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January 2022: Arc Flash and Shock Hazard Analysis
January 2022: Arc Flash and Shock Hazard Analysis
JANUARY 2022
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Revision
Comments / Nature
S. No. Document Identification
of Changes
No Date
EXECUTIVE SUMMARY
Cholamandalam MS risk services has carried out the site visit for ARC flash analysis at M/s.
Sun Pharmaceutical Industries Limited, Dewas on Janauary 28th to 31th, 2022 in line with IEEE
1584 – 2018 (IEEE guide for performing ARC flash Hazard calculations) recommendations
considering the scenario as plant running on full load with EB supply and separately on DG
supply.
PPE required are 12 cal/cm2 (Level-A) suit and 40 cal/cm2 (Level-B) suit as per the Appendix-1.
If the calculated Incident energy is above 40 cal/cm2, please de-energize the equipment and
commence LOTO to do any live maintenance.
The calculated Incident Energy in this report are based on the proposed protection device
setting from Relay Coordination report.
Based on reported mode of operation, Transformer-3 & 4 feeding PCC-3 & 4 and through tie
feeders of PCC-3 & 4, PCC-1 & 2 are energizing. In this mode of operation, short circuit
adequacy of equipment is not met in all the PCC. MCCB rating installed in PCC are 65kA, but
the 3Ph bolted fault current is 79.581kA.
Based on reported mode of operation, all the DG Panels and its breakers short circuit rating
are found inadequate.
For the assessment, the motor loads on every MCC and loads on individual DB have been
considered as a lump load
Bus Nominal
Incident Energy During DG Incident Energy During EB
S.No Equipment Voltage
Operation (Cal/cm2) Operation (Cal/cm2)
Name (kV)
CAPACITOR_
1 0.415 12.13 9.86
PANEL-1
CIPRO_HCL_
2 0.415 18.7 0.155846
OUTGOING
ETP_RO_MC
3 0.415 16.99 0.293721
C
ETP_RO_MC
4 0.415 16.78 0.140996
C-1
PCC_PANEL_
7 0.415 17.42 17.73
BUS-3
PLA-
8 2_SUB_PCC- 0.415 15.02 14.56
6
PLA-05_STM-
9 3_SUB_PCC- 0.415 15.89 17.47
2
UTLITY_MCC-
10 0.415 24.17 23.8
10
11 DG PCC 127.65 NE
PCC_PANEL_
12 0.415 127.65 38.68
BUS-1
PCC_PANEL_
13 0.415 42.77 33.72
BUS-2
SRP_SUB_PC
14 0.415 46.78 0.587749
C_A
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Bus Nominal
Incident Energy During DG Incident Energy During EB
S.No Equipment Voltage
Operation (Cal/cm2) Operation (Cal/cm2)
Name (kV)
33 kV SF6
15 33 NE 22.94
PANEL
33kV
16 CONNECTIO 33 NE 90.16
N-1
Colour Coding:
Yellow: Higher Energy observed during that particular mode of operation (Labels were taken in
Note:
1. The cells with “FCT Not Determined” in the above list denote “Fault Clearing Time Not
determined”. It means that, the Arc Flash could not be interrupted by any device. This may happen
due to one of the following
b) Multiple sources are feeding to the fault where the Arc Flash program (ETAP) could not select
the protective device.
It is recommended to consider these panels to be hazardous and perform LOTO before working
on them.
3. Hazard level of “Level-B” means that the Incident energy has exceeded 40cal/cm2. It is
recommended to perform LOTO and work on these panels.
4. Resulting Arcing current is very low for the protection device to interrupt.
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For the purpose of carrying out Thermography safely on panels, the recommended safe action may
be to turn off the power to the said panels just before opening the door for scanning. This is still
acceptable because the said panels assuming to have been working on full load condition until the
said shut-down (or power off with LOTO) will continue to operate at the same temperature for a small
period of time. Any drop-in temperature (because of power off) should be even across all the
phases/points i.e. the hotspot may still be evident upon scanning using an infrared detector/device
after taking power off/shut down.
