3.

14 ARC FLASH ANALYSIS

The purpose of conducting Arc Flash Analysis is to determine the

required Personal Protective Equipment (PPE) after the identification
of Flash Hazard Risk Category. The Incident Energy (cal/cm²)
discharged by faulted electrical board must be calculated to
determine this risk level. The workers may be exposed to the incident
energy and it is very important to determine how to protect them
from the heat, light and blast associated with an arc flash incident.
NFPA 70E and NFPA 70 requires arc flash risk assessment as part
of a complete electrical analysis.
The required information needed to identify hazard level:
 Short Circuit, three phase symmetrical fault
 Coordinated Overcurrent Protection Devices
 Calculate Arcing Current
 Calculate trip-time for arcing current
 Calculate the Incident Energy in cal/cm²

Guidelines set in IEEE Standard 1584 will be used for this technical
report. Low Voltage equipment will be calculated using both IEEE
1584:2002 and IEEE 1584:2018 guidelines for comparison. High
tension equipment will be calculated using “Ralph Lee Method” which
is proposed and accepted method in the NFPA 70E standard.

In previous sections, short circuit calculation and protection

coordination has been carried out. The values gathered such as three
phase symmetrical short circuit current and overcurrent protection
devices short circuit trip clearing time will be utilised as part of arc
flash analysis related calculations.

The flow of calculation process will be described on following process

block diagram.

Page | 263
 Figure 44: IEEE 1584:2018 Arc Flash Calculation Process, Hazard
Determination Process

3.14.1 IEEE 1584:2018, Low Voltage Arc Flash Calculation

Succeeding calculations will focus on fault at MSB-B level . The
other fault point calculation results to be shown and tabulated as part
of summary information.

3.14.1.1 Step 1: Determination of Given Parameters

Fault Point = “F2”
Fault Location = MSB-B Incoming
3-phase Fault = 24.18kA = Ibf
Voltage = 0.4kV
G (Bus Gap) = 32mm
D (Working Dist.) = 609.6mm

Page | 264
 EC (Electrode Configuration) =VCB
Voltage Category for “k” constants =600V
Enclosure:
Actual width = 650mm
Actual height = 750mm
Actual depth =650mm

 Bus Gap (G) Identification

Reference T: Typical Bus Gap for different class of equipment

*Gap =32 for Low-voltage switchgear

 Working Distance (D) Identification

Page | 265
Reference U: Working Distances for different class of equipment

Working Distance =609.6mm for Low-voltage switchgear

 Electrode Configuration

Reference V: Electrode Configuration

EC = VCB, Vertical Electrodes inside

Page | 266
3.14.1.2 Step 2: Calculate Intermediate arcing Current
(Iarc_Voc)

k1+k2logIbf +k3logG
Iarc_600 =10 ×
6 5 4 3 2
k4Ibf +k5Ibf +k6Ibf +k7Ibf +k8Ibf +k9Ibf + k10

Formula 43: Iarc_600, Intermediate Arcing Current at Voc = 600V

Where:
Iarc_600 = Arcing current at Voc = 600 V, in (kA)
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
G = gap distance between electrodes (mm)
Log base =10

k1 to k10 coefficients are given from this table:

Reference W: Coefficient for Intermediate Arcing Current – IEEE-

Std 1584-2018
Page | 267
Substituting Values to formula:

Iarc_600 = 10(-0.04287+1.035log24.18-0.083log32) x (0 +0 –4.783x10-9x 24.184

+1.962x10-6x24.183-0.000229x24.182+0.003141x24.18
+1.092)
Iarc_600 = 19.47kA

3.14.1.3 Step 3: Calculate Arcing Current (Iarc)

1
Iarc =
2 2 2
0.6 1 0.6 -VOC
× 2-
VOC Iarc_600
2
0.6 ×Ibf
2

Formula 44: Final Arcing Current

Where:
Iarc_600 = Arcing current at Voc = 600 V, in (kA)
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)

Substituting Values to formula:

1
Iarc =
2 2 2
0.6 1 0.6 -0.4
× 2-
0.4 19.47
2
0.6 ×24.17
2

Iarc = 16.23kA
T = 30.2ms

Page | 268
3.14.1.4 Step 4: Calculate Enclosure Size Correction Factor

VOC +A -1
Width1 = 660.4+ Width-660.4 ×( ) × 25.4 (1)
B

VOC +A -1
Height1 = 660.4+ Height-660.4 ×( ) × 25.4 (2)
B
Width1 + Height1
EES= (3)
2
2
CF=b1×EES +b2×EES+b3 (4)

