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Arc Flash

Boundaries
&
Design for Safety

NFPA 70E- Requirements for Two Types of


Boundaries

Shock
Flash

Knowing the boundaries not enough


Need to know PPE, Tools, etc.
In practice, need to address both boundary
types in integrated manner.

What are the NFPA 70E


requirements for shock hazard
and arc flash hazard?

NFPA 70E Boundaries

70E-2000 P. 10-11

Shock Protection Boundaries


Limited Approach Boundary
entered only by qualified persons or unqualified
persons escorted by qualified person
Restricted Approach Boundary
entered only by qualified persons required to use
shock protection techniques and equipment
Prohibited Approach Boundary
entered only by qualified persons requiring same
protection as if direct contact with live part

Flash Protection Boundary


linear distance to prevent serious injury from a
potential arc-flash

Shock Hazard Approach Boundaries


(from NFPA 70E-2000)
70E-2000 P. 51

Equipment

Flash
Flash Protection
Protection Boundary
Boundary (FPB)
(FPB)
Must
Must wear
wear appropriate
appropriate PPE
PPE
FPB
FPB dependent
dependent on
on fault
fault level
level and
and time
time duration.
duration.

Prohibited Shock Boundary: Qualified Persons Only. PPE as


if direct contact with live part
Restricted Shock Boundary: Qualified Persons Only
Limited Shock Boundary:

Qualified or Unqualified Persons*


* Only if accompanied by Qualified Person

Note: shock boundaries dependent on system voltage level

Flash Protection Boundary Calculations

Examples for tests on videos

Test 4

Test 3

Test 1

26.7 in.

3.74 in.

1.61 in.

640 A
Non
CurrentLimiting OCPD
6 cycles open

601 A
Current-

Limiting OCPD

30 A
CurrentLimiting OCPD

Safety BASICsTM
Current-Limitation - Arc-Energy Reduction
Test 4

Test 3

Non-Current Limiting

Reduced Fault Current


via Current-Limitation

Test 1

Flash Hazard - NFPA 70E


Part II - Chapter 2

70E-2000 P. 50

Part II 2-1.3.3 Flash Hazard Analysis.


Flash hazard analysis shall be done before a
person approaches any exposed electrical
conductor or circuit part that has not been
placed in an electrically safe work conditions.
What is required?
1. Determine Flash Protection Boundary
2. Determine the Personnel Protective Equipment

Flash Hazard
How?
1. Determine Flash Protection Boundary:
Calculate using Isca & clearing time
(or use tables - many qualifiers)
(or default to four feet - 600 V or less)
2. Determine the Personnel Protective Equipment :
A. Calculate incident energy exposure level for
distance of workers face and chest from the
possible arc source (18 typical - considers the
head and torso but not the hands and arms).
B. Select appropriate PPE for incident energy.

Flash Hazard Analysis


Flash Protection Boundary Calculations
1) (600 V or less) Distance formula based on
fault available and clearing time of
overcurrent protective device:
DC = [2.65 x MVAbf x t] 1/2 ) ft
where MVAbf = 1.73 (Isca) (Voltage) x 10-6
2) (> 600 V) Distance based on where incident
energy level is 1.2 or 1.5 cal/cm2

Flash Hazard Analysis -Example 1


Safety Basics

Flash Protection Boundary Calculation


Circuit using non-current limiting circuit breaker

Overcurrent protective device


with clearing time of 6 cycles
40896 Amperes Available
480 Volt,
3 phase
Main Lug
Only Panel

Answer
DC = 3 ft

Flash Hazard Analysis - Example 2


Safety Basics

Flash Protection Boundary Calculation


Circuit using current limiting fuses

Class J, 200 A fuse


clearing time of 1/4 cycle under
short circuit conditions.
40896 Amperes Available
6000 Equivalent RMS Let-Through
480 Volt,
3 phase
Main Lug
Only Panel

Answer
DC = .23 ft

Flash Hazard Analysis

Flash Protection Boundaries need


to be calculated for all levels of
fault current.

Incident Energy
To select proper Personal
Protective Equipment (PPE),
calculate incident energy. This is
a measure of the thermal energy
at a specific distance from the arc
flash.
Units: calories per cm2

Second Degree
Burn Threshold

1.2 cal/cm2
Note: medical treatment may still be required if bare
skin is exposed to this level of flash - full recovery to be
expected.