Any personnel responsible for thermal imaging should be aware of the environment especially with
respect to any openings in the panels and the presence of any rodents or any such a possibility which
may create a hazard upon opening. In such cases it is recommended to refrain from opening the panel
door until all power to the said equipment is cut off.
M/s Sun Pharmaceutical Industries Limited Dewas r is recommended to fix the warning labels provided
in Appendix 3 in the respective panels and to purchase and keep the Personal Protective equipments
(as suggested in the labels) for the use of electricians / electrical engineers during live work when
covers are open.
PPE may not be required if the equipment is turned off and proper specific LOTO procedure (for the
respective equipment) is implemented. The PPE specifications are provided in Appendix-1. Relevant
PPE shall be procured.
More Arc Flash incidents have been because of Human error than system or equipment error. The
IEEE 1584 case studies support this claim (Refer Appendix 11) – 39 out of 49 case studies presented
may be because of Human Error. However, in order to prevent any possibilities of arc flash incidents
due to system or equipment malfunction it is recommended to perform maintenance on a regular
basis in all those areas where there is lot of dust deposits in panels/panel rooms. It is recommended
to clean them more frequently
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Appendix 2 A brief explanation of the Arc Flash label provided. It may be used for better
understanding of the components of Arc Flash label.
Appendix 3 Warning Labels
Appendix 4 Short circuit calculation summary (IEC 60909) for all modes of operation
Appendix 5 Arc Flash hazard calculation summary (IEEE 1584) for all modes of operation
Appendix 6 The protective device settings considered are provided
Appendix 7 A simple short circuit calculation method is described
Appendix 8 A sample Arc Flash calculation is provided
Appendix 9 This Appendix may help in deciding the need for selection/use of Arc Flash PPE
during various site specific tasks
Appendix 10 Understanding the Protective device nomenclature used in this report
Appendix 11 Arc Flash case studies from IEEE 1584. 39 out of 49 arc flash incidents have been
caused by Human Error.
Appendix 12 Single line diagrams (SLDs)
Appendix 13 SLD with Short Circuit and ARC Flash Levels
NOTE: The Hazard levels mentioned here in the report are valid for the present system configuration
& connected load recorded in the Appendix (Appendix 5 and 12) of this report. Any change in the
system shall invalidate the analysis.
Note:
Since some of the feeders were in running condition during the time of audit, they could not be opened for the
verification of short circuit protection devices. For such feeders, information has been acquired
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TABLE OF CONTENTS:
1. INTRODUCTION …………………………………….... 09
2. METHODOLOGY …………………………………….... 15
Appendix 9 - NFPA 70E Reference table for Arc Flash PPE usage
Appendix 10 – Understanding the Protective device settings nomenclature (used in this report)
Appendix 13 - Single Line Diagram with Short Circuit and Arc Flash Levels
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SECTION 1
INTRODUCTION
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1. INTRODUCTION
GENERAL
Field data collection related to ARC flash analysis was done for M/s Sun Pharmaceutical Industries
Limited, Dewas by Cholamandalam MS Risk Services Limited. The data collection was done on 28
to 31 January 2022.
Mr.Suseendran A
Mr.Prince
Study Coverage
1.1. Installations
Following area Electrical installations were covered during the study:
HT Yard VCBs
Transformers
Main LT Panels (PCC) of Utility
DG sets
MCCs and
1.2. Records / Reports / Drawings reviewed
Data collected at site / Images pertaining to above said system
Data received through electronic mail for the above said panels
OBJECTIVES OF ARC FLASH AND SHOCK HAZARD ANALYSIS:
Broadly the ARC flash and Shock hazard analysis is conducted with the following objectives:
SCOPE:
HT Yard VCBs
Transformers
Main LT Panels (PCC) of Utility
DG sets
MCCs
Collected the data available at site for the installations mentioned above, this is required to develop
a single line diagram and feed the details as provided by M/s Sun Pharmaceutical Industries Limited
Dewas.
Based on the provided details, we have observed the mode of operation as follows:
Full load of the plant is supplied by EB through its 11kV Grid. DGs supply will cater to load requirements
during EB supply failure.