Formula 45: Equivalent and Correction Factor for Enclosure Size

Where:
Height1 = Equivalent enclosure height
Width1 = Equivalent enclosure width
Width = Actual enclosure width
Height = Actual enclosure height
VOC = System voltage (kV)
A = Constant equal to 4 for VCB and 10 for VCBB and HCB
B = Constant equal to 20 for VCB,24 for VCBB, and 22 for
HCB
EES = Equivalent enclosure size
CF = Enclosure size correction factor
b1 to b3 = Coefficient for Formula (4) provided in table:

Reference X: Coefficient for Intermediate Arcing Current – IEEE-

Std 1584-2018
Page | 269
 0.4+4 -1
Width1 = 660.4+ 650-660.4 ×( ) × 25.4
20
Width1 = 25.91mm

0.4+4 -1
Height1 = 660.4+ 750-660.4 ×( ) × 25.4
20
Height1 = 26.78mm

25.91+ 26.78
EES=
2
EES= 26.343

b1 = -0.0001923
b2 = 0.01935
b3 = 0.6899

2
CF=-0.0001923×26.343 +0.01935×26.343+0.6899
CF=1.066

3.14.1.5 Step 5: Calculate Intermediate Incident Energy

(E_Voc)

12.552 t
E600 = ×T×10
50
k3Iarc600
t=k1+k2logG+ 7 6 5 4 3 2
k4Ibf +k5Ibf +k6Ibf +k7Ibf +k8Ibf +k9Ibf +k10Ibf
+k11logIbf + k12logD + k13logIarc + log (1/CF)

Formula 46: Intermediate Incident Energy (E_Voc)

Page | 270
Where:
Iarc_600 = Arcing current at Voc = 600 V (kA)
Iarc = Arcing current (kA)
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
D = working distance (mm)
G = gap distance between electrodes (mm)
CF = Enclosure size correction factor
k1 to k13 coefficients are given from this table:

Reference Y: Coefficient for Incident Energy

Substituting Values to formula:

12.552 t
E600 = ×30.2×10
50
t = 0.753364+0.566log32 + ((1.752636x19.47) / (0+0-
4.783x10-9 x 24.185 + 0.000001962 x 24.184-0.000229 x
24.183 + 0.003141 x 24.182 + 1.092 x 24.18)) + 0 -
1.598log609.6 + 0.957log16.23 + log(1/1.066)
t = -0.383296
E600 = 3.14 J/cm2 or 0.75 cal/ cm2

Page | 271
3.14.1.6 Step 6: Arc Flash Boundary (AFB)

k3Iarc_600
k1+k2logG+ 7 6 5 4 3 2
⎛ k4Ibf +k5Ibf +k6Ibf +k7Ibf +k8Ibf +k9Ibf +k10Ibf⎞
⎜ 1 20 ⎟
+k11logIbf+k13logIarc+log -log
⎜ CF T ⎟
⎜ -k12 ⎟
⎜ ⎟

AFB600 = 10⎝ ⎠

Formula 47: Arc Flash Boundary (AFB)

Where:
Iarc_600 = Arcing current at Voc = 600 V (kA)
Iarc = Arcing current (kA)
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
D = working distance (mm)
G = gap distance between electrodes (mm)
CF = Enclosure size correction factor
k1 to k13 coefficients are same values taken from computation of
incident energy.

Substituting Values to formula:

1.752636×19.47
0.753364+0.566log32+
⎛ 0+0- 4.783x10-9 x 24.185 + 0.000001962 x 24.184 ⎞
-0.000229 x 24.18 + 0.003141 x 24.182 + 1.092 x 24.18
3
⎜ 1 20 ⎟
⎜ +0+0.957log16.23+log -log ⎟
1.066 30.2
⎜ 1.598 ⎟
⎜ ⎟
⎜ ⎟

AFB600 = 10⎝ ⎠

AFB600 = 454.14mm

Page | 272
 Figure 45: Illustration of Arc Flash Boundary

3.14.1.7 Step 7: Account for Arcing current variation. Find the

Correction factor

6 5 4 3 2
VarCf = k1*Voc +k2*Voc +k3*Voc +k4*Voc +k5*Voc +
k6*Voc+k7

Formula 48: VarCf, Arcing Current Variation Correction Factor

Where:
VOC = Open-circuit voltage (kV) = 0.4kV
k1 to k7 coefficients are given from this table:

