Arc-Flash Hazard Who is Eaton?: •Company Overview •Electrical •Engineering Services Arc Flash Overview What is Arc-Flash?: •Definitions / Examples •Dangers What Can Be Done?: •Costs •Engineering Studies & Training •A.R.M.S. •Arc-Resistant Gear •Remote Power Racking Tom Studer Eaton Electrical Power Systems Engineering Tempe, AZ © 2003 Eaton Corporation. All rights reserved. Who is Eaton • $12.3B 2006 Sales Global Diversified Industrial Company • Leader in fluid power systems; electrical power quality, distribution and control; automotive engine air management and fuel economy; and intelligent drive train systems for fuel economy and safety in trucks. Eaton – PSE’s Power Systems Engineers (PSE’s) • Average 15 years experience with multiple manufacturers equipment/devices (GE, Square D, ABB, AB) • Greater than 30% of PSE’s with Masters in EE • Licensed Professional Engineers • Use state of the art Software tools • Centralized core group – and – field deployed resources • Active on standards committees and recognized industry power experts • Headquartered in Cleveland, OH • Eaton has 60,000 employees and sells products in more than 129 countries. • 195 Manufacturing Sites • Website: www.eatonelectrical .com • NYSE Ticker: etn Business Segments Automotive Electrical Fluid Power Truck Engineering Studies ABSTRACT Power Quality Studies • Harmonic Analysis • Transient Analysis • Effective Grounding Safety & Reliability Studies • Power Quality Site Surveys • Arc Flash Studies & Labeling • Disturbance Monitoring • Protective Device Evaluation . • Protective Device Coordination • Power System Investigations • Grounding • Short Circuit • Power System Audit As more and more industry addresses arc flash electrical safety concerns, they are discovering high risk associated with what used to be normal maintenance tasks. In many cases, the excessively high arc flash incident energies make it so all maintenance must be done with equipment de-energized -not always acceptable to the process industries. We will address the multiple ways to significantly lower arc flash incident energy exposure by new system design and products, retrofits, retro-fills, equipment modifications, alternate protection settings, etc. In most cases, NFPA 70E Hazard Risk Category 2 or lower can be obtained with the right methods. Several real world examples will be discussed. 1 Standards Covering Arc Flash So… National Fire Protection Agency (NFPA) NFPA 70-2008 National Electric Code (NEC) NFPA 70E-2009 Standard for Electrical Safety in the Workplace . . Occupational Safety and Health Administration (OSHA) OSHA 29 CFR Part 1910 What does each standard have to say about the Arc Flash Hazard? Institute of Electrical and Electronics Engineers (IEEE) C2-2007 National Electric Safety Code (NESC) 1584-2002 Guide for Performing Arc Flash Hazard Calculations NEC Arc Flash Label NEC 2008 Edition Warning Sign Section 110.16 Flash Protection . Electrical equipment, such as switchboards, panelboards, industrial control panels, meter socket enclosures, and motor control centers that are in other than dwelling occupancies and are likely to require examination, adjustment, servicing, or maintenance while energized shall be field marked to warn qualified persons of potential electric arc flash hazards. The marking shall be located so as to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment. NFPA 70E-2009 NFPA 70E-2009 Article 100. Arc Flash Hazard. A dangerous condition associated with the possible release of energy caused by an electric arc. 130.3 Arc Flash Hazard Analysis . FPN No. 1: An arc flash hazard may exist when energized electrical conductors or circuit parts are exposed or when they are within equipment in a guarded or enclosed condition, provided a person is interacting with the equipment in such a manner that could cause an electric arc. Under normal operating conditions, enclosed energized equipment that has been properly installed and maintained is not likely to pose an arc flash hazard. FPN No. 2: See Table 130.7(C)(9) for examples of activities that could pose an arc flash hazard. FPN No. 3: See 130.3 for arc flash hazard analysis information . An arc flash hazard analysis shall determine the Arc Flash Protection Boundary and the personal protective equipment that people within the arc Flash Protection Boundary shall use. 2 Arc Flash Hazard Analysis and Labeling OSHA Code of Federal Regulations . IEEE C2-2007 (NESC) 1910.269(l)(6)(ii) – The employer shall train each employee who is exposed to the hazards of flames or electric arcs in the hazards involved. 1910.269(l)(6)(iii) – The employer shall ensure that each employee who is exposed to the hazards of flames or electric arcs does not wear clothing that, when exposed to flames or electric arcs, could increase the extent of injury that would be sustained by the employee. 1910.335(a)(1)(i) – Employees working in areas where there are potential electrical hazards shall be provided with, and shall use, electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed. IEEE 1584-2002 1.1 Scope Section 41. Supply and communications systems A. This guide provides techniques for designers and facility operators to apply in determining the arcflash hazard distance and the incident energy to which employees could be exposed during their work on or near electrical equipment. General 1. . The employer shall inform each employee working on or about communications equipment or electric supply equipment and the associated lines, of the safety rules governing the employee’s conduct while so engaged. When deemed necessary, the employer shall provide a copy of such rules. . 