THE GOOD,
THE VAULT
Presented to:
AND THE UGLY
Annual IES ALC Fall Conference
Tucson, Arizona - October 22, 2013
By:
Carl Johnson © 2013
The Good,
The Vault
&
The
Th Ugly
Th
l
The Good,
The Vault
V
&
The
Th Ugly
Th
l
The Vault
The Duke
The Pelotón
Presidente
anterior
The Vault
Banda de Frank
El Presidente
The Vault
The Good,
The Vault
&
The
Th Ugly
Th
l
The Good,
The Vault
&
The
Th Ugly
Th
l
Military 18L Vault
Military 18L Vault
Military 18L Vault
Industrial Safety
Vintage Safety & Morale
Posters by Susan Deluzain
Barry
Top 10 OSHA Violations of 2013
The preliminary figures for the FY 2013 Top 10 are:
SECTION
HAZARD
CITATIONS
1. 1926.501 – Fall Protection
2. 1910.1200 – Hazard Communication
3. 1926.451 – Scaffolding
4. 1910.134 – Respiratory Protection
5. 1910.305 – Electrical, Wiring Methods
6. 1910.178 – Powered Industrial Trucks
7. 1926.1053 – Ladders
8. 1910.147 – Lockout/Tagout
9. 1910.303 – Electrical, Gen. Reqmt.
10. 1910.212 – Machine Guarding
8,241
6,156
5,423
3,879
3,452
3,340
3,311
3,254
2,745
2,701
Worker Safety
• 1976 – Technical
Committee created.
• 1979 – First Edition
Published.
• 1995 – Arc Flash
Protection introduced.
• 2000 – PPE Charts
included.
Hazard Risk Category (HRC)
HRC-0
0 cal/cm2
< 1.2 cal/cm2
HRC-1
1.2 cal/cm2
4 cal/cm2
HRC-2
>4 cal/cm2
8 cal/cm2
HRC-3
>8 cal/cm2
25 cal/cm2
HRC-4
>25 cal/cm2
40 cal/cm2
Hazard Risk Category - HRC – is based upon the
available incident energy – aka – arc flash energy.
Hazard Control Measures
• Engineering Controls.
• Administrative Controls.
• Personal Protective
Equipment (PPE).
PPE is the last line of defense.
Hazard Control Measures
•
•
•
•
PPE is the last line of defense,
PPE does not make a person immune to injury,
PPE is designed to ensure the injury is survivable,
PPE is designed to limit the injury to onset of
second degree burns,
• PPE testing,
– 50% probability of sufficient heat transfer predicted to
cause onset of second degree burn,
– 50% probability of material break open.
PPE Testing
• PPE is the last line of defense,
• 50% probability of sufficient heat transfer predicted
to cause onset of second degree burn .
Arc Flash
Arc Flash
• Sudden, explosive electrical arc that results from a
short circuit through air.
• Intense light.
• Air in the vicinity of an arc flash is heated to
between 5,0000F and 35,0000F becoming an
electrically-conductive plasma.
• Arcing causes air to expand dramatically and metal
conductors to vaporize.
• Copper volume expands 67,000 times when it is
converted from solid to vapor.
Arc Flash
• Rapid expansion of air and metal vapor produce an
intensely hot blast and shock wave propelling
vaporized metal and shrapnel.
• When incident energy is greater than 40 cal/cm2 :
– De-energize or
– Increase working distance.
– PPE protects against burns, not physical trauma caused
by shock wave.
– Shockwave from a 40 cal/cm2 or greater arc flash can
cause significant trauma.
We wanted to “engineer out” as
much arc flash energy as possible.
WHY - Arc Flash Energy Reduction
• Arc flash can result in serious or fatal injuries to
personnel,
• Arc flash can result in considerable damage to
equipment,
• DOL - during a 7-year period, 2,576 US workers
died and 32,000 US workers suffered electrical
shock and burn injuries,
• 77 % of recorded electrical injuries were due to
arc flash incidents,
• According to CapSchell Inc, every day, in the US
alone, there are 5-10 ten arc flash incidents.
http://es.eaton.com/capelli/index.htm
WHY - Arc Flash Energy Reduction
• In more than 2/3 of the cases of arc flash injuries,
the victim was performing some form of electrical
work such as troubleshooting and repair.
• Overall, 34 % of the accidents involved some form
of component failure;
–
–
–
–
–
17% circuit breakers,
16% conductors,
13 % non-powered hand tools,
12% electrical meters and test leads,
11% connectors and plugs.
• 84 % of the cases reported occurred with
equipment at less than 600 Volts.
Arc Flash Energy Reduction
• HAZARD RISK CATEGORY 3 (HRC-3)
– Arc-Rated Clothing Minimum Arc
Rating of 25 cal/cm2
– Arc-rated arc flash suit jacket (AR),
– Arc-rated arc flash suit pants (AR),
– Arc-rated arc flash suit hood,
– Arc-rated gloves,
• Protective Equipment:
–
–
–
–
Hard hat,
Safety glasses or safety goggles (SR),
Hearing protection (ear canal inserts),
Leather work shoes.
