TCE.

10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 100 OF

BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.0 ARC FLASH HAZARD STUDY

10.1 Introduction
An arc flash is defined as a dangerous condition associated with the release
of energy caused by an electric arc explosion. It usually occurs due to short
circuit of energized conductors caused by improper maintenance or work
practices viz. such as touching a test probe to the wrong surface or slipped
tool etc. An arc flash caused by an electric arc can cause destruction of
equipment involved, fire, and injury to the worker.

The analysis determines the incident energy to which operating personnel

could be exposed during their work on or near electrical equipment, and the
associated risk of personal injury as a result of exposure to incident energy
from an electrical arc flash.

Arc flash hazard analysis is important in determining the rating of personal

protective equipment (PPE) to keep the personnel safe when working with
energized equipment. With adequate PPE and knowledge about hazardous
category at a particular work location, the likelihood of a serious injury is
reduced.

Arc flash analysis can be carried out by either NFPA 70E or IEEE 1584-2002
method. NFPA 70E provides Hazard Category tables, which highlight specific
PPE to be used on various low voltage and medium voltage electrical
distribution equipment. In order to correctly apply this table, knowledge of the
available short circuit current and the operating time of the protective device
are required. The IEEE 1584 method is a systematic approach which
calculates the arc flash energies from the electrical power system parameters.
T
electrical system.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 101 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.2 System Data and Assumptions

10.2.1 the
system data and assumptions indicated in Chapter-4
10.2.2 The operating time and time current characteristics (TCC) of protective
devices are taken from Chapter- Relay Settings and Relay Coordination
Study
10.2.3 Arcing fault current (Iarc) is calculated using ETAP Arc Flash module.
10.2.4 Working distance (D), i.e. the distance between the possible arc point and
the head and body of the worker positioned in place to perform the assigned
task, for different class of equipment is considered as per IEEE Std.1584-
2002.
10.2.5 X-factor and conductor gaps (G) used in the calculation of incident energy
are considered as per IEEE Std.1584-2002.
10.2.6 Breaker operating time is assumed as 30 ms.
10.2.7 As per IEEE std. 1584, the energy required to produce a curable, second
degree burn on unprotected skin has been considered as 5.0 J/cm2 (or 1.2
cal/cm2).

10.3 Objective

10.3.1 Calculation of incident energies for the 6.6 kV switchgear

10.3.2 Calculation of incident energies for 415 V switchgear
10.3.3 Estimation of arc flash protection boundary for each 6.6 kV and 0.415 kV
switchgear
10.3.4 Determination of required rating of PPE for arc flash hazard area
10.3.5 Recommendations to minimize arc flash hazardous level.

10.4 Methodology

10.4.1 Arc flash hazard study is carried out in accordance with IEEE std.1584-
2002 (IEEE Guide for Performing Arc Flash Hazard Calculations) and NFPA
70E standard (Standard for Electrical Safety in the Workplace).
10.4.2
software.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 102 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.4.3 Results of short circuit study and protective device coordination study are
used in the analysis of Arc flash study hazard assessment.
10.4.4 Results of the arc-flash hazard analysis are used to identify the flash-
protection boundary and the incident energy at assigned working distances
throughout the electrical distribution system.

10.4.5 Since the incident energy due to arc flash mainly depends on the arcing
current, the fault current contribution by motors is also considered for the
calculation of arcing current.

10.4.6 The IEEE Std. 1584-2002 arch flash calculation method includes nine
steps:

Step 1: Collect the system and installation data including,

Utility connection point, available fault current, operating voltage, and

connection.
Specifics information for each protective device in the electrical system
including manufacturer, model, available time/current settings and short-
circuit interrupting rating.
Transformer impedance, tap settings and ratings.
Cable specific data including lengths, sizes, and types

Step 2: Determine the system modes of operation

It is important to determine the available short circuit current for modes of

operation that provide both the maximum and the minimum short circuit
currents.

Step 3: Determine the bolted fault currents

A short circuit study is performed to determine the magnitude of current

occurs. These calculations is used to determine the bolted fault current,

which is essential for the calculation of incident energy and interrupting

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 103 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

ratings of equipment. Comparison of equipment ratings with calculated

short circuit and operating conditions will identify underrated equipment.