1.2 Purpose 2. The employer shall provide training to all employees who work in the vicinity of exposed energized facilities. The training shall include applicable work rules required by this Part and other mandatory referenced standards or rules. The employer shall ensure that each employee has demonstrated proficiency in required tasks. The employer shall provide retraining for any employee who, as a result of routine observance of work practices, is not following work rules. 3. Effective as of January 1, 2009, the employer shall ensure that an assessment is performed to determine potential exposure to an electric arc for employees who work on or near energized parts or equipment. If the assessment determines a potential employee exposure greater than 2 cal/cm2 exists (see Neal, Bingham, and Doughty [B59]), the employer shall require employees to wear clothing or a clothing system that has an effective arc rating not less than the anticipated level of arc energy. NFPA 70E 2009 NFPA 70E Standard for Electrical Safety in the Workplace 2009 Edition Arc Flash Hazard-Definition A dangerous condition associated with the possible release of energy caused by an electric arc. FPN No. 1: An arc flash hazard may exist when energized electrical conductors or circuit parts are exposed or when they are within equipment in a guarded or enclosed condition, provided a person is “INTERACTING” with the equipment in such a manner that could cause an electric arc. This guide presents methods for the calculation of arc-flash incident energy and arcflash boundaries in three-phase ac systems to which workers may be exposed. It covers the analysis process from field data collection to final results, presents the equations needed to find incident energy and the flash-protection boundary, and discusses software solution alternatives. Applications cover an empirically derived model including enclosed equipment and open lines for voltages from 208 V to 15 kV, and a theoretically derived model applicable for any voltage. Included with the standard are programs with embedded equations, which may be used to determine incident energy and the arc-flash-protection boundary. NFPA 70E 2009 FPN No. 2: See Table 130.7(C)(9) for examples of activities that could pose an arc flash hazard. FPN No. 3: See 130.3 for arc flash hazard analysis information. Arc Flash Hazard Analysis. A study investigating a worker’s potential exposure to arc flash energy, conducted for the purpose of injury prevention and the determination of safe work practices, arc flash protection boundary, and the appropriate levels of PPE. Under normal operating conditions, enclosed energized equipment that has been properly installed and maintained is not likely to pose an arc flash hazard. 3 What is an Arc-Flash? An arc flash starts with an arcing fault. An arcing fault can be defined as the flow of current through a path where it is not intended to flow. The current creates an electric arc plasma and releases dangerous amounts of energy NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Bolted Fault What is an “arc-fault”? An electric arc is the passage of substantial electrical current through ionized air and gasses. Bolted Fault A B Arc Fault Example: A B Short-Circuit Basics Causes of Bolted Faults • Re-energizing without removing temporary grounds • Incorrect connection of a parallel run of cables to a motor terminal box Conduit #1 Motor Conduit #2 NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Arcing Fault NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Arcing Fault • Faults which are not bolted. • Poor electrical connection between conductors can cause arcing. • Arcing results in tremendous heat. 35,0000 F 4 NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Arc Flash Introduction Common Causes of Arcing Faults Numerous workers injured/killed each year while working on energized equipment. Defining incident energy hazards raises awareness of the harm to humans that can result from an electric arc. This includes: • Insulation deterioration and failure • Work related incidents when working with tools, removing panels, taking power measurements, etc. • Loose connections (cable terminations, transformer connections, etc.) DEVELOPMENTS LEADING TO NFPA 70E-2004 • Severe skin burns • Hearing damage • Face and eye injuries • Blast pressure injuries NFPA 70E-2009 NFPA 70E 2009, Table 130.7(C)(10) PPE Requirements Important Temperatures HRC Energy cal/cm2 Typical Personal Protective Equipment Skin temperature for curable burn 1760F 0 >0 to 1.2 Non-Melting natural fibers such as 100% cotton (fabric weight at least 4.5 oz/yd2 + Safety Glasses & Hearing Protection Skin temperature causing cell death 2050F 1 >1.2 to 4 1 layer Flame Resistant (FR) clothing, min arc rating of 4 cal/cm 2 + Hard hat, safety glasses, Hearing Prot., Faceshield & Hand Prot. Ignition of clothing 2 >4 to 8 1 layer FR clothing, min arc rating of 8 cal/cm2 + Hard hat, safety glasses, Face shield, Hearing Prot., Hand Prot. & Foot Prot. (cotton T-shirt is optional, not required) Burning clothing 14720F 3 >8 to 25 Multilayer of FR clothing, min Arc rating of 25 cal/cm2 + Flash suit hood, safety glasses, hearing protection, hand & foot protection (cotton T-shirt is optional, not required) Metal droplets from arcing 18320F 4 >25 to 40 Multilayer of FR clothing, min Arc rating of 40 cal/cm2 + Flash suit hood, safety glasses, hearing protection, hand & foot protection (cotton T-shirt is optional, not required) Surface of sun 90000F Arc terminals 7520F-14720F 35,0000F NFPA 70E Protective Clothing and PPE Table (Table 130.7(C)(10)©NFPA) Hazard/Risk Category Protective Clothing and PPE Hazard/Risk Category 0 • • • • Undergarments: Must be non meltable fibers such as 100% cotton FR clothing: Shirt and pants. Alternative is coveralls Hand Protection: Leather gloves or Leather protectors over Rubber gloves Foot Protection: Leather Work shoes or boots NFPA 70E Protective Clothing and PPE Table (Table 130.7(C)(10)©NFPA) Hazard/Risk Category Protective