Page | 273
 Reference Z: Coefficient for Arcing Current Variation Correction
Factor

Substituting Values to formula:

5 4
VarCf = 0-0.0000014269*0.4 +0.000083137*0.4 -0.0019382
2
*0.43+ 0.022366*0.4 -0.12645*0.4+0.30226
VarCf = 0.255

Cf = 1-0.5*VarCf
Formula 49: Arcing Current Variation Correction Factor

Substituting Values to formula:

Cf = 1-0.5*0.225
Cf = 0.872

3.14.1.8 Step 8: Calculate Arcing Current (Iarc) - Minimum

Iarc_min = Iarc100% ×Cf

Formula 50: Arcing Current Minimum

Substituting Values to formula:

Iarc_min =16.23 ×0.872
Iarc_min =14.162kA
T = 30.2ms

Page | 274
3.14.1.9 Step 9: Calculate Intermediate Incident Energy
(E_Voc) - Minimum

12.552 t
E600_min = ×T×10
50
k3Iarc600
t=k1+k2logG+ 7 6 5 4 3 2
k4Ibf +k5Ibf +k6Ibf +k7Ibf +k8Ibf +k9Ibf +k10Ibf
+k11logIbf + k12logD + k13logIarc_min + log
(1/CF)

Formula 51: Intermediate Incident Energy (E_Voc)-minimum

Where:
Iarc_600 = Arcing current at Voc = 600 V (kA)
Iarc_min = Arcing current (kA) , minimum
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
D = working distance (mm)
G = gap distance between electrodes (mm)
CF = Enclosure size correction factor
k1 to k13 coefficients are given from previous Incident energy
calculation

Substituting Values to formula:

12.552 t
E600_min = ×30.2×10
50
t = 0.753364+0.566log32 + ((1.752636x19.47) / (0+0-
4.783x10-9 x 24.185 + 0.000001962 x 24.184-0.000229 x
24.183 + 0.003141 x 24.182 + 1.092 x 24.18)) + 0 -
1.598log609.6 + 0.957log14.162 + log(1/1.066)
t = -0.383296
E600_min = 2.75 J/cm2 or 0.66 cal/ cm2

Page | 275
3.14.1.10 Step 10: Arc Flash Boundary (AFB) - Minimum

AFB600 _min=
k3Iarc_600
k1+k2logG+ 7 6 5 4 3 2
⎛ k4Ibf +k5Ibf +k6Ibf +k7Ibf +k8Ibf +k9Ibf +k10Ibf⎞
⎜ 1 20 ⎟
+k11logIbf+k13logIarc_min+log -log
⎜ CF T ⎟
⎜ -k12 ⎟
⎜ ⎟

10⎝ ⎠

Formula 52: Arc Flash Boundary (AFB) - minimum

Where:
Iarc_600 = Arcing current at Voc = 600 V (kA)
Iarc_min = Arcing current (kA) , minimum
VOC = Open-circuit voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
D = working distance (mm)
G = gap distance between electrodes (mm)
CF = Enclosure size correction factor
k1 to k13 coefficients are same values taken from computation of
incident energy.

Substituting Values to formula:

1.752636×19.47
0.753364+0.566log32+
⎛ 0+0- 4.783x10-9 x 24.185 + 0.000001962 x 24.184 ⎞
-0.000229 x 24.18 + 0.003141 x 24.182 + 1.092 x 24.18
3
⎜ 1 20 ⎟
⎜ +0+0.957log14.162+log -log ⎟
1.066 30.2
⎜ 1.598 ⎟
⎜ ⎟
⎜ ⎟

AFB600_min = 10⎝ ⎠

AFB600_min = 418.5mm

Page | 276
3.14.2 IEEE 1584:2002, Low Voltage Arc Flash Calculation
Low voltage equipment will be calculated based on IEEE
1584:2002. Outcome will be compared and tabulated with earlier
calculation results of IEEE 1584:2018.

