Electrical Arc Flash Hazards: Emerging

Workplace Global Safety Standards &

Eaton Solutions

Eaton Industries P/L

Aaron Teo
Key Account Manager

• Electrical Systems: Design - Install -

Maintain
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Real Life: Arc Flash while racking in a breaker

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 What is an Arc Flash?
An Arc Flash is a dangerous condition associated
with explosive release of energy caused by an
electrical arc due to either a phase to earth or
phase to phase fault.

80 percent of all electrical injuries are burns

that result from the electric arc flash

Arc flashes cause electrical equipment to
explode, resulting in an arc-plasma fireball

Solid copper vaporizes, expands to 67,000
times its original volume

Temperatures exceed 19,000 oC

Detected sound levels of 141.5 dB

Pressure levels of 1kg/cm2 (15PSI)

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 Research studies say ….

• Five to 10 arc flash explosions occur in

electrical equipment every day in the United
States, according to statistics compiled by
CapSchell, Inc., a Chicago-based research
and consulting firm that specializes in
preventing workplace injuries and deaths.

Based on the incidents reported … Unreported cases and

“near misses” are estimated to be many times this
number

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Arc Flash – a real danger

• ~2000 injuries/year in U.S.

• An injured worker can spend one day in the hospital for
each single percent of body burned
• $10,000 to $15,000,000 cost per injury
• High personal cost
• Other injuries besides thermal burns

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Electrical injuries cost more than other injuries

• Although injuries are infrequent, the very high

costs associated with these injuries make
them one of the most important categories of
injuries
• In one utility, electrical injuries represented
<2% of all accidents, but 28% - 52% of injury
costs

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 Injury costs can last a lifetime

A study of one utility revealed these costs of a

survivable serious electrical injury

• Immediate direct costs…… $250,000

• Direct costs after year 1….. $1.3 million
• Indirect costs ……………… $11.24 million
Total ….. $12.8 million*
*1991 dollars. Equivalent in 2003 dollars is $17.4 million

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 National Fire Protection Association
NFPA 70E-2009
Will this become a global Standard?

Addresses electrical safety-related work practices

Developed in cooperation with OSHA, to fulfill their
needs.

Assumes an NEC compliant installation.

1979: First published,

1995: Added Flash Protection Boundary

2000: Focused on use of personal protective
equipment (PPE).

2004: Emphasizes safe work practices.

2009: Energized work permits, Adopted across
LAM, Harmonized CSA Z462 introduced

2012: Next edition release

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 National Fire Protection Association
NFPA 70E-2009 Article 130.3

National Fire Protection Association Standard 70E-2009

“Standard for Electrical Safety in the Workplace”

First published in 1979 – Established at the bequest of OSHA.

• 130.3 Arc-Flash Hazard Analysis Mr. Ouch!

“A flash hazard analysis shall be done…”
• 130.3 (B) Personal Protective Equipment (PPE)
“… Where it has been determined that work will be performed
within the flash protection boundary by 130.3(A), the flash
hazard analysis shall determine, and the employer shall
document, the incident energy exposure of the worker (in
calories per square centimeter)… and personal protective
equipment (PPE) shall be used by the employee based upon
the incident energy exposure”

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Electrical Workplace Safety Standards Summary

The intent of NFPA 70E/CSA Z462 regarding arc flash

is to provide guidelines which will limit injury to the
onset of second degree burns (1.2 cal/cm2).

Note: The heat reaching the skin of the worker is

dependent primarily upon:

Power of the arc at the arc location

Distance of the worker to the arc

Time duration of the arc exposure

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 IEEE 1584-2002
“Guide for Performing Arc
Flash Calculations”

Provides guidance for the calculation of
incident energy and arc flash protection
boundaries.

It presents formulas for numerically quantifying
these values.

The IEEE 1584 Guide also includes an Excel
Spreadsheet “Arc-Flash Hazard Calculator”
which performs the actual calculations using
the formulas stated in the Guide.

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How Do You Fix the Problems
Discovered?