Clothing and PPE Hazard/Risk Category 2 - Protective Clothing ,Non-melting (According to ASTM F 1506-00) or Untreated Natural Fiber Shirt (long sleeve) Pants (long - FR Protective Equipment Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (AN) (Note 2) Hazard/Risk Category 1 - FR Clothing ,Minimum Arc Rating of 4 (Note 1) Arc-rated long-sleeve shirt (Note 3) Arc-rated pants (Note 3) Arc-rated coverall (Note 4) Arc-rated face shield or arc flash suit hood (Note 7) Arc-rated jacket, parka, or rainwear (AN) - FR Protective Equipment Hard hat Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (AN) (Note 2) Leather work shoes (AN) - FR Clothing ,Minimum Arc Rating of 8 (Note 1) Arc-rated long-sleeve shirt (Note 5) Arc-rated pants (Note 5) Arc-rated coverall (Note 6) Arc-rated face shield or arc flash suit hood (Note 7) Arc-rated jacket, parka, or rainwear (AN) - FR Protective Equipment Hard hat Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (AN) (Note 2) Leather work shoes (AN) Hazard/Risk Category 2* - FR Clothing ,Minimum Arc Rating of 8 (Note 1) Arc-rated long-sleeve shirt (Note 5) Arc-rated pants (Note 5) Arc-rated coverall (Note 6) Arc-rated arc flash suit hood (Note 10) Arc-rated jacket, parka, or rainwear (AN) - FR Protective Equipment Hard hat Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (AN) (Note 2) Leather work shoes (AN) 5 NFPA 70E Protective Clothing and PPE Table (Table 130.7(C)(10)©NFPA) Hazard/Risk Category Protective Clothing and PPE Hazard/Risk Category 3 NFPA 70E Protective Clothing and PPE Table (Table 130.7(C)(10)©NFPA) Hazard/Risk Category Protective Clothing and PPE Hazard/Risk Category 4 - FR Clothing ,Minimum Arc Rating of 25 (Note 1) Arc-rated long-sleeve shirt (AR) (Note 8) Arc-rated pants (AR) (Note 8) Arc-rated coverall (AR) (Note 8) Arc-rated arc flash suit jacket (AR) (Note 8) Arc-rated arc flash suit pants (AR) (Note 8) Arc-rated arc flash suit hood (Note 8) Arc-rated jacket, parka, or rainwear (AN) - FR Clothing ,Minimum Arc Rating of 40 (Note 1) Arc-rated long-sleeve shirt (AR) (Note 9) Arc-rated pants (AR) (Note 9) Arc-rated coverall (AR) (Note 9) Arc-rated arc flash suit jacket (AR) (Note 9) Arc-rated arc flash suit pants (AR) (Note 9) Arc-rated arc flash suit hood (Note 9) Arc-rated jacket, parka, or rainwear (AN) - FR Protective Equipment Hard hat FR Hard Hat Liner (AR) Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (Note 2) Leather work shoes - FR Protective Equipment Hard hat FR Hard Hat Liner (AR) Safety glasses or safety goggles (SR) Hearing protection (ear canal inserts) Leather gloves (Note 2) Leather work shoes NFPA 70E Protective Clothing and PPE Table (Table 130.7(C)(10)©NFPA) Why is an Arc Hazardous? AN = As needed (optional) AR = As required SR = Selection Required Notes: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. See Table 130.7(C)(11). Arc Rating for a garment or system of garments is express in cal/cm2. If rubber insulating gloves with leather protectors are required by Table 130.7(C)(9), additional leather or arc-rated gloves are not required. The combination of rubber insulating gloves with leather protectors satisfies the arc flash protection requirement. The FR shirt and pants used for Hazard/Risk Category 1 shall have a minimum arc rating of 4. Alternate is to use FR coveralls (minimum arc rating of 4) instead of FR shirt and FR pants. The FR shirt and pants used for Hazard/Risk Category 2 shall have a minimum arc rating of 8. Alternate is to use FR coveralls (minimum arc rating of 8) instead of FR shirt and FR pants. A face shield with a minimum arc rating of 4 for Hazard/Risk Category 1 or a minimum arc rating of 8 for Hazard/Risk Category 2, with wrap-around guarding to protect not only the face, but also the forehead, ears, and neck (or alternatively, an arc-rated flash suite hood), is required. An alternate is to use a total FR clothing system and hood, which shall have a minimum arc rating of 25 for Hazard/Risk Category 3. The total clothing system consisting of FR shirt and pants and/or FR coveralls and/or arc flash coat and pants and hood shall have a minimum arc rating of 40 for Hazard/Risk Category 4. Alternate is to use a face shield with a minimum arc rating of 8 and a balaclava (sock hood) with a minimum arc rating of 8 and which covers the face, head and neck except for the eye and nose areas. 35,000 °F Molten Metal Pressure Waves Sound Waves Shrapnel Copper Vapor: Solid to Vapor Expands by 67,000 times Hot Air-Rapid Expansion Intense Light Courtesy of Cooper Bussmann Bad things can happen. An electric arc fault is a bad thing! Bad things can happen. An electric arc fault is a bad thing! 6 Bad things can happen. An electric arc fault is a bad thing! Bad things can happen. An electric arc fault is a bad thing! •Large Hydro in Pacific NW •6.9kV Swgr •Racking in Breaker •AF occurred •One worker injured •7+ years, $10+ million Bad things can happen. An electric arc fault is a bad thing! Bad things can happen. An electric arc fault is a bad thing! Bad things can happen. An electric arc fault is a bad thing! Bad things can happen. An electric arc fault is a bad thing! 7 Arc Flash Injuries Arc Blast Pressure 165 db Arc Blast Pressure The pressure from an electric arc is developed from two sources: < 740 mph IR Visible 27,000°F 50 cal/cm2 UV 1830 °C 2000 psf Arc Blast Pressure Example Expansion of the metal as it vaporizes Heating of air by the arc energy When copper vaporizes, it expands by a factor of 67,000. This accounts for the expulsion of nearvaporized droplets of molten metal from the arc (droplets could be propelled up to 10 feet). Inhalation Injuries Inhalation Injuries In addition to burns, an arc flash can cause inhalation injuries. More than a hundred known toxic substances are present in fire smoke. When inhalation injuries are combined with external burns the chance of death can increase significantly. Failed 50kA 5kV available fault current 0.5sec – FULL SPEED Toxic Smoke Example DEVELOPMENTS LEADING TO NFPA 70E-2004 Burn Injuries Burns are classified as first, second, or third degree, depending on how deeply the layers of skin (dermis and epidermis) are damaged. 