Step 4: Determine the arc fault currents

The arc fault current at the point of concern and the portion of that current
passing through the first upstream protective device is calculated. The arc
fault current primarily depends on the bolted fault current. The arc fault
current will be lesser than the bolted fault current due to arc impedance.

The following equations are used to calculate the three-phase arc current
as mentioned in IEEE 1584 2002 standard:

For application with a system voltage under 1 kV, the following equation is
used:
log ( Ia) = K + 0.662 log( Isc) + 0.0966 V+ 0.000526 G + 0.5588 V (log Ibf)
0.00304 G (log Isc)

For application with a system voltage of 1kV and higher, the following
equation is used:
log ( Ia) = 0.00402 + 0.983 log Ibf
Where
Iog: is the log10
Ia: Arcing current
K: box configurations
V: Three-phase supply voltage in kV
G: Distance between phase conductors in mm
Ibf: Bolted fault current for three phase faults in kA (Symmetrical RMS)

Step 5: Find the protective device characteristics and the duration of the
arcs

Protective device coordination is performed to ensure selection and

coordination of protective devices, which limits the effects of an over current
situation. Fault Clearing Time (FCT) plays an important role in the arc flash
hazard category. If the response time of the protective device is more, the

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 104 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

degree of arc flash injury will be higher. TCC curves is used for finding the
relation between current (A) and response time (sec).

Step 6: Document system voltages and classes of equipment

For each bus document the system voltage and class of equipment. This
will allow application of equation based on standard classes of equipment
and bus to bus gaps. Typical clauses of equipment and bus gaps (mm) are
given in IEEE Std.1584-2002.

Step 7: Select the working distances

Arc flash protection is always based on the incident energy level on the

the hands or arms. Typical working distance for different class of equipment
is given in IEEE Std.1584-2002.

Step 8: Determine the incident energy for all equipment

Incident energy at a particular distance can be determined as per the

equations given in IEEE Std.1584-2002.

For LV and MV systems, the incident energy (E) may be found from the
following
IEEE 1584 equations:

E = En Cf (t/0.2) (610x/Dx) (6)

log (En) = K1 + K2 + 1.081 log (Ia) + 0.00110 G

Where
En: Normalized incident energy for arc duration of 200 ms and for a
distance from the arc of 610 mm (24 in.)
K1:
K2: 0, ungrounded or high-resistance grounded system; 0.113,
grounded system
Cf: is a calculation factor (1.0 for voltages above 1 kV and 1.5 for voltages
at or below 1 kV)
G: Distance between phase conductors in mm
R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 105 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

t: Time duration in seconds

D: Distance from arc electrodes (phase conductors)
X: Distance factor. 2.000, LV & MV open air and cable; 0.973, MV
switchgear; 1.473, LV switchgear; 1.641 LV motor control centers and
panels

Step 9: Determine the flash-protection boundary for relevant equipment

To find the flash protection boundary, the equation for finding the incident
energy can be solved for the distance from the arc source at which one set
of second degree burn could occur. The incident energy must be set at the
minimum energy beyond which a second degree burn could occur.

Calculations of incident energy levels and flash protection boundaries will

be completed for all relevant equipment busses. The category of arc
hazards level and corresponding PPE requirement will be determined as
per NFPA 70E 2012.

10.4.7 The incident energy levels and corresponding PPE Requirement based on
NFPA 70E-2012, is given below:

Table 10.1: Incident Energy Level and PPE requirements as per NFPA 70E-2012

Hazardous
Incident energy
category PPE Requirement
Exposure cal/cm²
Level

Non-Melting or untreated natural fiber long-

0 < cal/cm² < 1.2 0 sleeve shirt, long pants, safety glasses, hearing
protection and leather gloves.

Flame resistant long sleeve shirt (minimum arc

rating of 4), worn over untreated cotton T shirt
1.2 1
with Flame resistant pants (minimum arc rating
if 8) or FR coveralls (minimum arc rating of 8)

Flame resistant long sleeve shirt (minimum arc

rating of 4), worn over untreated cotton T shirt
2
with Flame resistant pants (minimum arc rating
if 8) or FR coveralls (minimum arc rating of 8)

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 106 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

A total clothing system consisting of Flame

resistant shirts and pants and/or Flame
3
resistant coveralls and/or arc flash coat and
pants (clothing system minimum arc rating of 4)

A total clothing system consisting of Flame

resistant shirts and pants and/or Flame
4
resistant coveralls and/or arc flash coat and
pants (clothing system minimum arc rating of 4)

N/A

10.4.8 The Incident energy at all 6.6 kV switchgears with existing settings is very
less as instantaneous over current stage (50) is enabled along with IDMT

recommended. But disabling instantaneous stage and relying only on IEC-

Normal Inverse (NI) curve is causing high incident energies which is not
advisable Arc flash point of view. So, to overcome above problem IEC-Very
inverse (VI) curve has been suggested.