1. Label Equipment & Train Personnel on Good

Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

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Label Equipment and
Restrict Access (Keep People Away)

• By Qualified Engineer
• IEEE 1584
• Incident Energy Calcs
• AF protection boundaries
• Includes spreadsheet
• Standardized Data
Collection Templates
• Labels, Training,
Recommendations

Methods 1 (Label) and 2 (Restrict)

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Train others…
• Arc-Flash Safety – for electricians, technicians or
equipment operators whose employers have already
declared them to be "qualified" according to OSHA
rules but need the new information contained in NFPA
70E-2004 (0.4 CEUs)
• Electrical and Arc-Flash Safety – for electricians,
technicians and equipment operators who are not
"qualified" but who might be exposed to arc-flash
hazards (0.8 CEUs)
• Understanding Arc Flash – for engineers, safety
managers, consultants and electricians
(0.8 CEUs)
Method 3 (Train)
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 Flash Protection Boundary

When an energized conductor is exposed, you may not

approach closer than the flash protection boundary without
wearing personal protective clothing and PPE.
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Implement Safe Practices…

• De-Energize Equipment versus “Working It

Live” unless increased hazards exist or
infeasible due to design or operational
limitations. Method 4
• Switching remotely (if possible) Method 5

• Closing and tightening door latches or door

bolts before operating a switch. Method 6
• Standing to the side and away as much as
possible during switching operations. Method 7
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NFPA 70E-2009: Table 130.7 (C) (11)
Protective Clothing Characteristics

Hazard Clothing Description Required

Risk (Typical Number of clothing layers given in parenthesis) Minimum
Category Arc Rating of
PPE cal/cm2
0 Non-melting, flammable materials (i.e., untreated cotton, wool, N/A
rayon, or silk, or blends of these materials) with a fabric weight
at least 4.5 oz/yd2 (1)
1 FR shirt and FR pants or FR coverall (1) 4
2 Cotton underwear – conventional short sleeve and brief/shorts, 8
plus FR shirt and FR pants (1 or 2)
3 Cotton underwear plus FR Shirt and FR pants plus FR coverall, 25
or cotton underwear plus two FR coveralls (2 or 3)
4 Cotton Underwear plus FR Shirt 40
and FR Pants plus multilayer flash suit (3 or more)

Based upon maximum energy for a 2nd degree burn (1.2 cal/cm2)

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 Understand “Good” Safety Practices

Bad – Exposed Back of Neck, Head and Hair Good – All of Body Protected

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 Remember

Personal Protective Equipment,

PPE, for the arc flash is the last line
of defense.
It is not intended to prevent all
injuries, but is intended to mitigate
the impact of an arc flash, should
one occur.

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Heat Stress Warning
Just as this clothing
blocks heat energy
from the outside, it
also slows the
escape of heat from
you body. This may
quickly cause a you
to overheat and
develop heat stress
problems.

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This is uncomfortable. . .

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This is REALLY uncomfortable……

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Another Category of Methods …
1. Label Equipment & Train Personnel on Good
Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

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 Remote Racking and Control Options
Method 20 Method 21
Remote
Remote Racking (new
Racking Device
equipment)

SCADA Software Motor Operated Switch

Method 22 Method 23
Remain physically outside the flash protection boundary.
Therefore NO ARC FLASH HAZARD protection required!
 How Do I Reduce Available Fault Current?
• Operate with a Normally Open Tie During
Maintenance Method 8
• Change Out Transformer – Smaller KVA and/or
Higher Impedance, if possible Method 9

• Add Reactors to limit starting current Method 10

• Whatever you do, commission arc flash study first

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 Use High Speed Molded Case Breakers
Incident Energy at
Bolted Fault Current
IEEE 1584 Generic
Min Mid Max Equation
225 A MCCB with Thermal-Magnetic Trip Unit 15x 156x 444x
Bolted fault current 3.4 kA 35 kA 100 kA IEEE 1584 Using Time
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm 2) N/A1 1.7 4.7 Current Curve Input
Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm 2) 59.6 1.1 2.3
Measured Incident Energy (Cal/cm 2) 0.08 0.1 0.11 Tested Value
1200 A MCCB with Electronic Trip Unit 16x 29x 83x
Bolted fault current 20 kA 35 kA 100 kA 1
2
N/A = Not Applicable
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm ) N/A1 3.5 9.4
Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm 2) 218 3.5 5.8 because it is outside the
Measured Incident Energy (Cal/cm 2) 1.86 1.2 1.64 range of the IEEE 1584
Generic Equation
• 1584 predicts higher than actual incident energy for breakers and lower
than possible incident energy for fuses
• Incident energy release from Eaton MCCB protected circuit will be HRC 1 or
less for any current above 15x handle rating up to and including 100 kA