8 DEVELOPMENTS LEADING TO NFPA 70E-2004 DEVELOPMENTS LEADING TO NFPA 70E-2004 Diagram of Normal Skin Epidermis A First Degree Burn is red and sensitive to touch. There is minimal skin damage and only the skin surface is involved. Dermis Example: Sunburn Hypodermis or subcutaneous tissue Muscle DEVELOPMENTS LEADING TO NFPA 70E-2004 A Second Degree Burn involves the first and second layers of skin. The skin reddens intensely and blisters develop. Severe pain and swelling occur and chance for infection is present. DEVELOPMENTS LEADING TO NFPA 70E-2004 What Is a Calorie? A calorie is the energy required to raise one gram of water one degree Celsius at one atmosphere. DEVELOPMENTS LEADING TO NFPA 70E-2004 A Third Degree Burn causes charring of skin and coagulation of blood vessels just below the skin surface. All three layers of skin are affected. Extensive scarring usually results. DEVELOPMENTS LEADING TO NFPA 70E-2004 The intent of NFPA 70E regarding arc flash is to provide guidelines which will limit injury to the onset of second degree burns. At 1 second, 1.2 cal/cm2 of heat energy can cause a second degree burn. 9 DEVELOPMENTS LEADING TO NFPA 70E-2004 DEVELOPMENTS LEADING TO NFPA 70E-2004 Definition of Incident Energy The intent of NFPA 70E regarding arc flash is to provide guidelines which will limit injury to the onset of second degree burns. Three Main Factors Affecting Incident Energy and Arc Flash Skin damage will occur based on the intensity of the heat generated by an electrical arc accident. The heat reaching the skin of the worker is dependent on the following three factors: Main Factors Affecting Arc Flash: IEEE defines incident energy as 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 calories/cm2 or in Joules/cm2. DEVELOPMENTS LEADING TO NFPA 70E-2004 The following table shows how the power of the arc and/or time duration of the arc will affect incident energy when the worker distance is held constant at 18 inches from the arc flash. Note: The incident energy calculations were performed using the “Arc in a Box” equations. • Power of the arc at the arc location • Distance of the worker to the arc • Time duration of the arc exposure Illustration of Power and Time Effects on NFPA Calculations for Arc in a Box Hold Distance Constant Holdtime SC ••Hold currentat 3 constant constant cyclesat 30 kA • Vary the SC • Vary from the current time 3 to 16kAfrom to 50kA 60 cycles • Relatively • Significant small change change in terms in of terms of required PPE required (~ 2 cal toPPE ~9 (~ 3 cal) cal to ~ 60 cal) Distance 18 18 18 18 18 18 18 18 (inches) Clearing 3 6 10 20 30 40 50 60 Time (cyc) (sec) 0.05 0.10 0.17 0.33 0.50 0.67 0.83 1.00 SC kA cal/cm2 cal/cm2 cal/cm2 cal/cm2 cal/cm2 cal/cm2 cal/cm2 cal/cm2 16 2.07 4.14 6.90 13.81 20.71 27.62 34.52 41.42 18 2.03 4.06 6.76 13.52 20.29 27.05 33.81 40.57 20 2.04 4.08 6.80 13.60 20.40 27.21 34.01 40.81 22 2.11 4.21 7.02 14.05 21.07 28.09 35.11 42.14 24 2.23 4.46 7.43 14.85 22.28 29.71 37.13 44.56 26 2.40 4.81 8.01 16.02 24.04 32.05 40.06 48.07 28 2.63 5.27 8.78 17.56 26.34 35.12 43.90 52.67 30 2.92 5.84 9.73 19.46 29.18 38.91 48.64 58.37 32 3.26 6.52 10.86 21.72 32.58 43.44 54.30 65.16 34 3.65 7.30 12.17 24.35 36.52 48.69 60.86 73.04 36 4.10 8.20 13.67 27.34 41.00 54.67 68.34 82.01 38 4.60 9.21 15.34 30.69 46.03 61.38 76.72 92.07 40 5.16 10.32 17.20 34.41 51.61 68.81 86.02 103.22 42 5.77 11.55 19.24 38.49 57.73 76.98 96.22 115.46 44 6.44 12.88 21.47 42.93 64.40 85.87 107.33 128.80 46 7.16 14.32 23.87 47.74 71.61 95.49 119.36 143.23 48 7.94 15.87 26.46 52.92 79.37 105.83 132.29 158.75 50 8.77 17.54 29.23 58.45 87.68 116.91 146.13 175.36 NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Calculating Prospective Short-Circuit Current, ISC NFPA 70E-2004, Annex D.3©NFPA provides the “well known” formula that is used to calculate the short-circuit symmetrical amperes from a bolted 3-phase fault at a transformer terminals: I SC = MVABase × 10 6 100 × 1.732 × V %Z (4 - 1) 10 NFPA 70E CALCS FOR FLASH PROTECTION BOUNDARY AND INCIDENT ENERGY Arc-Flash Costs: Human Classroom Exercise 4a: Perform a Calculation of Prospective Short Circuit Current Problem: Using equation (4-1), calculate the prospective short circuit current for a fault at the 480 V terminals of a 1500 kVA transformer which has a nameplate impedance of 5.5%. I SC 1.5 ×106 100 × = 1.732 × 480 5.5 = 32,805 Amps PPE – Too Much Employee performed some troubleshooting on 15KV Gear and determined that he did not have control power Customer was instructed to restore power to the 15KV B side main breaker and remove power from the A side main breaker Employee locked out the A side main breaker and the tie breaker Employee pulled the CPT drawer on the A side main on the front of the switchgear and adjusted the secondary contacts Employee visually inspected the routing of the 15 kV power cables on the A side CPT connections in the rear of the switchgear Customer was instructed to restore power to the A side main and the employee verified the control power was still not present Clothed areas can be burned more severely than exposed skin. The most severe burns are caused by ignited clothing, not by the original flash fire or electric arc exposure. PPE – Not Enough Nor this Not this Accident Description Accident Description Continued Employee crawled into the lower compartment of vertical section 6 Employee opened the shutter in the VT compartment to see if the 15 kV jumper cables were installed and connected between the CPT and VT drawers When Employees flashlight