10.5 Labeling of Equipment

In accordance with NFPA-70E standard, a label should be applied to the

equipment or at the equipment access point to provide minimum information
about the flash hazards/risks to the worker. A minimum labeling requirement
includes information regarding permissible arc flash boundary and PPE
level, and it should be of an easily readable size.
Typical arc flash labels should include the following details:

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 107 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Flash protection boundary: This boundary is the closest that anyone may
approach without the use of PPE. The available short circuit current,
predicted fault duration and the voltage are all needed to determine the flash
protection boundary. This boundary is the distance from the arc source
where there is potential heat energy of 1.2 calories/cm 2 falling on the surface
of the skin for 0.1 seconds.

Limited approach boundary: This boundary may only be crossed by an

n.
Documented training for the hazards of the equipment being serviced, as
well as general training on the hazards of working on energized equipment,

this training.

Restricted shock approach boundary: This boundary may only be crossed

techniques.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 108 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Prohibited shock approach boundary: This boundary may only be crossed

planning on direct contact with live parts.

PPE required: The Personal Protective Equipment (PPE) required is

dependent on the incident energy at every point a person may perform work
on energized equipment. An electrical engineer or other qualified person
should perform the calculations that determine the incident energy. The
appropriate PPE should cover all parts of the body that may be exposed to
an arc flash. This could include shoes, gloves, flame resistant clothing,
safety glasses, etc.

Available short-circuit current: The magnitude of the prospective currents

fl owing through the power system at various time intervals after a fault
occurs are determined by short-circuit studies. This model is then used to
perform a short-circuit analysis. The resulting data is used to determine the
bolted three-phases short-circuit current which allows for the calculation of
the arcing fault current.

Incident energy (in cal/cm2): This is the energy per unit area on a surface
located at a distance from the potential arc source. The incident energy is
measured in units of calories per square centimeter. Second degree burns
occur at an energy level of approximately 1.2 calories/cm2.

Voltage shock hazard: The hazard based on the voltage of a system that is
used to determine the glove rating when working on that system. NFPA 70E
has a table for glove ratings based on the voltage shock hazard.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 109 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.6 Case Studies

10.6.1 The following five cases covering normal and contingency operating
configurations TPL system are considered for arc flash hazard analysis.

Table 10.2: Arc Flash Study Cases _ Op. Configurations

Unit to Station
Generator LT Switchgear
Station Tie B/C
Case D.UAT E.UAT F.UAT
D E F
D E F D E F I/C-1 I/C-2 B/C
station station station
1(base) x x x x x x x
1A x x x x x x
1B x x x x x x
1C x x x x x x
1D x x x x x x x
Note: ( ) indicates source/circuit is available, (x) indicates source/circuit is not available.

CASE 1: Normal operating condition

Generators D, E and F are operating normally in synchronism with GETCO
SBI grid. Ties between unit and station switchgear are open. All LV
switchgears are fed through two incomers with bus coupler open.

CASE 1A: Outage of D.UAT and DC1B Incoming feeder

Generators D, E and F are operating normally in synchronism with GETCO
SBI grid. D.UAT is not available, DC1B Incoming feeder is not available and
bus coupler is closed. Rest of the system configuration remains same as base
case - 1

CASE 1B: Outage of E.UAT and EC 1B Incoming feeder

Generators D, E and F are operating normally in synchronism with GETCO
SBI grid. E.UAT is not available, EC 1B Incoming feeder is not available and
bus coupler is closed. Rest of the system configuration remains same as base
case 1

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 110 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

CASE 1C: Outage of E.UAT and OSA-A Incoming feeder

Generators D, E and F are operating normally in synchronism with GETCO
SBI grid. F.UAT is not available, OSA-A Incoming feeder is not available and
bus coupler is closed. Rest of the system configuration remains same as base
case 1

CASE 1D: Outage of one of the Incomers at LV switchgear

Generators D, E and F are operating in synchronism with GETCO SBI grid
and all 415 V switchgears are fed by singe incomer with bus-coupler closed.
(Maximum fault condition of 415 V switchgears)

10.6.2 Short circuit study has been conducted for all the above cases and found that
the short circuit current is maximum at 6.6 kV switchgears in case 1A,1B ,1C
whereas the maximum fault level at 415V switchgears in obtained in case-1D.
Hence detailed arc flash analysis has been conducted for above cases along
with normal operating case. The results are discussed in the following section.