3.14.2.1 Step 1: Calculate Arcing Current (Iarc)

Iarc=10^[k+0.662logIbf+0.0966V+0.000526G+0.5588V(l
ogIbf)-0.00304G(logIbf)]

Formula 53: Arcing Current, IEEE 1584:2002

Where:
Iarc = arcing current in (kA)
V = system voltage (kV)
Ibf = three-phase symmetrical bolted fault current (kA)
G = gap distance between electrodes (mm)
k =0.153 for open air and -0.097 for arcs in a box
log base =10
Given:
Ibf = 24.18 kA
V = 0.4 kV
G = 32 mm
k = -0.097

Substituting Values to formula:

Iarc =10 ^ [-0.097 + (0.662)(log24.18) + 0.0966(0.4) +
0.000526(32) + 0.5588(0.4)(log24.18) - 0.00304(32)(log24.18)]
Iarc =11.194kA

Page | 277
3.14.2.2 Step 2: Calculate Incident Energy (Ei)

Ein=10^{k1+k2+[1.081x(logIarc)]+0.0011G}
Formula 54: Normalized Incident Energy, IEEE 1584:2002

Calculating Ei for condition Ein normalized in 0.2s and 610mm

working distance:

Ei=4.184 x Cf x Ein [(t/0.2)x(610/D)^x]

Formula 55: Incident Energy, IEEE 1584:2002

Where:
Iarc = arcing current in (kA)
k1 = -0.792 for open air and -0.555 for arcs in a box
k2 = 0 for high impedance and -0.113 for grounded
Cf = calculation factor 1.0 for V>1kV, 1.5 for V<=1kV
t = arching time in seconds from time current curve
G = gap distance between electrodes (mm)
X = distance exponent,
switchgear=1.473, MCC and panel = 1.641
D = working distance
Given:
Iarc = 11.194kA
k1 = -0.555
k2 = -0.113
Cf = 1.5
t = 0.0302s
G = 32mm
X = 1.473
D = 609.60mm

Page | 278
Substituting Values to formula:
Ein=10^{-0.555-0.113+[1.081x(log11.194)]+0.0011(32)}
Ein=3.171cal/cm²

Ei=4.184 x 1.5 x 3.171 [(0.0302/0.2)x(610/609.60)^1.473]

Ei=3.008J/ cm² or 0.722cal/cm²

3.14.2.3 Step 3: Calculate Arc Flash Boundary (AFB)

AFB={4.184 x Cf x Ein [(t/0.2)x(610^x/Eb)]}^(1/x)

Formula 56: Arc Flash Boundary, IEEE 1584:2002

Where:
AFB = Arc Flash Boundary in mm
Eb = Incident Energy at arc flash boundary, typically
1.2cal/cm² or 5j/cm²
Ein = Incident Energy normalized
Cf = calculation factor 1.0 for V>1kV, 1.5 for V<=1kV
t = arching time in seconds from time current curve
X = distance exponent,
switchgear=1.473, MCC and panel = 1.641
Given:
Eb = 5j/cm²
Ein = 3.171cal/cm²
Cf = 1.5
t = 0.0302s
X = 1.473
Substituting Values to formula:
AFB={4.184 x 1.5 x 3.171 [(0.0302/0.2)x (610^1.473/5)]} ^
(1/1.473)
AFB=431.69mm

Page | 279
3.14.3 Arc flash Calculation for 22kV equipment
To calculate arcing current, incident energy and arc flash boundary
at 22kV equipment, Ralph Lee method will be used.

3.14.3.1 Step 1: Calculate Arcing Current (Iarc)-Lee Method

Iarc=10^(0.00402+0.983logIbf)
Formula 57: Arc Flash Boundary, Lee method
Where:
Ibf =three-phase symmetrical bolted fault current (kA)
=20.97kA at fault 1
Substituting Values to formula:
Iarc =10^(0.00402+0.983log20.97)
Iarc =20.098kA

3.14.3.2 Step 2: Calculate Incident Energy (Ei)-Lee Method

6 t
Ei= 2.142X10 VIbf 2
D
Formula 58: Incident Energy, Lee method

Where:
V = voltage system
Ibf = Three Phase Bolted fault current
D = Distance from possible arc point to person in mm
t = Is the arcing time in Sec.

Given:
V = 22kV
Ibf = 20.97kA
D = 910mm
t = 0.08 seconds (Refer to next table, for the clearing Time)

Page | 280
Reference AA: Power Circuit Breaker Operating Times from IEEE
Std. 1584 Guide for Performing Arc Flash Hazards Calculation,2002

Substituting Values to formula:

6 .08
Ei= 2.142X10 (22)(20.97) 2
910
Ei= 95.466 J/cm² or 22.82cal/cm²

3.14.3.3 Step 3: Arc Flash Boundary (AFB)-Lee Method

6 t
AFB = 2.142×10 VIbf
Eb

Formula 59: Arc Flash Boundary, Lee method

Where:
V = voltage system
Ibf = Three Phase Bolted fault current
Eb = incident energy at the boundary distance in J/cm²
Typical value is 5J/ cm²
t = Is the arcing time in Sec.