got too close to the ionized air, there was an arc flash incident 11 Arc Flash Incident Arc Flash Incident Arc Flash Incident Arc Flash Incident Arc Flash Incident Arc Flash Incident 12 Injury Consequences Burn injuries can be fatal. Survival depends on age, health, exposure intensity and time, area of the body burned. Treatment of second degree burns requires weeks, for third degree burns it can be years. Arc-Flash Costs: Monetary National Institute for Occupational Safety and Health (NIOSH) from the US Bureau of Labor Statistics Arc Flash Example Failed 50kA 5kV available fault current 0.5sec – FULL SPEED The Personal Cost Is Devastating Due to disfigurement and intense pain the victim will often not want to live, depression is common. Children will likely not be able recognize the burn victim after the accident. The victim’s spouse will be traumatized, divorce is common. Treating Burn Injury Is Very Expensive The cost of treatment can exceed $1,000,000 USD for a single case. Treatment can require years of skin grafting and rehabilitation. The victim may never be able to return to work. Arc Flash Example Failed 50kA 5kV available fault current 0.5sec – SLOW MOTION 13 Arc Flash Standards and OSHA Six-Point Plan NIOSH Data for the year 2000 Four separate industry standards concern the prevention of arc flash incidents: OSHA 29 Code of Federal Regulations (CFR) Part 1910 Subpart S. NFPA 70-2008 National Electrical Code. IEEE Standard 1584-2002 Guide for Performing Arc Flash Hazard Calculations. NFPA 70E-2009 Standard for Electrical Safety in the Workplace. Nonfatal injuries and illnesses = 5.7 million Days away cases = 1.7 million Fatal work related injuries = 5,920 Compliance with the latest OSHA standards involves adherence to a six-point plan: A facility must provide, and be able to demonstrate a safety program with defined responsibilities. Calculations for the degree of arc flash hazard. Correct personal protective equipment (PPE) for workers. (FR Rated Clothes, HV Gloves, Face Shield) Training for workers on the hazards of arc flash. Appropriate tools for safe working. (Grounds, rubber mats, voltage detectors, hot sticks etc.) Warning labels on equipment. (Arc Flash Labels with Incident Energy (cals) & appropriate PPE) Companies will be cited and fined for not complying with these standards. NIOSH Electrical fatalities by industry, 1992-2000. Days away electrical cases = 3,786 Electrical Fatalities = 260 About 1 of every 450 nonfatal accidents involved electricity, but…. 1 of every 23 deaths was caused by electricity. Nonfatal electrical shock and burn injuries involving days away from work 1992-2000 by industry NIOSH’s summary & conclusions from these statistics: Electrical accidents are more likely to result in death than many other types of accidents. Contact with overhead power lines is the leading cause of onthe-job electrical death. The construction industry accounted for 45% of electrical deaths followed by: Agriculture (12%); Transportation (11%); Manufacturing (11%); Service (10%). Nonfatal electrical accidents are: distributed more evenly across all industries than are fatalities, but construction industry is still highest. Electrical shock and electrical burns and their distribution varies widely by industry. Arc Flash History Timeline 1968 Dow implements arc flash PPE program 1980 Published article on use of arc flash PPE 1981 Ralph Lee publishes theory for hazard calculations 1986 DuPont implements arc flash PPE program 1990 OSHA subpart S does not address arc flash details 1994 OSHA 1910.269 addresses clothing hazards 1995 DuPont undertakes arc flash R&D 1995 ASTM Arc Test Method development 14 ARC FLASH Avoidance: Arc Flash History Timeline Superior Protection with the Right Products What Can Be Done: 1995 NFPA70E defines arc flash boundary 1996 DuPont arc flash research published Engineering Studies: 1997 DuPont protective clothing research published Arc Flash Study!...(includes Arc Flash Labels) 1998 ASTM standards for PPE testing Protective Device Coordination (Breaker Settings) Short Circuit Study 1999 Arc Flash rated PPE appears 2000 NFPA70E expands arc flash requirements 2002 NEC requires arc flash hazard warning 2002 IEEE 1584 calculation guide published 2004 NFPA 70E major reorganization Training Personal Protective Equipment Arc Flash Reduction Maintenance Switch Arc-Resistant Switchgear & Controls Remote Power Racking STANDARDS EESS NFPA70E Arc Flash Compliance NFPA 70E (2009) Key Features Asset Optimization Knowledge Management Eaton Engineering Services & Systems Arc Flash Studies Integrated Project Solutions Equipment shall be field marked with a label containing the available incident energy or required level of PPE. (130.4(C)) Power Systems Engineering Solutions Power Systems Modernization Arc Flash Hazard Analysis shall be updated when a major modification or renovation takes place. (130.3) New Equipment Services Field Services 70+ Power Systems Engineers Standardized Data Collection Templates Studies, Labels, Training, Recommendations Arc Flash Hazard Analysis shall be reviewed periodically, not to exceed 5 years. (130.3) Hazard Risk Categories (0-4). Changes in PPE; Level 1 PPE includes face shield. (130.7(C)(10)) NFPA 70-2005 (NEC) E-ESS ARC FLASH PROGRAM Warning Sign A calorie is the energy required to raise one gram of water one degree Celsius at one atmosphere. At 1 second duration, 1.2 cal/cm2 of incident heat energy can cause a second degree burn. E-ESS PROTECTIVE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT MATRIX Protective Clothing & Equipment NFPA 70E Hazard/Risk Category Number Range of Arc Rating (cal/cm2) FR Clothing Coveralls (1 layer) Minimum Arc Rating = 8 cal/cm2 Two Coveralls (2 layer) worn over Minimum Arc Rating (for 2 layers) = 40 cal/cm2 Jacket, parka, or rainwear Protective Systems for