Flash Hazard Analysis


70E-2000 P. 71 B-5.2

Incident Energy Calculation


Formula:

EMB = 1038.7 DB-1.4738 tA[0.0093F2-.3453F+5.9675] cal/cm2


EMB = Incident Energy (cal/cm2)
DB = Distance, (in.) [for Distances > 18 inches]
tA = Arc Duration, (sec.)
F = Bolted Fault Short Circuit Current [16KA to 50kA]

Flash Hazard Analysis - Example 1


Incident Energy Calculation @ 18
Circuit using non-current limiting circuit breaker

Overcurrent protective device


with clearing time of 6 cycles
40896 Amperes Available
480 Volt,
3 phase
Main Lug
Only Panel

Answer
EMB = 10.92 cal/cm2

Flash Hazard Analysis


Incident Energy Calculation @ 18
Example 1: 40896 amps of available fault current, 480 volt 3
phase system, Non-current limiting overcurrent device 6
cycle (0.1 sec) opening time.
EMB = 1038.7 DB-1.4738 tA[0.0093F2-.3453F+5.9675]
EMB = 1038.7 (18)-1.4738(.1) [0.0093(41)2- .3453(41)+5.9675]
EMB = 10.92 cal/cm2

Flash Hazard Analysis - Example 2


Incident Energy Calculation @ 18
Circuit using current limiting fuses

Class J, 200 A fuse


clearing time of 1/4 cycle
under short circuit conditions.
40896 Amperes Available
6000 Equivalent RMS Let-Through
480 Volt,
3 phase
Main Lug
Only Panel

Answer
EMB < .17 cal/cm2

Flash Hazard Analysis


Incident Energy Calculation
Example 2: 40896 amps of available fault current, 480 volt
3 phase system, Current Limiting overcurrent device 1/4
cycle (0.004 sec) opening time
[using Bussmann LPJ-200SP LOW-PEAK Fuses - with
equivalent RMS let-through of 6000 amperes.]
EMB = 1038.7 DB-1.4738 tA[0.0093F2-.3453F+5.9675]
EMB = 1038.7 (18)-1.4738(.004) [0.0093(16)2.3453(16)+5.9675]
EMB = .17 cal/cm2 (for 16KA)
Equation is valid for fault range of 16 to 50KA. So this calculation is at 16KA, not 6KA.

Therefore, incident energy for this case at 6000 A letthru is much less than .17 cal/cm2.

Flash Hazard Analysis

Incident energy exposure


needs to be calculated for all
levels of fault current.

Comparison of Example 1 & 2


Flash
Protection
Boundary

Incident
Energy
@ 18 inches

36 inches

10.92 cal/cm2

Example 1
non current- limiting
6 cycle opening

Example 2
current-limiting
1/4 cycle clearing

2.76 inches

Less than

.17 cal/cm2

Flash Hazard - NFPA 70E


Part II - Chapter 2

70E-2000 P. 50

NFPA 70 E permits some alternative ways to


calculate Flash Protection Boundary and Personal
Protective Equipment necessary for hazard
analysis.
The alternatives are different for 600 Volts or less
and greater than 600 volts.
When using the alternatives it is necessary to be
attentive to the specified qualifiers and footnotes.
Full calculations provide for the most accurate
assessment and in some cases, full calculations
are required.

Flash Hazard - NFPA 70E


Part II - Chapter 2

70E-2000 P. 50

Flash Protection Boundary 600 Volts or less


1. Default to four feet (based on 300kA-cycles)
(50,000 amps fault - six cycles to clear)
2. Alternatively
- may calculate if less than 300kA-cycles
- must calculate if over 300kA-cycles
3. Alternatively
- can follow Personal Protective Equipment
(PPE) requirements of 3-3.9 of Part II (P 55 & 59)
(this alternative does not take advantage of
current-limitation & has footnotes for condition
qualifiers)

NFPA 70E: Simply Use Tables Per Task


Page 55 Table 3-3.9.1
(1) Read Headings
(2) 600 V Class MCC
(3) Read Notes 2 & 3 (P. 58)
(4) Work on energized parts
(5) What is required?
(6) 2* (P. 58), V gloves, V tools
Page 59 Table 3-3.9.2
(1) What is required
(2) Read legend & notes (P. 60)