Page | 281
Given:
V = 22kV
Ibf = 20.97kA
Eb = 5J/ cm²
t = 0.08 seconds

Substituting Values to formula:

6 0.08
AFB = 2.142×10 ×22×20.97
5

AFB = 3676.31mm

3.14.3.4 Step 4: Calculate Arcing Current, Incident Energy

and Arc Flash Boundary at Ibf=85%

Ibf@85%= 24.18kA x 0.85

Ibf@85%= 17.825kA

Iarc@0.85 =10^(0.00402+0.983log17.825)
Iarc@0.85 =17.131kA

6 0.08
Ei@0.85 = 2.142X10 (22)(17.825) 2
910
Ei@0.85 = 81.146 J/cm² or 19.395 cal/cm²

6 0.08
AFB@0.85 = 2.142×10 ×22×17.825
5

AFB@0.85 = 3665.98mm

Page | 282
3.14.3.5 Tabulation of Calculated Results and Identifying
Flash Hazard Risk Category
Note: There are three Low voltage equipment fault points
considered for this report’s arc flash calculation. Only MSB-B fault
point’s arc flash calculation has been shown in detail. The summary
will include two more points which are in sub and distribution board
level subsequently. Detailed calculations for both were done in
Microsoft Excel Program.

TABLE: ARC-FLASH HAZARD RISK CATEGORIES AND PERSONAL

PROTECTION EQUIPMENT (PPE) RATINGS

Range of
Flash
Calculated Minimum
Hazard
Incident PPE Rating Clothing Required
Risk
Energy [cal/cm2]
Category
[cal/cm2]

0 0 ≤ E ≤ 1.2 N/A 4.5 - 14.0 oz/yd2 untreated Cotton

1 1.2 < E ≤ 4 4 Flame Retardant (FR) shirt and pants

Cotton underclothing plus FR shirt
2 4<E ≤8 8
and pants
Cotton underclothing plus FR shirt,
3 8 < E ≤ 25 25
pants overall or equivalent
Cotton underclothing plus FR shirt,
4 25 < E ≤ 40 40 pants, plus double layer switching
coat and pants or equivalent

Cotton underclothing plus FR shirt

5 40 < E ≤ 100 100 ,pants, plus multi-layer switching
coat and pants or equivalent
Credits: NFPA 70E and ABB

Reference BB: Personal Protective Equipment (PPE) Flash Suit

Categories

As result, all low voltage equipment has very low calculated incident
energy and therefore identified as “0” under Flash Hazard Risk
Category. The circuit breaker has a very fast short circuit current
clearing time which results to diminish the growth of incident energy
during fault.

Page | 283
 Table 38: Summary of Arc Flash Analysis (0.4kV) IEEE 1584:2018

Page | 284
Table 39: Summary of Arc Flash Analysis (0.4kV) IEEE 1584:2002
As observed, both calculations of IEEE 1584 for 2002 and 2018
versions have almost same incident energy results and the hazard
risk fell into same category. On the other hand, the calculated arcing
current has significant non-similarity due to more detailed calculation
approach in IEEE 1584:2018 version.

The hazard risk category in High Tension side landed in category “3”
for having an incident energy of more than 8 but less than 25. This
project has SF6 gas insulated switchgear for 22kV switchboard. It
may not be necessary for working personnel to wear a PPE with
minimum rating of 25cal/cm² due to the arc quenching feature of the
switchgear. Furthermore, the design of 22kV network on this project
allows the total de-energization of switchgear, if necessary, by
isolating the “before and after” adjacent switchgear in the loop. The
calculation done on high tension side is good for studying purpose
only.

Currently, there are no visible Danger Sign for Arc Flash Hazard at
site substation. It may not be necessary for the reason that the Flash
Hazard risk category on low voltage side is “0”. Also, for high tension
side, it’s good to know that the incident energy calculated can
correspond to category “3” hazard. However, having a Gas Insulated
Switchgear played its important part to mitigate any high current
arching that can result to release of huge incident energy.

Page | 285
Page | 286
Table 40: Summary of Arc Flash Analysis (22kV) Lee method
Figure 46: Arc Flash Hazard Danger Sign

Page | 287
Figure 47: Arc Flash Hazard Risk Categories and Personal
Protection Equipment (PPE) Ratings

Page | 288