Hazard/Risk Category 0 1 2 3 4 > 0 to 1.2 1.2 to 4 4 to 8 8 to 25 25 to 40 X X X AN AN X X AN AN 15 Arc Flash Hazard Analysis and Labeling NFPA 70E 2009 Annex H Simplified two Category FR Clothing Categories 0,1 & 2: 8+ Calorie FR long-sleeve shirt 8+ Calorie FR Pants Arc Flash Hazard Analysis and Labeling Eaton Recent Arc Flash Study’s Categories 3 & 4 40+ Cal Jacket 40+ Cal Pants 40+ Cal Hood Gloves, Faceshield/Hood, Hearing Protection Leather Shoes, Safety Glasses, (per hazard level) Eaton Local Arc Flash Study’s Asarco Copper Mines Sky Harbor Airport USAA Insurance Group TEP Springerville Wild Horse Pass Casino Chase Field Cargill 179 Sites Georgia Pacific 54 Sites VA Hospitals 25 Sites Enbridge Pipeline 25 Sites Weyerhaeuser 104 Sites Woodbridge Group 14 Sites GM 12 Sites Ford 10 Sites Arc Flash Incident 16 Arc Flash Incident Arc Flash Incident Arc Flash Incident Training Understanding Arc-Flash •Existing and Proposed Standards •Determining Safe Approach Distance •Methods for Calculating Prospective Short Circuit Current •IEEE Standard 1584 & NFPA 70E Methods for Calculating Flash Protection Boundary Distance and Incident Energy Value Training Understanding Arc-Flash •Determining Hazard Risk Category •Selecting Protective Clothing and the PPE Matrix Flash Protection Boundary And Limits Of Approach •ATPV Values for Common Types of Garments •Practical Methods for Reducing Arc-Flash Hazard •Eaton can award 0.8 CEUs for the successful completion of this training. 17 FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH Approach / Flash Protection Boundaries Definitions of Boundaries and Spaces The closer you approach an exposed, energized conductor or circuit part, the greater the chance of an inadvertent contact and the greater the injury that an arc flash will cause. NFPA 70E2004, Annex C©NFPA defines approach boundaries and work spaces. The diagram on the next slide illustrates these. FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH NFPA 70E-2004, Table 130.2(C)NFPA Approach Boundaries to Live Parts for Shock Protection. (All dimensions are distance from live part to employee.) (1) (2) (3) (4) (5) Qualified Person (OSHA 29CFR1910) (Cont.) 1 Limited Approach Boundary Restricted Approach 1 Boundary ; Includes Inadvertent Movement Adder Nominal System Voltage Range, Phase to Phase Exposed Movable Conductor Exposed Fixed Circuit Part Prohibited Approach Boundary1 < 50 Not specified Not specified Not specified Not specified 50 to 300 10 ft 0 in. 3 ft 6 in. Avoid contact Avoid contact 301 to 750 10 ft 0 in. 3 ft 6 in. 1 ft 0 in. 0 ft 1 in. 751 to 15 kV 10 ft 0 in. 5 ft 0 in. 2 ft 2 in. 0 ft 7 in. 15.1 kV to 36 kV 10 ft 0 in. 6 ft 0 in. 2 ft 7 in. 0 ft 10 in. 36.1 kV to 46 kV 10 ft 0 in. 8 ft 0 in. 2 ft 9 in. 1 ft 5 in. 46.1 kV to 72.5 kV 10 ft 0 in. 8 ft 0 in. 3 ft 2 in. Know what precautions to take to work safely, including: • how to carry out lockout/tagout procedures • how to manage and maintain a safe work area • how to use protective grounds Know how to use PPE Know how to use insulating and shielding materials Know how to use insulated tools 2 ft 1 in. 1. See definitions in NFPA 70E-2004 Article 100, and text in NFPA 70E-2004 130.2 (D)(2) and Annex C for elaboration. FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH Qualified Person (OSHA 29CFR1910) (Cont.) Note: A qualified person must be certified by his employer before working on or near energized equipment, (1910.269a2vii) and must have his or her qualifications reviewed annually. (1910.269a2iii) FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH Work intentionally performed on or near energized equipment or circuits is limited by standards and regulations, such as those issued by OSHA. Only qualified persons may work on energized electric circuits. (1910.333c2) Only qualified persons may perform tests on electric circuits or equipment. (1910.334c1) Only qualified persons may work on or with exposed lines or parts of equipment. (1910.269l1) 18 FLASH PROTECTION BOUNDARY AND LIMITS OF APPROACH Only qualified persons may work in areas containing unguarded, uninsulated energized lines or parts of equipment operating at 50 volts or more. (1910.269l1) Live parts to which an employee may be exposed shall be de-energized before the employee works on or near them, unless the employer can demonstrate that de-energizing introduces additional or increased hazards or is infeasible due to equipment design or operational limitations. (1910.333) SOLUTIONS THAT REDUCE ARC FLASH INJURIES and DAMAGE Label Equipment & Train Personnel Minimize Risk with Good Safety Practices Reduce Available Fault Current Faster Clearing Time Move People Further Away Redirect Blast Energy Prevent Fault PRACTICAL METHODS FOR REDUCING ARC FLASH HAZARDS Minimize Risk with Good Safety Practices De-Energize Equipment versus “Working It Live” unless increased hazards exist or infeasible due to design or operational limitations. Switching remotely (if possible) Closing and tightening door latches or door bolts before operating a switch. Standing to the side and away as much as possible during switching operations. PRACTICAL METHODS FOR REDUCING ARC FLASH HAZARDS Minimize Risk with Good Safety Practices - if you can maintain fast clearing times Practical Methods for Reducing Arc Flash Hazards Minimize Risk with Good Safety Practices PRACTICAL METHODS FOR REDUCING ARC FLASH HAZARDS Minimize Risk with Good Safety Practices Using the proper tools and equipment (Line side of Main). Bad – Exposed Back of Neck Good – All of Body Protected 19 PRACTICAL METHODS FOR REDUCING ARC FLASH HAZARDS PRACTICAL METHODS FOR REDUCING ARC FLASH HAZARDS Minimize Risk with Good Safety Practices Equipment Alternatives Using the proper tools and equipment (Load side of Main). Current-Limiting Breakers / Fuses - Reduces the clearing time which reduces the