American NFPA 70E standard can with regard to
quantify the potential risk and show that excessive high this subject- be seen as an analogous to EN 50110 (and
arc flash incident energy necessitates de-energizing of their national extensions). It covers shock hazard in a
the equipment before maintenance can be performed. similar way. In addition it requires risk assessment for arc
Yet, this is not always acceptable to plant operations. This flash hazard, meaning that before work can be carried out
paper will address various approaches to significantly near energized conductors the following must be done:
lowering the probability of an arc flash incident and ways the hazard must be known (through an arc flash
to limit the consequences by system design, equipment hazard analysis),
modifications and alternate protection settings and work measures are to be taken to reduce risk,
methods. It will also discuss strategies to deal with wearing the appropriate PPE when risk cannot be
personal protection equipment (PPE). reduced through other means.
Index Terms Arc Flash Hazard Analysis, Incident Leveraging knowledge and practical experiences both
energy, Flash Protection, Boundary, IEEE 1584, Personal from Europe and U.S., this paper describes solutions to
Protective Equipment (PPE) avoid arc flash hazard, as well as solutions to limit its
effect. Either the probability or the effect can be
I. INTRODUCTION acceptable, however the combination is most important. If
there is any arc flash risk, the first question is how to
An arc flash is a rapid release of energy due to an prevent the risk. When no sufficient options for risk
arcing fault between a phase conductor and another prevention apply, the next question will be how to
phase conductor, a neutral conductor or ground. An arc minimize the effect. After all, the workers need clear
flash (arc) happens when electric current flows through air information about the risk. The approach is used both for
between two conductive parts. Arc faults are generally network design or extension, as well as for maintenance
limited to systems where the voltage is in excess of 120 activities. Although DC systems can have significant
Volts AC or 50 Volts DC. Most of arc flashes are related potential arc energy as well, this paper will focus on AC
to work on the electrical system. systems. A formal calculation method for potential arc
energy in DC systems is under development
An important point is how arc flash hazards can be
dealt with by a companys safety standards. Each country This paper will discuss solutions that can be applied to
has its own code for working on electrical installations, in prevent or reduce arc flash hazards and damage to
CENELEC countries these are based on European equipment. The options to prevent Arc Flash incidents are
Standard EN 50110: Operation of electrical installations. based on:
One of the key concepts of this standard is that work is safe systems,
divided into three categories: live working, dead working way of working,
and working in the vicinity of live parts. Because most proper maintenance.
work is carried out under the dead working condition it is
often assumed that arc flash hazard is not a concern. To reduce the arc flash energy level, there are several
Some work activities however take place in close design options, retrofit methods, and work procedures
proximity of energized conductors. Even making the one can implement .These options are based on:
equipment safe to work can expose the worker to a reduce potential arc fault energy,
hazard. safety practices.
If in the end there is still an unacceptable risk, proper
selected PPEs should be used as a last line of defense.
II. PROBABILITY OF AN ARC FLASH III. POTENTIAL ARC FLASH EFFECT
A number of factors can contribute to arc faults within In the event of an arc flash the initial flash usually
switchgear, however the human factor plays a paramount establishes a highly conductive plasma that sustains the
role in arc flash safety. Experts estimate that over 70% of current. The plasma will conduct as much energy as is
Arc-Flash incidents in Europe occur during or immediately available and is only limited by the impedance of the arc
after electrical work. and the overall electrical system impedance. This
massive energy discharge burns the bus bars or wiring,
Most of the arc flash incidents that the authors learned vaporizing the copper or aluminum and thus causing an
about, were the result of human error, such as touching a explosive volumetric increase. The result is a fiery
test probe to the wrong surface, tools or accessories such explosion, possibly leading to serious and fatal injuries.
as breaker shaft extensions slipped on live parts of the
installation, forgotten tools, dangling unshielded
secondary wiring, or a worker entering the wrong panel.
Some work activities such as voltage testing, impedance
measurements, fault finding, and commissioning take
place with energized conductors in close proximity, either
because they are allowed exceptions or because the
activity requires it. Even making the equipment safe to 19.000 C
Most arc flash incidents happen during isolation, work The potential arc flash energy can be reduced through
or testing. The first question should be if particular reducing available fault current, or fast clearing of the fault
activities such as racking in and racking out are really before it develops into a serious arc flash condition.
necessary, and if there is no simpler way to achieve the Another option to reduce the potential energy exposure, is
same result. Some operations have become a habit to move people further away. There are few ways to
rather than a strictly necessary activity. Proper and clear reduce the available fault currents in power systems:
safety rules are important to minimize the risk of arc flash Operate double-ended substations with a Normally -
incidents. In these safety rules general rules should be Open tie
given for methods of isolation, use of measuring Change out transformer Smaller kVA and/or higher
instruments and use of PPEs. These general rules impedance
should cover most situations. However sometimes it is Add Reactors
necessary to have location specific or equipment type
specific rules. Reasons for this can be: known safety One of the best and most efficient ways to lower the
issues with certain equipment due to non-ideal design incident energy, which inherently lowers the HRC at
characteristics or condition. electrical equipment, is to clear the fault quicker, hence
the protective device trips faster. The ways and methods
In general minimizing arc flash incidents starts with to clear a fault faster using various protective devices
awareness. Many electrical personnel have been working described in this paper are based on:
for years according certain rules and might not Protective devices and coordination
understand the need for change. The awareness comes Zone selective interlocking
also with understanding the safety rules and most Arc reduction maintenance settings
important, the reason why those rules are there is a basic
condition for the acceptance of these rules. A series of Customer-specific equipment, or adjustments of
information sessions and training is common to achieve protection units can affect the performance of the
that people will work accordingly. switchgear construction. Therefore serious attention
should be paid to required protection settings for the
Article 6 of European Council Directive 89/391/EC on users application and settings that are valid for the
risk assessment sets out employer's duties under the integrity of the whole assembly, as tested.