10.7 Study Results

The results of arc flash studies for the above cases are summarized in the
table 10.3 and corresponding exhibits are attached in the Annexure-1.

Case-1: Normal operating condition

The arc flash results obtained for all 6.6 kV switchboards of D, E & F
stations are given in the Table -10.3.
The arc flash results obtained for 415 V switchboards of D, E & F stations
are shown in Table -10.4.
The detailed arc flash report is attached in Annexure-2.
The arc flash results obtained for 415 V switchboards are shown in
Table-10.5. The total arc flash incident energy is under the hazardous
category level of 2 to 4.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 111 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Table 10.3: Arc Flash results at 6.6 kV switchgear _ Case 1

Working Total Final

Bus AFB Energy Ia at FCT
Unit Bus ID Distance Energy FCT
kV (m) Levels (kA)
(cm) (cal/cm²) (Sec)
BUS-1A 6.6 91 13.81 11.3 3 0.376 20.09
BUS-1B 6.6 91 14.64 12 3 0.4 20.12
D-station
DC1A 6.6 91 20.25 16.7 3 0.505 22.38
DC1B 6.6 91 20.41 16.82 3 0.485 23.21
BUS-2A 6.6 91 11.98 9.73 3 0.315 20.63
BUS-2B 6.6 91 13 10.58 3 0.343 20.63
E-station
EC1A 6.6 91 17.25 14.15 3 0.441 21.84
EC1B 6.6 91 18.09 14.86 3 0.441 22.59
6SA BUS 6.6 91 12.79 10.41 3 0.366 19.16
6SB BUS 6.6 91 11.10 9 3 0.318 9.05
F-station
OSA-A 6.6 91 16.62 13.62 3 0.424 21.89
OSA-B 6.6 91 16.81 13.78 3 0.4 23.11

Table 10.4: Arc Flash results at 415 V switchgear_ Case-1

Working Total Final Ia at

Bus AFB Energy
Unit Bus ID Distance Energy FCT FCT
kV (m) Levels
(cm) (cal/cm²) (sec) (kA)

CW MCC 1A 0.415 61 4.09 19.84 3 0.723 12.8

CW MCC 1B 0.415 61 4.09 19.84 3 0.716 12.9

DM PMCC 1A 0.415 61 2.16 7.74 2 0.359 10.05

D-station DM PMCC 1B 0.415 61 1.8 5.93 2 0.402 7.09

SSS-2 1A 0.415 61 5.32 29.22 4 1.079 12.81

SSS-2 1B 0.415 61 5.08 27.3 4 0.993 12.88

415 V SSS-1 1A 0.415 61 4.08 19.77 3 0.813 11.52

415 V SSS-1 1B 0.415 61 4.17 20.42 3 0.821 11.73

E STN CW MCC 2A 0.415 61 4.56 23.23 3 0.828 13.15

E STN CW MCC 2B 0.415 61 4.61 23.64 3 0.838 13.2

E STN DM PMCC 1A 0.415 61 2.2 7.96 2 0.416 9.04

E STN DM PMCC 1B 0.415 61 2.19 7.89 2 0.419 8.94

E-station
E STN SSS-2 SEC-2A 0.415 61 7.14 44.98 >4 1.63 13.34

E STN SSS-2 SEC-2B 0.415 61 6.85 42.36 >4 1.51 13.52

E STN SSS-3 SEC-2A 0.415 61 1.99 6.88 2 0.473 7.01

E STN SSS-3 SEC-2B 0.415 61 2.1 7.44 2 0.458 7.78

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 112 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

6PA SEC-A 0.415 61 5.14 27.74 4 1.099 12.14

6PA SEC-B 0.415 61 5.2 28.2 4 1.107 12.21

6PC 0.415 61 2.35 8.74 3 0.583 7.23

6PD 0.415 61 2.35 8.75 3 0.582 7.26

F-station
APA SWGR SEC-A 0.415 61 5.11 27.52 4 1.057 12.26

APA SWGR SEC-B 0.415 61 5.18 28.05 4 1.075 12.3

TPA SWGR SEC-A 0.415 61 5.14 27.71 4 1.08 12.27

TPA SWGR SEC-B 0.415 61 5.25 28.59 4 1.094 12.47

Arc flash label for typical 6.6 kV switchgear is shown below. Parameters
included in arc flash labels are tabulated below.