Single line diagram (SLD) shall be developed in the ETAP software, based on the site and provided
data.
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The Bolted Fault current and Arcing Fault current using Short circuit study (As per IEC 60909) module
in the software for the developed Single line diagram. Summary of results for the same are enclosed
in relevant Appendix.
Step: 5 - ARC flash and Shock hazard analysis (as per IEEE 1584 2018)
Incident Energy & Arc Flash Boundary shall be calculated using ARC flash (As per IEEE 1584-2018)
module in the software for the developed Single line diagram. Summary of results for the same are
enclosed in the relevant Appendix.
Engineering mitigating solutions (to reduce the energy level thereby PPE Level) where ever possible
to reduce the incident energy level by changing the relay/breaker settings or replacement of hardware
if economical, shall be recommended.
The studies have been performed using ETAP. This software has the following modules:
AC Network Analysis
- Short-circuit analysis – IEC 60909 -2016
- ARC Flash – NFPA 70E - 2021 / IEEE 1584 - 2018
To understand the results of the ETAP simulation, it is necessary to understand the following
definitions specific to the software:
Arc Flash Boundary: Minimum distance from the arc, within which a second-degree burn
could occur if no protective clothing is worn.
Working Distance: Closest distance a worker’s body exposed to the arc.
Incident Energy: Energy released at the specified working distance expressed in cal/cm2 or
J/cm2.
PPE Class: Minimum clothing class designed to protect a worker from second degree burns.
It should be noted here that the calculation of the arc fault current is based on IEEE 1584-2018 and
the formulae for calculation of the arc fault and the incident energy will be briefly explained in Section
3 of this document.
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ACKNOWLEDGEMENT
CMSRS wishes to express its sincere thanks to the entire team of M/s.Sun Pharma Limited for the
cooperation extended in the successful completion of this report.
Disclaimer
This report is for the sole use by the Client for the purpose for which they have claimed it is required to
us. We are not responsible to any other person/party for any decision of such person/party based on
this report. It is hereby notified that reproduction, copying or otherwise quoting of our report or any
part thereof other than the aforementioned purpose, can be done only with our prior permission.
The report cannot be used or relied by the Client for any other purpose or any other third party for any
purpose whatsoever and we will not be liable which the client may incur on this account including in tort
(including but not limited to negligence) arising out of or in connection with this Report. This Report is
not intended to identify all hazards which may exist nor is it intended to be an exhaustive review of all
possible eventualities. The recommendations for risk improvement contained in the report are purely
advisory and the decision and responsibility for implementation rests with the Client.
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SECTION 2
METHODOLOGY
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Site Visit
Interaction with
employees
Data Collection
Modes of
Modeling the Single Line diagram
operation
Draft Report
Submission
Submission of
Final Report
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SECTION 3
In this report, the approach to the study will be based on IEEE 1584-2018. The primary aim is to
calculate the Incident energy released in an arc fault, the arc flash boundary and recommending
the type of PPE class for personnel safety.
1.1. DEFINITIONS
The following definitions are taken from IEEE 1584 and will be used in this report:
Arc-flash hazard: A dangerous condition associated with the release of energy caused by an
electric arc.
Arcing fault current: A fault current flowing through electrical arc plasma, also called arc fault
current and arc current.
Available fault current: The electrical current that can be provided by the serving utility,
facility-owned electrical generating devices and large electric motors, considering the amount
of impedance in the current path.
Bolted fault current: A short circuit or electrical contact between two conductors at different
potentials in which the impedance or resistance between the conductors is essentially zero.
Exposed (lived parts): 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.
Flash hazard analysis: A method to determine the risk of personal injury as a result of
exposure to incident energy from an electrical arc flash.
Flash-protection boundary: An approach limit at a distance from live parts those are
uninsulated or exposed within which a person could receive a second-degree burn.
Incident energy: The amount of energy impressed on a surface, a certain distance from the
source, generated during an electrical arc event. Incident energy is measured in joules per
centimetre squared.
Shock hazard: A dangerous condition associated with the possible release of energy caused
by contact or approach to live parts.