NFPA 70E: Simply Use Tables Per Task


Page 55, Table 3-3.9.1/ Page 59,Table 3-3.9.2
600 V Class MCC - Work on energized parts
including voltage testing - What is required?
V-rated gloves
V-rated tools
Doubled-layered switching hood and hearing protection
Untreated natural fiber: T-shirt & Long pants
FR Clothing: Long sleeve shirt, Pants, Coveralls
FR Protective Equipment: Hard hat, safety glasses, leather
gloves, leather work shoes
(Note there are footnotes altering above due to fault current
levels and duration. And there are some substitutions
permitted.)

Flash Hazard - NFPA 70E


Part II - Chapter 2

70E-2000 P. 50

Flash Protection Boundary above 600 Volts


1. Calculated distance where incident energy is:
A. 1.5 cal/cm2 where fault clearing time is 0.01
or less

seconds

B. 1.2 cal/cm2 fault clearing greater than 0.01 seconds


2. Alternatively
- can follow Personal Protective Equipment (PPE)
requirements of 3-3.9 of Part II
(this alternative does not take advantage of current-limitation
& has footnotes for condition qualifiers)

Safety Basics

Flash Hazard Analysis- OCPD Opening Times


TYPE OF DEVICE
Standard molded case circuit
breakers (600 volt & below)
without short-time-delay (STD)
with short-time-delay (STD)
Insulated case circuit breakers
(600 volt & below)
without short-time-delay
with short-time-delay
Low voltage power (air frame)
circuit breakers (600 volt & below)
without short-time-delay
with short-time-delay
Current limiting Overcurrent Devices

TIME (Seconds)

.0083-.0167
STD Setting
.033
STD Setting
05
STD Setting
.

004-.008

Industry accepted values for overcurrent devices

Flash Hazard - NFPA 70E


Part II - Chapter 2
To enter or work within Flash Protection Boundary:
shall do flash hazard analysis
employer shall document incident energy
exposure of worker
worker shall use appropriate flame resistant (FR)
clothing and personal protective equipment (PPE)
for level of incident energy exposure

Design for Safety


Electrical System
Work Practices

Design for Safety


Electrical System Design
General Design
Non - Current Limiting OCPD
Design
Current Limiting OCPD Design

General Design
Specify Insulated Bus

Reduces Chance
Self Extinguish (600V and
below)

General Design

Use Remote Switch Operator on


Medium Voltage Switches and
Circuit Breakers

General Design
Isolate the Circuit
Disconnects capable of Lockout/Tagout
In Sight Motor Disconnects
Selectively Coordinated overcurrent
protection

General Design
Motor Disconnects Within Sight

Can
Lock
Open

Barrier, Wall or
Isle with an
obstruction

Revised NEC Requirement,


Good for Safety Shut-Off
M

Combination
Controller

Insight Motor Disconnect

General Design

Safety Basics

Finger-Safe guards and covers reduce


the chance of incident occurrence
NFPA 70E requires covers or barriers be
installed if a worker could accidentally
contact energized parts 50 volts and above:
IP20

IP

International Protection
Protection against solid objects
2 - 12mm (finger)
Protection against liquids
0 - no protection

IEC60529

Specify & Install Finger Safe


(IP20) Electrical Products

General Design
1200A

Typical 1200A
MCC
Split Large
Feeder
MCC

General Design
600A

600A

MCC

MCC
M

Reduces Wire
Size
Reduces OCPD
Size
Reduces Short
Circuit Current

Non-Current Limiting OCPD Design


Design using High
Impedance Components
Helps to Limit potential
arc energy

Non-Current Limiting OCPD


Design
No Short Time Delays on Circuit
Breakers
Panelboards, Switchboards, and
MCCs tested for only 3 cycles.
Increases time fault exists
Selective Coordination can be
achieved with other devices.