Table 10.5: Arc flash label details for typical 6.6kV switchgear _ Case 1

Flash Protection Boundary 11.26 m

Incident Energy (cal/cm )
2
13.8
Working Distance 91 cm
PPE Rating 3
Shock Hazard Voltage 6600 V
Limited Approach Boundary 1.52 m
Restricted approach Boundary 0.66 m
Prohibited approach Boundary 0.15 m

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 113 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Arc flash label for typical 415 V switchgear buses is shown below.
Parameters included in arc flash labels are tabulated below.

Table 10.6: Arc flash label details for typical 415V switchgear _ Case 1
Flash Protection Boundary 4.09 m

Incident Energy (cal/cm ) 19.8

2

Working Distance 61 cm

PPE Rating
Shock Hazard Voltage 415 V

Limited Approach Boundary 1.07 m

Restricted approach Boundary 0.30 m

Prohibited approach Boundary 0.03 m

Observations:

a. 6.6 kV switchboards are under the hazardous category level 3 as per

standard calculation.
b. The total arc flash incident energy at various 415 V switchboards is under
the hazardous category level of 2 to 4. But for E Station SSS-2
switchgear, arc flash incident energy exceeded level 4 due to high Fault
Clearing Time (FCT).

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 114 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Arc flash results of a typical 6.6 kV and 415 V switchgears with the proposed
and existing relay settings (FCT) are compared for Case-1 operating
configuration. Incident energies and energy levels at these switchgear buses
are tabulated in Table 10.7 below:

Table 10.7: AF results _with existing Vs proposed relay setting (FCT)

*AF results with Existing AF results with Proposed relay

relay setting (FCT) setting (FCT)
Switchgear Voltage
Total Final Total Final
Energy Energy
Energy FCT Energy FCT
Levels Levels
(cal/cm²) (Sec) (cal/cm²) (Sec)
DC1A 6.6 78.62 >4 2.036 20.25 3 0.505
CW MCC 0.415 15.26 3 0.549 19.84 3 0.723
* Above results with existing relay settings (FCT) corresponds to back-up fault clearing time after
disabling instantaneous over current protection of incoming feeders.

Case-1A, 1B & 1C: Outage of UAT I/C and one station incomer at D, E & F
station respectively

This case corresponds to the maximum fault condition for all 6.6 kV
switchgear.
The results of arc flash studies for Case-1A, 1B and 1C are given in
Table-10.7 to 10.9.
Detailed arc flash report is attached in Appendix-9.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 115 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Table 10.7: Arc Flash results at 6.6 kV switchgear buses _ Case-1A

Working Total Final Ia at
AFB Energy
Unit Bus ID Bus kV Distance Energy FCT FCT
(m) Levels
(cm) (cal/cm²) (sec) (kA)

BUS-1A 6.6 91 13.87 11.31 3 0.282 26.1

BUS-1B 6.6 91 14.46 11.81 3 0.294 26.1
D-station
DC1A 6.6 91 24.48 20.28 3 0.507 26.1
DC1B 6.6 91 24.48 20.28 3 0.507 26.1
BUS-2A 6.6 91 11.98 9.73 3 0.315 20.63
BUS-2B 6.6 91 13 10.58 3 0.343 20.63
E-station
EC1A 6.6 91 17.25 14.15 3 0.441 21.84
EC1B 6.6 91 18.09 14.86 3 0.441 22.59
6SA BUS 6.6 91 12.79 10.41 3 0.366 19.16
6SB BUS 6.6 91 11.10 9.0 3 0.318 19.05
F-station
OSA-A 6.6 91 16.62 13.62 3 0.424 21.89
OSA-B 6.6 91 16.81 13.78 3 0.4 23.11