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Working distance: The dimension between the possible arc point and the head and body of
the worker positioned in place to perform the assigned task.
In the IEEE 1584, the theoretical derived model is only applicable for applications where faults
will escalate to three-phase faults. Where this is not applicable, the model will give a conservative
result.
Equation 1:
Where:
This will determine the arcing fault current based on the voltages and the fault levels that are
passing through the equipment.
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Equation 3:
Where,
The incident energy calculation will determine the effect of the arcing three-phase fault on the
protection system. Ideally, the protection should be able to clear the arcing fault within a time
that would not cause a secondary burn at a distance specified (D). The incident energy is
dependent upon the arc fault current as well as the duration of the arcing time.
The incident energy will then be used to determine the type of Personal Protective Equipment
(PPE) to be used. The category of PPE will refer to NFPA 70E and are summarised in Appendix -1
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Ibf: The three-phase fault level, which was internally calculated in the software.
V: System voltage which will be based on the result of the short circuit value.
K: Open or boxed configuration. In this study, it will be boxed by selection of switchgear.
G: Gap between bus bar. The bus-gap is which is taken as per IEEE 1584.
t: The arcing time is based on the protection plus breaker operating time. It is assumed that
the protection operating time includes CT errors, relay errors etc.
D: The distance from possible arc point to the person will be based on typical value in IEEE
1584 for low-voltage switchgear. This is approximately the distance for racking the ACB’s.
x: The distance factor is taken from IEEE 1584.
1.7. RESULTS
The simulated results based on IEEE 1584 for the selected LV switchboards are shown in
Appendix–7.
The protection TCC showing the protection operating time at the simulated arc fault is shown
in Appendix-8.
The Warning / Danger labels for each switchboard are included in Appendix-3 respectively.
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SECTION 4
Dewas
ELECTRICAL SYSTEM
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Presently the power requirement for the Industry is fed by Madhya Pradesh Poorv
Kshetra Vidyut Company Ltd
For Connection-1, the industry is receiving power by 33kV voltage level from the grid
and the 33kV voltage is stepped down to 0.415kV using 3Nos of 2.5 MVA transformer
and also with the support from 6Nos of Diesel generator in case of power failure from
the grid. The power from the Trafo and DG is delivered to the PCC-1 panel which consist
of three Bus arrangement with two bus section.
The Normal Mode (also called as regular mode) of operation reported is as follows:
The arc flash study determines the level of incident energy due to arc faults that could occur
during switching operation of the circuit breaker, isolators, withdrawable trays etc. Too high
incident energy may pose personnel risk which would require either Personal Protective
Equipment (PPE) to be worn or mitigation solutions on the switchboards or both.
The arc flash study has been performed under fault conditions (as specified in IEC 60909) to
determine the highest incident energy possible.
In the calculations, it is assumed that the switchboards and protective devices are in reasonably
good condition and they shall work as intended.
The Arc Flash Labels have been generated keeping in view the worst case i.e. highest PPE
requirement in all the modes of operation (Appendix-3).
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The higher the PPE, the lesser ability for the personnel to coordinate and make judgment.
The higher the PPE, lesser would be the personnel’s sense of touch.
The higher the PPE, the more difficulty for the personnel to work.
The higher the PPE, the more restricted movement and vision of the personnel.
PPE may be costly and if sharing is required, then question of personal hygiene has to be
considered.
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PPE
*Table for PPE Selection while using ‘PPE Category Method for Arc Flash Risk
Assessment’AN: as needed (optional). AR: as required. SR: selection required.
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Notes:
(2) Face shields are to have wrap-around guarding to protect not only the face but also the forehead,
ears, and neck, or, alternatively, an arc-rated arc flash suit hood is required to be worn.
(3) If rubber insulating gloves with leather protectors are used, additional leather or arc-rated gloves
are not required. The combination of rubber insulating gloves with leather protectors satisfies the
arc flash protection requirement.
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1
8
2 7
3 9
4
10
5
6
12
11
Legend:
10. The clear distance for a qualified person (to stay away) from the equipment/panel when
he/she has not worn any PPE. No qualified person shall approach or take any conductive
object closer to exposed energized electrical conductors
11. The equipment/panel/DB for which the label is generated. This label has to be pasted on the
said equipment/DB/panel.