incident energy. Metal-Clad Switchgear - Structural design reduces the possibility of arcing faults within the enclosure. Arc Resistant Switchgear - Structural design includes robust design and pressure relief vents, which redirect the blast away from the worker. ARC FLASH Avoidance: ARC FLASH Avoidance: Superior Protection with the Right Products Superior Protection with the Right Products What is PPE? What is PPE? Personal Protective Equipment It is worn by everyone. Police officers, professional athletes, construction workers, chefs and everyone in between. Hard Hat with Arc Face Shield Rubber Gloves 31 Cal. Arc Suit & Hood F/R Coveralls Electrical PPE ARC FLASH Avoidance: ARC FLASH Avoidance: Superior Protection with the Right Products Superior Protection with the Right Products ARMsTM* – Retrofit for Low Voltage Circuit Breakers Arc-flash Reduction Maintenance Switch (ARMS) •Used to reduce the trip delay of LV circuit breakers while performing maintenance. •Enabled with the circuit breaker door closed by a door mounted lockable switch •Preserves coordination under normal conditions (not enabled continuously) Door Mounted Components Breaker Mounted Components DIGITRIP Harness Lockout Switch Battery *Arcflash Reduction Maintenance Switch 20 Practical Methods for Reducing Arc Flash Hazards Medium Voltage ARMS FP--5000 – Group Settings Using FP Multiple Settings Groups • Similar to LV maintenance switch, only for MV applications FP-5000 Relay • Used to reduce the trip delay of medium-voltage relays while maintenance is being performed on equipment Indicating Light • Requires relay with multiple settings groups capability, such as the Cutler-Hammer FP-5000 Switch Reduce Clearing Time FlashGard® MCC Network Protectors The Ultimate Arc Fault preventive solution ARC FLASH Avoidance: FlashGard® FlashGard® Motor Control Center Superior Protection with the Right Products The FlashGardTM Bucket Racking Tool Receiver Bucket Position Unit Latch Internal Shutter Position Features Open Closed Connected Test Withdrawn Handle Mechanism Device Island • Start, Stop, Auto, Man Breaker Starter Specially designed Stab Assembly • Designed to fit tightly with the labyrinth vertical bus bar making it virtually arc free 480 Volt Isolation via stab shutter Extendable and Retractable power stabs – up to 400 Amp Stab • Allows you to engage or disengage the stab with the vertical bus while the door is closed keeping you at a safe distance while performing this operation RotoTractTM assembly – No over torque • Special screw design spins free at the end of travel in either direction preventing over torque of the mechanism Status Indication • Stab position indication • Stab shutter position indication 21 FlashGard ® Door Accessories Remote Racking “wired” Accessory Accessory to perform RotoTract racking safely behind NFPA Arc Flash boundaries ARC FLASH Avoidance: Superior Protection with the Right Products How it works Bucket Position Indicator Internal Shutter Indicator Connected 120 VAC motor driven Open Test Mounts to RotoTract Mechanism Closed Withdrawn Wired pendant station for “rack-in”/ “rack-out” operation. Momentary Jog Mounting offset bracket to clear device panel ARC FLASH Avoidance: Superior Protection with the Right Products Overrunning mechanism prevents stripping of the mechanism or overtorquing Breaker must be open to access racking tool receiver Makes insertion of large size 4,5 buckets a much safer evolution. No more shoving buckets on to the vertical bus. APPLICATIONS Fiber Optic Arc Mitigation Devices Electrical Incidents Motor Control Centers account for the second highest frequency of electrical accidents. As a result of this finding, the industry is in need of a Motor Control Center that addresses all of these potential hazards. MCC’s Fiber Optic Arc Mitigation Devices APPLICATIONS Fiber Optic Arc Mitigation Devices UL Listing Issues NO INDUSTRY STANDARD exists for the design, application, or performance for these systems. On January 27, 2010, Underwriters Laboratories held a meeting to address this issue. UL clearly stated in the January meeting that they do NOT recognize any arc flash detection (light detection) systems. Able to Distinguish Between Light from Fault and Background Lighting Fast Acting Relay Trips Breaker Instantaneously European Design (Vaasa, ABB, Etc.) SEL, iGard & Eaton APPLICATIONS Fiber Optic Arc Mitigation Devices UL Listing Issues Eaton and UL are fully aware that several suppliers of devices that sense internal arcs and operate upstream protective devices have obtained UL labels. These labels, however, have been obtained utilizing generic standards intended for other types of devices, such as protective relays. In essence, they are misleading users relative to the certified capabilities of these devices. Customers need to be aware, that should UL labeled equipment integrated with these devices become involved in accidents that result in damage or injury, the suppliers of these devices will not have a legitimate industry standard upon which to claim safety compliance. 