Table 10.8: Arc Flash results at 6.6 kV switchgear buses_ Case-1B

Working Total Final Ia at
Bus AFB Energy
Unit Bus ID Distance Energy FCT FCT
kV (m) Levels
(cm) (cal/cm²) (sec) (kA)
BUS-1A 6.6 91 13.81 11.3 3 0.376 20.09
BUS-1B 6.6 91 14.64 12.0 3 0.4 20.12
D-station
DC1A 6.6 91 20.25 16.7 3 0.505 22.38
DC1B 6.6 91 20.41 16.82 3 0.485 23.21
BUS-2A 6.6 91 12.15 9.87 3 0.237 26.56
BUS-2B 6.6 91 12.89 10.49 3 0.253 26.56
E-station
EC1A 6.6 91 22.08 18.24 3 0.445 26.56
EC1B 6.6 91 22.08 18.24 3 0.445 26.56
6SA BUS 6.6 91 12.79 10.41 3 0.366 19.16
6SB BUS 6.6 91 11.10 9.0 3 0.318 19.05
F-station
OSA-A 6.6 91 16.62 13.62 3 0.424 21.89
OSA-B 6.6 91 16.81 13.78 3 0.4 23.11

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 116 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Table 10.9: Arc Flash results at 6.6 kV switchgear buses _ Case-1C

Working Total Final Ia at

Bus AFB Energy
Unit Bus ID Distance Energy FCT FCT
kV (m) Levels
(cm) (cal/cm²) (sec) (kA)
BUS-1A 6.6 91 13.81 11.3 3 0.376 20.09
BUS-1B 6.6 91 14.64 12 3 0.4 20.12
D-station
DC1A 6.6 91 20.25 16.7 3 0.505 22.38
DC1B 6.6 91 20.41 16.82 3 0.485 23.21
BUS-2A 6.6 91 11.98 9.73 3 0.315 20.63
BUS-2B 6.6 91 13 10.58 3 0.343 20.63
E-station
EC1A 6.6 91 17.25 14.15 3 0.441 21.84
EC1B 6.6 91 18.09 14.86 3 0.441 22.59
6SA BUS 6.6 91 12.56 10.21 3 0.259 25.63
6SB BUS 6.6 91 11.36 9.21 3 0.233 25.63
F-station
OSA-A 6.6 91 20.29 16.72 3 0.426 25.63
OSA-B 6.6 91 20.29 16.72 3 0.426 25.63

Arc flash label for typical 6.6 kV switchgear bus and parameters included
in arc flash labels are tabulated below.

Table 10.10: Arc flash label details of typical 6.6 kV switchgear

Flash Protection Boundary 11.31 m
Incident Energy (cal/cm )
2
13.9
Working Distance 91 cm
PPE Rating Level 3
Shock Hazard Voltage 6600 V
Limited Approach Boundary 1.52 m
Restricted approach Boundary 0.66 m
Prohibited approach Boundary 0.18 m

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 117 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Case-1D: Outage of one of the Incomers at LV switchgear

This case corresponds to worst case fault condition at LV switchgear.

The results of arc flash at 415 V switchgear level under this condition
are given in the Table 10.11.
Detailed arc flash report for Case-1D is attached in Appendix-9.

Table 10.11: Arc Flash results at 0.415 kV level_ Case-2

Working Total Final Ia at

Bus AFB Energy
Unit Bus ID Distance Energy FCT FCT
kV (m) Levels
(cm) (cal/cm²) (sec) (kA)