12. The protective device selected by ETAP (automatically) for Arc Flash calculation.
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APPENDIX-3
APPENDIX-4
APPENDIX-5
APPENDIX-6
Relay/Release Settings
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The short circuit analysis is performed (by the ETAP software) as per IEC 60909. An easy to do method
which yields results which are acceptable for power system design/commissioning decisions is
presented below -
MVA Method to calculate Short circuit currents:
Basically, the MVA method is a modification of the Ohmic method in which the impedance of a circuit
is the sum of the impedances of the various components of the circuit. Since, by definition, admittance
is the reciprocal of impedance, it follows that the reciprocal of the system admittance is the sum of
the reciprocals of the admittances of the components. Also, by definition, the admittance of a circuit
or component is the maximum current or KVA at unit voltage which would flow through the circuit or
component to a short circuit or fault when supplied from a source of infinite capacity.
Component 1, the system, is normally given a short circuit MVA rating. So, one merely writes down
500, which is its system short circuit MVA. Sometimes, if the system MVA is not available, but its
voltage and impedance are given, the short circuit MVA can be calculated with the application of
The short circuit MVA of the transformer is equal to its own MVA base divided by its own per unit
impedance. (Use reactance X with the MVA method.)
The short circuit MVA contribution of the motor is equal to its own MVA base divided by its own per
unit impedance. (Use reactance X with the MVA method.)
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Now, let us examine the MVA diagram. If a short circuit is taken at point F, there will be a series flow
of MVA1 and MVA2, and their combination will be in parallel with MVA3. The question now is: how
do you combine the MVA values in series and in parallel? The answer is again simple arithmetic
From above, it can easily be recognized that series MVA combinations are exactly as resistances
computed in parallel. Parallel MVA combinations are exactly as resistances computed in series.
The MVASC at point F then can be calculated as follows:
The term with the asterisk is the new MVA1 value which is the result of combining MVA1 and MVA2.
After the operation, the new MVA, which is 250 MVA, replaces the old MVA1 and MVA2. This scheme
of replacing old quantities with new quantities relates to computer data memory storage system.
At this point the short circuit MVA is solved. To find the current value, only the voltage value is
required. For example, if the voltage is 13.8 kV, the current ISC is
An example below:
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The 69kV cable here is 3.87 ohms. The MVASC for the cable can be calculated by
This way any network can be reduced into short circuit MVA and the fault at any point can be found.
This is a simple method to solve any type of network for finding short circuit level. However, it must
be noted that this method may become very cumbersome for complex networks when solved by hand.
A computer program is always preferable for such computations.
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The short circuit analysis is performed (by the ETAP software) as per IEC 60909.
From the short circuit analysis report (Appendix-4), the following panel is considered for this example.
Ibf = 70.19
From the equations of IEEE 1584, the arcing current is calculated from:
Where:
This will determine the arcing fault current based on the voltages and the fault levels that are
passing through the equipment.
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Where Height1 is the adjusted height used to find the equivalent box size, the equivalent
enclosure size value is:
Incident Energy:
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E = 37.97 Cal/cm2
The time (t) here is the time taken by the protective device to clear the fault is 0.5 S. If the Fault
Clearing time is above 2 Seconds, the arc flash module will take 2 seconds for fault clearing
time. It is because of the human reaction time stated by NFPA 70E-2021 and IEEE 1584-2018
From the Time current curve above, it can be said that the release can clear the arc fault (23.39kA)
in 0.5S ; Here E= 47.40 Cal/cm2, t=0.5 S ; DB=3.727 metres is the Arc Flash Boundary.
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APPENDIX-9 – NFPA 70E REFERENCE TABLE FOR ARC FLASH PPE USAGE
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WL II 3200S ETU 27B release. The following is a sample image of the above device.
Release Model
ETU 27B
APPENDIX-11 – ARC FLASH CASE STUDIES (IEEE 1584)
4 R- Relay