Arc Flash Energy Reduction
• HAZARD RISK CATEGORY 2 (HRC-2)
– Arc-Rated Clothing, Minimum Arc
Rating of 8 cal/cm2
– Arc-rated long-sleeve shirt and pants,
– Arc-rated flash suit hood or arc-rated
face, shield and arc-rated balaclava,
• Protective Equipment:
–
–
–
–
–
Hard hat,
Safety glasses or safety goggles ,
Hearing protection (ear canal inserts),
Heavy duty leather gloves ,
Leather work shoes.
Arc Flash Energy Reduction
• HAZARD RISK CATEGORY 1 (HRC-1)
– Arc-Rated Clothing, Minimum Arc
Rating of 4 cal/cm2
– Arc-rated long-sleeve shirt and pants
or arc-rated coverall,
– Arc-rated face shield or arc flash suit
hood,
• Protective Equipment:
–
–
–
–
–
Hard hat,
Safety glasses or safety goggles,
Hearing protection (ear canal inserts),
Heavy duty leather gloves,
Leather work shoes.
Arc Flash Energy Reduction
• HAZARD RISK CATEGORY 0 (HRC-0)
• Protective Clothing, Nonmelting or
Untreated Natural Fiber with a Fabric
Weight of at Least 4.5 oz/yd2.
– Shirt (long sleeve),
– Pants (long),
• Protective Equipment:
– Safety glasses or safety goggles,
– Hearing protection (ear canal inserts),
– Heavy duty leather gloves.
Arc Flash Energy Reduction
• EVERYDAY WEAR.
• Arc-Rated Clothing, Minimum Arc
Rating of 8 cal/cm2.
– Arc-rated long-sleeve shirt ,
– Arc-rated pants.
• Protective Equipment:
– Safety glasses as needed,
– Hearing protection as needed,
• Other PPE readily available for HRC
encountered.
18L Vault Today
18L Vault Layout
Interior Lighting
• STATE FUND - California's largest provider of
workmen’s compensation insurance estimates a
worker at age 60 requires eight times the amount
of light to see an object as clearly as a 20 year old.
• STATE FUND - recommends updating lighting as
required to support the aging work force.
Interior Lighting Circa 1969
Interior Lighting Circa 1989
Interior Lighting 2013
Free Advice
• Lessons Learned.
• Mature Workforce.
• Political Correctness.
• Google Search.
• Bing Search.
Do not use “MATURE” in your
search description.
Service Entrance/ATS/Generator
Switchgear
• Vintage 1989.
• Reliability.
• High Maintenance.
• Parts Availability.
• Vintage 1989.
• Reliability.
• High Maintenance.
• Parts Availability.
Service Entrance/ATS/Generator
Switchgear
Switchgear Safety Improvements
• Switchgear is equipped for remote racking and
remote operation of the circuit breakers.
• Switchgear is equipped with ARC FLASH REDUCTION
MAINTENANCE SYSTEM (ARMS).
– Reduces arc flash energy at the ATS from 18.8 cal/cm2 to
1.0 cal/cm2.
– Reduces arc flash energy at Panel EDP-1 from 18.7
cal/cm2 to 1.0 cal/cm2.
• Switchgear is equipped with IR Windows.
Remote Racking and Remote
Operation
• Provides a means of remotely inserting or removing
a circuit breaker.
• Enables the remote operation of a circuit breaker.
• Operating personnel are
typically within two feet of the
front of the power circuit
breaker during the racking
process.
Remote Racking and Remote
Operation
• PPE for high levels of arc flash can be bulky, hot and
uncomfortable; or simply not available when
incident energy exceeds 40 cal/cm2.
• One way to reduce the danger from arc flash
occurrences is to increase the distance between an
operator and the front of the switchgear during
racking or operating the circuit breaker (up to 25
feet).
• The remote racking device is installed
with the cubicle door closed.
Remote Racking and Remote
Operation
• 16.75’ Arc Flash
Boundary (Util.).
• 62.5 Cal/Cm2 (Util.).
• 9.0’ Arc Flash
Boundary (Gen.).
• 22.5 Cal/Cm2 (Gen.)
Remote Racking and Remote
Operation
NFPA 70E, 130.7(A)
Informational Note No. 2: States:
“It is the collective experience of the Technical
Committee on Electrical Safety in the Workplace that
normal operation of enclosed electrical equipment,
operating at 600 volts or less, that has been properly
installed and maintained by qualified persons is not
likely to expose the employee to an electrical
hazard.”
Remote Racking and Remote
Operation
The Informational Note in 130.7(a) raises two issues:
• Has the equipment been properly maintained?
Maintenance is often reduced or eliminated when
funding gets tight, and “run to failure” may become
a valid maintenance process. (Gary Becken)
• When the arc flash calculations are completed and
the incident energy is over 40 cal/cm2, does keeping
the door closed contain the blast or just add to the
shrapnel? (Gary Becken)
Remote Racking and Remote
Operation
NFPA 70E, 130.7(C)(15)
Informational Note No. 2: States:
“The collective experience of the task group is that,
in most cases, closed doors do not provide enough
protection to eliminate the need for PPE for
instances where the state of the equipment is known
to readily change (for example, doors open or closed,
rack in or rack out).”