CW MCC 1A 0.415 61 20.4 4.17 3 0.73 13.03

CW MCC 1B 0.415 61 20.4 4.17 3 0.73 13.03

DM PMCC 1A 0.415 61 7.98 2.21 2 0.359 10.24

D-station DM PMCC 1B 0.415 61 7.98 2.21 2 0.359 10.24

SSS-2 1A 0.415 61 27.66 5.13 4 1 13.04
SSS-2 1B 0.415 61 27.66 5.13 4 1 13.04
415 V SSS-1 1A 0.415 61 21.19 4.28 3 0.835 12.05
415 V SSS-1 1B 0.415 61 21.19 4.28 3 0.835 12.05
E STN CW MCC 2A 0.415 61 24.31 4.7 3 0.849 13.47
E STN CW MCC 2B 0.415 61 24.31 4.7 3 0.849 13.47
E STN DM PMCC 1A 0.415 61 8.16 2.24 3 0.415 9.23
E STN DM PMCC 1B 0.415 61 8.16 2.24 3 0.415 9.23
E STN SSS-1 SEC-2A 0.415 61 13.22 3.11 3 0.524 11.57
E-station
E STN SSS-1 SEC-2B 0.415 61 13.22 3.11 3 0.524 11.57
E STN SSS-2 SEC-2A 0.415 61 43.25 6.95 >4 1.54 13.85
E STN SSS-2 SEC-2B 0.415 61 43.25 6.95 >4 1.54 13.85
E STN SSS-3 SEC-2A 0.415 61 7.8 2.17 2 0.464 7.96
E STN SSS-3 SEC-2B 0.415 61 7.8 2.17 2 0.464 7.96
6PA SEC-A 0.415 61 29.04 5.3 4 1.128 12.56
6PA SEC-B 0.415 61 29.04 5.3 4 1.128 12.56
6PC 0.415 61 8.86 2.37 3 0.578 7.36
6PD 0.415 61 8.86 2.37 3 0.578 7.36
F-station
APA SWGR SEC-A 0.415 61 28.39 5.22 4 1.083 12.44
APA SWGR SEC-B 0.415 61 28.39 5.22 4 1.083 12.44
TPA SWGR SEC-A 0.415 61 29.27 5.33 4 1.11 12.77
TPA SWGR SEC-B 0.415 61 29.27 5.33 4 1.11 12.77
R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 118 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

OPA BUS SEC-A 0.415 61 28.25 5.2 4 1.082 12.35

OPA BUS SEC-B 0.415 61 28.25 5.2 4 1.082 12.35

Typical arc flash label for 415 V switchgear and parameters included in
arc flash labels are tabulated below:

Table 10.12: Arc flash label details of typical 415 V switchgear

Flash Protection Boundary 4.17 m

Incident Energy (cal/cm2) 20.4

Working Distance 61 cm

PPE Rating 3

Shock Hazard Voltage 415 V

Limited Approach Boundary 1.07 m

Restricted approach Boundary 0.3 m

Prohibited approach Boundary 0.03 m

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 119 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.8 Assessment Criteria

Incident energy level and the Flash protection boundaries should be

calculated based on Arc fault current and corresponding Fault Clearing
Time (FCT) in accordance with IEEE std. 1584.
PPE requirement should be determined as per NFPA 70E 2009
Arc flash Label for individual HV and LV buses should be generated as
per NFPA 70E 2009 format.

10.9 Summary of Observations

10.9.1 From the results of arc flash study conducted for the TPL system for the
above cases, it is found that arc flash Incident energy at all 6.6 kV level buses
for case 1A,1B,1C is little higher than that of Case 1, but in the both cases 6.6
kV level buses are having the same hazardous level of 3.

10.9.2 The arc flash incident energies at most of the 415 V switchgear are in range
of hazardous level 2 to 4 for the maximum fault current and highest fault
clearing time. However, in case of SSS-2 switchgear of E station, incident
energy level has exceeded maximum permissible level as specified in NFPA
70E standard.

10.9.3 Arc flash incident energies at 415 V level are higher as compared to the 6.6
kV switchgears, due to higher Fault Clearing Time (FCT).

10.9.4 The available clearances at site is compared with the required Arc Flash
Boundaries (AFB) for the worst case fault conditions, and summarized in the
table below:

Table 10.13: Summary of AF results

Voltage Working Total AFB Clearance

Energy
Switchgear tag rating distance Energy calculated available
level
(kV) (cm) (cal/cm²) (m) (m)

BUS-1A 6.6 91 13.87 3 11.31 < 11.31

BUS-1B 6.6 91 14.46 3 11.81 < 11.81

DC1A 6.6 91 24.48 3 20.28 < 20.28

DC1B 6.6 91 24.48 3 20.28 < 20.28

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 120 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

Voltage Working Total AFB Clearance

Energy
Switchgear tag rating distance Energy calculated available
level
(kV) (cm) (cal/cm²) (m) (m)