Method 12
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 Use High Speed Molded Case Breakers
Incident Energy at
Bolted Fault Current
IEEE 1584 Generic
Min Mid Max Equation
225 A MCCB with Thermal-Magnetic Trip Unit 15x 156x 444x
Bolted fault current 3.4 kA 35 kA 100 kA IEEE 1584 Using Time
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm 2) N/A1 1.7 4.7 Current Curve Input
IEEE
Inc. Energy via IEEE 1584 &1584 Predicted
Trip Curve (Cal/cm 2) 59.6 1.1 2.3
Measured Incident EnergyActual
2
(Cal/cmMeasured
) 0.08 0.1 0.11 Tested Value
1200 A MCCB with Electronic Trip Unit 16x 29x 83x
Bolted fault current 20 kA 35 kA 100 kA 1
2
N/A = Not Applicable
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm ) N/A1 3.5 9.4
IEEE
Inc. Energy via IEEE 1584 &1584 Predicted
Trip Curve (Cal/cm 2) 218 3.5 5.8 because it is outside the
Measured Incident Energy 2
(Cal/cmMeasured
Actual ) 1.86 1.2 1.64 range of the IEEE 1584
Generic Equation
• 1584 predicts higher than actual incident energy for breakers and lower
than possible incident energy for fuses
• Incident energy release from Eaton MCCB protected circuit will be HRC 1 or
less for any current above 15x handle rating up to and including 100 kA

Method 12
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 Low Voltage Power Circuit Breakers

• Unless a Low Voltage Power Circuit Breaker

operates in the Instantaneous trip mode, the
arc flash energy values will require Category
3 PPE or greater
• Testing on Eaton’s Zone Selectively Interlocked Magnum Breakers
provided significantly lower Arc Flash energy values. Maximum
Category 2 PPE (8 cal/cm2) required with proper instantaneous
settings, 4000A maximum.
• During maintenance it is recommended to temporarily adjust the
Instantaneous and Ground Fault (if available) trip settings to their
lowest value

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 For Even Better AF Performance, try …
M1

1. Bus Differential (87B)

• MV or HV Method 13 SD=
0.5S
2. Zone Selective Interlocking
• Usually LV 35kA fault current
F1 F2 X F3

Method 14
SD= SD= SD=
0.3S 0.3S 0.3S

Without ZSI = 0.5 S: With ZSI = 0.08 S:

43.7 Cal/cm2 7.0 Cal/cm2
Greater than Cat. 4 PPE Cat. 2 PPE
DANGER! FR Shirt & Pants

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Keep Blast Away From People …
1. Label Equipment & Train Personnel on Good
Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

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 5/15/27/38 kV Arc Resistant Switchgear
Arc Flaps

Control
Section
2000A or
3000A breaker
with Vent
VT
drawer

Manual Close /
1200A can be 1
Open Push Buttons
high or 2 high

Method 24
LV Arc Resistant Switchgear
Arc Flaps

Method 25
MV Arc Resistant Motor Control Center

Arc Plenum
(available side
or rear exhaust)

Method 26
Arcflash Resistant Motor Control Center
Bucket Position Racking Tool Receiver Internal Shutter
 Connected 3/8” Square Position

 Test  Open
 Withdrawn  Closed
Handle
Mechanism

Breaker
Device Island
• Start, Stop, Auto, Man
Starter

Remote Motor Operated

Racking with Pendant Station

Method 27
You Can Also …
1. Label Equipment & Train Personnel on Good
Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

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 Transformer Bushing Monitoring
• Monitor Transformer Bushings
• Capacitance
• Power Factor

Method 28

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 Partial Discharge Monitoring
• Monitor Insulation Integrity
• Switchgear
• Generators
• Motors

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 Enable Safer Inspection
• Infrared Scanning Windows
for LV/MV Assemblies

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 Continuous Thermal Monitoring
• Monitoring connecting joints on a • Monitoring Individual
computer room power distribution Connections
unit (PDU) switchboard, utilizing
plastic bracket system
IR Sensor

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Or You Can …
1. Label Equipment & Train Personnel on Good
Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

Both work to
Reduce Energy
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Faster Clearing Times
ARMSTM (Arc Flash Reduction Maintenance System)

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ARMS Maintenance Mode
ACB Application

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Design the Hazard Out (Safety by Design)
PowerXpert CX with ARMS

Type Tested to IEC61439-1 (ASNZS3439)

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Design the Hazard Out (Safety by Design)
PowerXpert CX with ARMS