Current Limiting OCPD Design

Use Current Limiting Overcurrent


Protective Devices:

Current-limiting Circuit
Breakers

Current-limiting Fuses

Current Limiting OCPD Design


Use Overcurrent Protective Devices with
the Highest Degree of Current-Limitation
Fuses:
Use Class J, CC, T, RK1, L
Rather than Class RK5
Definitely not Class H
Current Limiting CBs:
Determine degree of current-limitation

Current Limiting OCPD Design


Size OCPD Devices as Small as Possible
Higher Degree of C.L.

50 KA Available

50 KA Available

Class L
1200A

Class RK1
600A

23 KA Let Through

15 KA Let Through

Current Limiting OCPD Design


Size OCPD Devices as Small as Possible
Size Motor OCPD lower than Code Max

Code Max = 125A


Optimal Sizing = 100A
M

50 HP 480V
FLA = 65A

* See Motor Tables in the SPD

Current Limiting OCPD Design

Specify Type 2 No Damage


Protection for Motor Starters
Backed by Testing
Limits Energy Let Through

Current Limiting OCPD Design


Design using Low Impedance
Components
Maximizes Current Limitation
Better Voltage Regulation
Power Loss Minimized

Design for Safety


Safety Basics

Work Design

Safety Principles

Training, Planning and Writing Procedures


Plan every job
Anticipate Unexpected Results
Use Procedures as Tools
Identify the Hazard
Assess Peoples Abilities

Safety Principles

Providing an Electrically Safe Work


Condition
Use the Right Tool for the Job
Isolate the Equipment
Protect the Person
Minimize the Hazard
Audit these Principles

Hazard/Risk Analysis

Safety Basics

Hazard/Risk Analysis is a decision making process required


to:
evaluate circuit information drawings
determine the degree and extent of hazards
job planning necessary to safely perform task
determine Shock Approach Boundaries requirements
determine Flash Protection Boundary requirements
determine Incident Energy Exposure
determine appropriate Personal Protective Equipment (PPE)
based on the potential hazards present
evaluate personnel qualifications

110.16
2002 NEC New Arc Flash
Hazard Marking Requirement

110.16 Flash Protection. Switchboards, panelboards, industrial control panels,


and motor control centers in other than dwelling occupancies, that 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.
FPN No. 1: NFPA 70E-2000, Electrical Safety Requirements for Employee
Workplaces, provides assistance in determining severity of potential exposure,
planning safe work practices, and selecting personal protective equipment.
FPN No. 2: ANSI Z535.4-1998, Product Safety Signs and Labels, provides
guidelines for the design of safety signs and labels for application to products.
Reprinted from NEC 2002

WARNING

Arc Flash and Shock Hazard


Appropriate PPE Required
Courtesy E.I. du Pont de Nemours & Co.

WARNING

Arc Flash and Shock Hazard


Appropriate PPE Required
24 inch Flash Hazard Boundary
3
cal/cm2 Flash Hazard at 18 inches
1DF
PPE Level, 1 Layer 6 oz Nomex ,
Leather Gloves Faceshield
480 VAC Shock Hazard when Cover is removed
36 inch Limited Approach
12 inch Restricted Approach - 500 V Class 00 Gloves
1 inch Prohibited Approach - 500 V Class 00 Gloves
Equipment Name:Slurry Pump Starter
Courtesy E.I. du Pont de Nemours & Co.

WARNING

Arc Flash and Shock Hazard


Appropriate PPE Required
24 inch Flash Hazard Boundary
3
cal/cm2 Flash Hazard at 18 inches
1DF
PPE Level, 1 Layer 6 oz Nomex ,
Leather Gloves Faceshield
480 VAC Shock Hazard when Cover is removed
36 inch Limited Approach
12 inch Restricted Approach - 500 V Class 00 Gloves
1 inch Prohibited Approach - 500 V Class 00 Gloves
Equipment Name:Slurry Pump Starter
Courtesy E.I. du Pont de Nemours & Co.

What Are the OSHA Regulations and


NFPA 70E Requirements for
Working
on Live Equipment?

2001 Cooper Bussmann, Inc.

Safe Work Practices


OSHA 1910.333 (a) (1) & NFPA 70E 2-1.1.1

not to work hot or live except :


1. Deenergizing introduces additional
or increased hazards
2. Infeasible due to
equipment design
or operational
limitations

Wearing Proper PPE?

Safe Work Practices

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