22 APPLICATIONS Fiber Optic Arc Mitigation Devices Other Issues with these Devices Eaton will not utilize these devices to reduce PPE Requirement calculated in an Arc Flash Study. No test standard to justify engineering calculation for arc flash study. Infrared Scanning Windows for LV/MV Assemblies Other arc mitigation devices like GE Arc Vault also would have UL issue. Can install in Non-Listed Assemblies May be utilized as a “back-up” system. Remote Switching: Chicken Switch Safety Related Solution Offerings Without Remote Racking of MV Breakers VCP-W 5/15 kV Swgr – New Swgr With Remain physically outside the flash protection boundary. Therefore NO ARC FLASH HAZARD protection required! Increase Working Distance Increase Working Distance ARC FLASH Avoidance: ARC FLASH Avoidance: Superior Protection with the Right Products Remote Racking Superior Protection with the Right Products Remote Racking – Eaton’s Universal Design for Retrofit Applications • LV or MV VS • Any breaker o Air-Magnetic o Vacuum o Vacuum Replacement o SF6 • 1-2 high MV & 1- 4 high LV • Flashgard MCC 23 AmpGard Motor Operated Iso Switch Motor Operated Iso Switch New Optional Accessory For Remote Operation Of Ampgard Isolation Switch And Increased Operator Safety. Temporarily Mounts To Front Of Starter Door Equipped With Mounting Provisions. Operation By Control Station Connected To Motor Operator Via 25foot Cable. ArcArc-Resistant Switchgear 5/15 kV Arc Construction Arc Flaps Redirects Arc Energy and Particulates Control Section 2000A or 3000A breaker with Vent VT drawer LV Arc Resistant Switchgear - Testing 1200A can be 1 high or 2 high Manual Close/Open Push Buttons Substations Without Main Secondaries AFL Retrofit Test @ 65kA / 508V Arc initiated in breaker compartment Plenum Design March 2008 - PASS Arc out-gassing through plenum No arc flash out of the front of the gear 24 Substations Without Main Secondaries Substations Without Main Secondaries Pri Fuse Only = 594 Calories Pri Bkr Only= 289 Calories Pri. Bkr + Maint. Switch= 7.5 calories Substations Without Main Secondaries ASTM F1506-02a - Standard Performance Specification for Textile Material for Wearing Apparel for Use by Electrical Workers Exposed to Momentary Electric Arc and Related Thermal Hazards, 2002a Developed to give min performance specs for protective clothing. Major requirement being that the fabric is flame resistant. Results must be reported to the end user as an Arc Rating on a garment label. Sense at 480V TxmrTrip Primary Use Group Settings for ARMS Many Variations Must Meet ANSI C37.59 ARC FLASH Avoidance: Superior Protection with the Right Products • • • • • • • • ASTM F1506 Standard Retrofill Primary Fuse with Mini Vac Bkr MV AMPGARD MV VCP-W I/R Windows FlashGard Motor Control Centers Door Mounted Metering and Controls Thru-Door racking capability High Impedance Transformers High Resistance Grounding Definition of Arc Rating Arc Rating Previously the Arc Thermal Performance Exposure Value (ATPV) Minimum incident thermal energy on a fabric or material that results in sufficient heat transfer through the fabric or material to cause the onset of a second degree burn based on the energy transmitted through the clothing. Arc Rating is expressed in cal/cm2. This energy is related to the Stoll curve. The Arc Rating is an average of 20 tests performed using the ASTM F1959-99 standard. 25 Layering of FR Clothing Layering of FR Clothing Layering of Clothing Layering significantly increases the level of protection. Two thin layers are better than one thick layer. Layer of air acts as a “buffer zone” between layers of flame resistant fabrics. Some multi-layer testing has been done by various fabric manufacturers and ASTM Task Groups (varies dramatically with different two-ply systems.) Wear life & Laundering of FR Clothing Layering of FR Clothing The single layer and multi-layer ratings for two FR fabrics are shown as an example below: Tested per ASTM F1959/F1959M-04 Standard Test Method for Determining the Arc Thermal Performance Value of Materials for Clothing Single-Layer Fabrics INDURA® Ultra Soft® Style 301 Style 801 Product / Style Fabric Description 7oz (237g/m2) Shirting Twill 13oz (440g/m2) Heavyweight Sateen ATPV (cal/cm2) 8.7 Expected Lifetime and Effects of Cleaning Wear life is affected by laundering. Industrial laundering will create more wear on a garment than home laundering. Garments manufacturer’s provide the expected lifetime based on use and laundering. • 21.0 Multi-Layered Systems • ATPV 2 (cal/cm ) INDURA® Ultra Soft® Systems 301- 7oz (237g/m2) over 301- 7oz (237g/m2) 27.2 801- 13oz (440g/m2) Heavyweight Sateen over 301- 7oz (237g/m2) 51.5 • FireWear - Inherently flame resistant, a characteristic that cannot be degraded by laundering. Expected wear life of 18 to 30 months when worn and home laundered once per week. Nomex IIIa - Inherently flame resistant, a characteristic that cannot be degraded by laundering. Expected wear life of 30-48 months. Indura Cotton - Cotton fabric made flame resistant through an ammonia cure process. Expected wear life of 12 to 18 months when worn and home laundered once per week. Laundering Instructions for Indura Garments Laundering Instructions for Indura Garments Washing Washing Wash Garments inside out Do not use chlorine bleach Do not overload washer Do not use tallow soap: (One containing animal fats) Use high water level For optimum results use an acid sour. Softened water provides the best results Wash at temperature necessary to clean garment (Maximum 165°F, or 74°C) Use recommended amount of quality detergent. (Phosphate can be used) 26 Laundering Instructions for Indura Garments Laundering Instructions for Indura Garments Drying Pressing Dry garments inside out. Do not use extreme heat or leave in for long periods. (Maximum stack temperature 165°F, or 74°C) Press garment to remove wrinkles. Use cotton setting. Remove garment when slightly damp. Complete drying on a hanger. Garments may be line dried. Specialized Arc Flash Protective Equipment ARC FLASH Avoidance: Superior Protection with the Right Products Specialized Arc Flash Protective Equipment Flash Suits / Switching Coats Two-Layer Flash Suit, ATPV = 42 cal/cm2 Use: Hazard/Risk Category 4 We do we go from here? 1. Power System Studies • Arc Flash Hazard Study • Protective Device Coordination • Short Circuit Study • Updated Plant One-Line • Arc-Flash Hazard Labels 2. Power Systems Training Program • Understanding Arc-Flash • Electrical & Arc-Flash Safety 3. Institute PPE Program 4. Vigilantly enforce Safety & PPE Program….Everyday Thank You! We sincerely thank you for your time! 27