Remote Racking and Remote
Operation
• Permits us to REMOTELY:
– Rack in a breaker,
– Rack out a breaker,
– Close a breaker,
– Open a breaker.
• Which allows us to wear HRC-2
everyday wear.
Arc Flash Reduction
Maintenance Switch
Incident Energy vs. Fault Duration Time
BOLTED FAULT
ARCING FAULT
FAULT DURATION
INCIDENT ENERGY
kA
kA
sec
cal/cm2
40.0
20.0
2.00
89.0
40.0
20.0
0.50
22.2
40.0
20.0
0.40
17.8
40.0
20.0
0.30
13.3
40.0
20.0
0.20
8.9
40.0*
20.0*
0.05*
2.2*
Table Notes:
Incident energy values shown in the table were calculated using the IEEE 1584 method for a 480 V system with a
working distance of 24 in. (609.6 mm). Other parameters are:
Grounding Type = Solid Grounded, and
Equipment Type = Switchgear
* Typical fault clearing time using the Arc flash Reduction Maintenance Switch will be 0.05 seconds. Note that
this time will vary slightly depending on the circuit breaker manufacturer and type.
Time
Current
Curve
• Vertical axis –Time in
seconds.
• Horizontal Axis –
current in amperes.
• Instantaneous trip.
• Short time delay.
• Long time delay.
ARMS
• Protective strategy
for personnel.
• Moves trip functions
into the
instantaneous trip
region of the circuit
breaker.
• Lowers
instantaneous trip
setting from 6,400
amps to 4,000 amps.
ARMS
• 8.0’ Arc Flash
Boundary
• 1.4’ Arc Flash
Boundary
ARMS
• Without ARMS:
– 8.0’ Arc Flash Boundary (Util.).
– 18.7 cal/cm2 (Util.).
– 8.0’ Arc Flash Boundary (Gen.).
– 18.7 cal/cm2 (Gen.).
• With ARMS:
– 1.4’ Arc Flash Boundary (Util.).
– 1.0 cal/cm2 (Util.).
– Clears in 0.04 seconds
IR Windows
• IR Windows allow for IR testing w/o
opening the equipment.
• Switchgear is UL listed.
• Switchgear manufacturer had to locate and
punch holes for IR Windows.
• Sent IR Window template to manufacturer.
IR Windows
Free Advice
• Lessons Learned.
• Read instructions.
• Read the fine print.
• Read the software license
agreements.
• We all click on AGREE
AGREE!!
18L Vault Layout
CCR BUS I
CCR BUS IV
Arc Flash Energy Reduction
• 8.75’ Arc Flash Boundary
• Incident Energy 22 cal/cm2
• 1.1’ Arc Flash Boundary
• Incident Energy 0.7 cal/cm2
Time
Current
Curve
Time
Current
Curve
Arc Flash Energy Reduction
• 8.75’ Arc Flash Boundary
• Incident Energy 22 cal/cm2
• 1.1’ Arc Flash Boundary
• Incident Energy 0.7 cal/cm2
Arc Flash Energy Reduction
• 10” Arc Flash Boundary
• Incident Energy 0.5 cal/cm2
• 1.1’ Arc Flash Boundary
• Incident Energy 0.7 cal/cm2
Summary
• Human life is PRICELESS!
• We cannot put a cost to human suffering or loss of
quality of life.
• Burn treatment requires approx. 1.5 days
hospitalization per % burn,
• Average hospitalization is 19 days, at costs
exceeding $18,000/day,
• Total hospitalization cost typically ranges from
$200,000 to $750,000, with many over $1,000,000
USD.
Summary
• Improved safety programs and practices are simply
good business,
• Arc Flash Energy Reduction can be achieved in new
electrical designs,
• Arc Flash Energy Reduction can be achieved in
electrical upgrade designs,
• Arc Flash Energy Reduction can be achieved simply
as part of an arc flash energy reduction program,
• Engineer the hazard away.
Summary
• The arc flash energy reduction design will require
coordination with equipment supplier/engineers,
• The remote racking device added $11,000.00 to the
cost of the project.
• The ARMS unit added $2,500.00 to the project cost,
• The IR windows were about $1,000.00 each –
installed,
• The SHLD6 circuit breaker cost $1,500.00 more than
the standard HLD breaker, list price about
$9,500.00.
Free Advice
Be Mature!
Read the Fine
Print!
http://es.eaton.com/capelli/index.htm
The Good,
The Vault
&
The
Th Ugly
Th
l
Thank You!
The Good, The Vault and The Ugly
THE GOOD,
THE VAULT
Presented to:
AND THE UGLY
Annual IES ALC Fall Conference
Tucson, Arizona - October 22, 2013
By:
Carl Johnson © 2013