Arcing Current = 5.6kA

Normal: HRC = 3 (11 cal/cm2)
Maintenance: HRC = 1 (3 cal/cm2)
Type Tested to IEC61439-1 (ASNZS3439)

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 Arcflash Reduction Maintenance System

• Available with new

equipment or as retrofit
Remote ARMS MV ARMS
DT520 MC Trip Unit
with ARMS built-in

Indicating Breaker Mounted Components

Light
DIGITRIP Retrofit Trip Unit Harness

Lockout
Switch
Battery

Door Mounted Components Pickup Level Setting

 Eaton Testing to Validate ARMS
Eaton Arc Flash Test Setup
Lab Output Load
Terminals Conductors

Circuit
Breaker
3/4” Diameter Copper
Electrodes
Line
Conductors 7
Calorimeter
Array

18 AWG Shorting
Wire between 3
Phase Electrodes

Output =
Arc Flash Energy

Open Side of
20”x20”x20” Enclosure Enclosure

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Eaton Testing to Validate ARMS
Results of Eaton Moulded-Case Breaker Testing
Incident Energy at
Bolted Fault Current
Min Mid Max
225 A MCCB with Thermal-Magnetic Trip Unit
Bolted fault current 3.4 kA 35 kA 100 kA
2
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm ) N/A1 1.7 4.7
Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm 2) 59.6 1.1 2.3
2
Measured Incident Energy (Cal/cm ) 0.08 0.1 0.11
1200 A MCCB with Electronic Trip Unit
Bolted fault current 20 kA 35 kA 100 kA
Inc. Energy via IEEE 1584 Table E.1 Generic (Cal/cm 2) N/A1 3.5 9.4
Inc. Energy via IEEE 1584 & Trip Curve (Cal/cm 2) 218 3.5 5.8
2
Measured Incident Energy (Cal/cm ) 1.86 1.2 1.64

IEEE 1584 Generic Equation 1 N/A = Not Applicable

IEEE 1584 Using Time because it is outside the
Current Curve Input range of the IEEE 1584
Generic Equation
Tested Value
Arc Flash Test Setup

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 Arcflash Reduction Maintenance System
(ARMS™)

Nominal reduction values (pickup) with a tolerance of ± 15% are:

Maintenance mode at: 2.5x , 4x , 6x , 8x , 10x
A blue LED indicating light verifies Maintenance Mode setting is active!

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Arcflash Reduction Maintenance System:
Reduces Hazard Risk Category

Example:

• Normal settings –
HRC = 3 (10.7 cal)

• With Arcflash Reduction

Maintenance Switch –
HRC = 1 (2.2 cal)

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 ARMS Maintenance Mode
600A Interruption Devices (5kA @ 480V)

Fuse Breaker w/ Instantaneous Breaker w/ Maintenance Mode

(Click videos to view)

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How is the ARMS system used to
reduce incident energy?

When the Arcflash Reduction Maintenance System

is enabled and fault current is detected, the clearing
time of the associated circuit breaker is reduced.

The table in next slide shows how the incident

energy varies with fault duration times where the
bolted fault level is 40 kA.

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 Incident energy varies with fault
duration times
Bolted Arcing Fault Incident Hazard
Fault Fault Duration Energy Risk
(kA) (kA) (secs) (cal/cm²) Category
_________________________________________________________
40 20 2 89 >4
40 20 0.5 22 3
40 20 0.3 13 3
40 20 0.1 4.4 2
40 20 0.05 2.2 1
________________________________________________________

40 20 0.04 1.8 1
_________________________________________________________

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Hazard Analysis, Risk Estimation and Risk
Evaluation Procedure (NPFA 70E, Annex F)

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 Conclusion: Safety By Design
Moving Electrical Safety & Reliability Upstream

NEC, OSHA, MSHA, NFPA70E,

IEC60439, ASNZS3439 = Retrofit!

Business Design Build Operation Dismantle

Concepts Maintenance Recycle

Prevention Protection

Safety By Design: Moving from an afterthought to a forethought in

product, process, and facility design

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Conclusion of different methods you can
employ to make your facility safer

1. Label Equipment & Train Personnel on Good

Safety Practices
2. Move People Further Away
3. Redirect Blast Energy
4. Prevent Fault
5. Reduce Available Fault Current
6. Shorten Clearing Time

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 Questions?

Questions?

Electrical Systems: Design - Install - Maintain

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