BUS-2A 6.6 91 12.15 3 9.87 < 9.87

BUS-2B 6.6 91 12.89 3 10.49 < 10.49

EC1A 6.6 91 22.08 3 18.24 < 18.24

EC1B 6.6 91 22.08 3 18.24 < 18.24

6SA BUS 6.6 91 12.56 3 10.21 < 10.21

6SB BUS 6.6 91 11.36 3 9.21 < 9.21

OSA-A 6.6 91 20.29 3 16.72 < 16.72
OSA-B 6.6 91 20.29 3 16.72 < 16.72
CW MCC 1 A&B 0.415 61 20.4 3 4.17 4.79
DM PMCC 1 A&B 0.415 61 7.98 2 2.21 < 2.21
SSS-2 1 A&B 0.415 61 27.66 4 5.13 < 5.13
ESP MCC 0.415 61 4.10 2 1.4 7.08
415 V SSS-1 1A&B 0.415 61 21.19 3 4.28 < 4.28

E STN CW MCC 2A&B 0.415 61 24.31 3 4.7 14 [ ]

E STN DM PMCC 1A&B 0.415 61 8.16 3 2.24 4.88

E STN SSS-1 SEC-2A&B 0.415 61 13.22 3 3.11 < 3.11
E STN SSS-2 SEC-2A&B 0.415 61 43.25 >4 6.95 < 6.95
E STN SSS-3 SEC-2A&B 0.415 61 7.8 2 2.17 < 2.17
6PA SEC-A&B 0.415 61 29.04 4 5.3 < 5.3
6PC&6PD 0.415 61 8.86 3 2.37 < 2.37
APA SWGR SEC-A&B 0.415 61 28.39 4 5.22 < 5.22
TPA SWGR SEC-A&B 0.415 61 29.27 4 5.33 Data is not clear
OPA BUS SEC-A&B 0.415 61 28.25 4 5.2 < 5.2

10.9.5 From the above table, it can be inferred that the available clearances in most
of the switchgear are lesser than the required flash protection boundaries.

10.9.6 Results of arc flash study for a typical 6.6 kV switchgear (DC1A), with the
existing and proposed fault clearing time, are compared for Case-1 operating
configuration, and it is observed that with the proposed settings, the incident
energy level is reduced to level-3 from the hazardous level greater than 4.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 121 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

10.10 Conclusions and Recommendations

i. The arc flash incident energies at most of the 415 V switchgear are in range
of hazardous level 2 to 4 for the maximum fault current and highest fault
clearing time. However, in case of SSS-2 switchgear of E station, incident
energy level has exceeded maximum permissible level as specified in NFPA
70E standard.

ii. The arc flash incident energies at all the 6.6 kV switchgear buses of TPL
system are found to be in the hazardous category level of 3.

iii. PPE recommended for level 2 should include the following specification:

FR long-sleeve shirt (minimum arc rating of 8), worn over untreated cottons T-
shirt with FR pants (minimum arc rating of 8) or FR overalls (minimum arc
rating of 8)

iv. PPE recommended for level 3 and 4 should include following specification:

A total clothing system consisting of FR shirt and pants and/or FR coveralls

and/or arc flash coat and pants (clothing system minimum arc rating of 40)

v. The study of existing equipment layouts reveals that the available clearance
from the equipment under assessment is less than the calculated Arc Flash
Protection Boundary (AFB).

vi. The switchgear where minimum clearance is not available, it is recommended

that nobody should enter into the room without having recommended PPE.

vii. In case of CW MCC 1, E STN CW MCC 2, E STN DM PMCC 1 switchgear, it

is observed that even though sufficient clearance is there inside the room,
entry door is near to panel as per layouts. Hence, it is recommended to use
proper PPE whenever a person enters inside the room.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 122 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

viii. In case of STN SSS-2 switchgear, it is found that arc flash hazard level
exceeds level 4 due to higher fault clearing time of the protective relays (1.63
sec at 415V PCC). In order to reduce the arc flash incident energy level, it is
recommended to limit the fault clearing time of protective devices within 0.8
sec.

ix. Alternatively, a standing instruction should be issued for not to perform work
in energized (high risk) locations.

x. Each panel must be marked with an approved Arc Flash Hazard Warning
Label to warn and instruct workers of the arc flash hazard, voltage, arc flash
boundary and required PPE (Personal Protective Equipment) for safety.

xi. Proper PPE has to be selected as per recommendation before working on all
the equipments.

R2

FILE NAME: F-120-Rev-R3.docx

TCE.10210B-EL- TATA CONSULTING ENGINEERS LIMITED SHEET 123 OF
BS-700-01
143
ELECTRICAL SYSTEM STUDIES REPORT

APPENDICES

R2

FILE NAME: F-120-Rev-R3.docx