"general principles of prevention" of incidents. As always
there will be risks associated with activities and they have For both reducing fault current and tripping times the
to be addressed in the safety rules. Most difficult question eventual implications on operations should be taken in
is to determine what risk is acceptable. There are no consideration.
A. Protective devices and coordination Arc quenching devices can respond on fault currents
within a few milliseconds. The arc is instantly sensed
Reducing fault current sounds good in theory, however through catching the light of the arc flash. An electronic
lowering the fault current doesnt automatically reduce the circuit checks for an overcurrent in the main circuit. Then,
incident energy during an arcing fault, especially when the quenching device makes the short circuit at ultra-high
fuses are used for circuit protection. As shown in the speed, and the arc is quenched. The bolted short circuit
Time-Current Curve of Fig.4, the arcing fault current can current flows through the quenching device until the circuit
be very low, especially at equipment located electrically breaker opens. Combination of arc quenching device with
far down in the power system. Also, the arcing fault current limiting fuses is a potential solution to overcome
current can be as low as 33% of the calculated bolted the limitations of current limiting fuses, and this
fault current at any particular location per the NFPA 70E- combination also mitigates the stress to the equipment by
2012. Because of this, many times, when fuses are used reducing the fault clearing time. Like an air bag in a car,
for circuit protection, the available fault current is not high proper installation and operation of the device cannot be
enough for the fuse to go into current-limit, hence taking primary tested after installation, which could eventually be
much longer to trip and causing the incident energy and considered as a disadvantage.
HRC levels to increase. At high available fault currents,
the fuse will go into current limit, hence tripping faster and
keeping the incident energy and HRC lower. In the
example of Fig. 4, the electronic trip circuit breaker
protecting the same circuit can be adjusted for complete
coordination and still trip fast on the low arcing fault
current. In this case, the circuit breaker works the best for
low available fault current. Optimization of relay settings
may in some cases require replacement of old protection
devices.
Using good safety practices is another important VII. LABEL EQUIPMENT & TRAIN PERSONNEL
contributor to prevent injuries and mitigate arc flash
hazards. The Starting point should always be to de- When hazards are known and steps have been taken
energize equipment versus working it live unless de- to prevent and reduce them, the next step is to embed arc
energizing increases hazards or if it is infeasible due to flash safety into the daily routines. Hazard Rating
design. If possible, any switching should be done Categories have to be visible for anybody who has
remotely. access to the substations, and it is important to train
personnel and contractors to get them familiar with arc
flash hazards and how your electrical safety program has
changed. Implementing the results of an arc flash hazard
analysis takes time and there may be locations where
work methods or PPE requirements need to be changed
temporarily until implementation is finalized. High hazard
locations may be marked for extra care during procedure
to get a work permit.
First, it appears that the awareness of arc flash hazard XII. VITA
has improved at plants that participated in arc flash
hazard assessments, for example when it comes to Hans Picard, B.Ec has worked in
protecting the person next to the one who is working in engineering, sales and marketing for
the electrical installation. Measures based on facts are Emerson, Holec and Eaton. During the
easier to explain than measures based on guesses and years he has gathered professional
feelings. It is also a fact that the selection and use of PPE experience in contract management,
has improved. Arc Flash calculations showed several project management, electrical services
times how misleading guesses and feelings can be. In and asset optimization. He is currently
practice we encounter many HV systems which have Product Manager for the Eatons
HRC lower than 25cal/cm2. Much more often we see Electrical Services & Solutions business unit, with
potential danger in LV. Especially, if protective devices marketing responsibilities for Engineering Services &
are only on the high voltage side of the transformer. LV Field Services in Europe, Middle East and Africa.
systems are less transparent, hazards are often [email protected]
underestimated, and operation staff for LV systems is
usually less skilled than for HV systems. Last but not least
Jan Verstraten, B.Sc graduated
, situations with potential back flow of electrical energy are
from HTS Hilversum. Currently a Sr.
more obvious. The performed Arc Flash hazard analyses
electrical specialist, he has worked for
do have implications for new projects as well. Arc Flash
Dow Benelux BV in Terneuzen since
calculations should now be part of the design calculations
1990, in various departments:
for expansion and new constructions to make sure that
Maintenance central E&I, Maintenance
new installations despite of arc safe designs, have
Technology Department and
acceptable potential fault energy levels.
Powerplant. Since 2004 he has held the
post of Installation Responsible Person for Dow in the
As is the case with many maintenance and safety
Netherlands, Electrical SME for Dow in Benelux, UK &
topics, quantification of the financial returns of an arc flash
Scandinavia and Electrical Safety and Reliability auditor.
hazard analysis is rather complex. Fact is that safety in
Member of: NEC 623
the oil and gas industry is important. The probability of an
[email protected]
Arc Flash is low but the consequences can be enormous.
Thanks to the hazard analysis, we can now determine
the effect. In itself, performing an hazard analysis does Rien Luchtenberg, B.Sc graduated
not offer any guarantee that fewer accidents will occur, from HTS in Zwolle in 1983. Currently
but it does provide the right pointers for making well- working in Shell upstream Europe as
considered decisions. Team lead electrical. Worked in NAM /
Shell for more than 25 years in
engineering / maintenance and
X. ACKNOWLEDGEMENTS
construction, also held the post of
Installation responsible person.
The authors would like to acknowledge and express
[email protected]
their thanks to Martin Baier from Eaton for providing
important feedback.