25th annual Electrical Engineering Safety Seminar 2015

1. November 2015 Prepared by Alan Mason AME Pty
LTD
1
Arc Flash CAT 0
Electric Mining Shovel
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

2. November 2015 Prepared by Alan Mason AME Pty
LTD
2
AIM of
PRESENTATION
 Is to show how
–two Electric Mining Shovels
–were modified
–to achieve Arc Flash CAT 0.
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

3. November 2015 Prepared by Alan Mason AME Pty
LTD
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CONTENTS
1. CAT 0 Term
2. Consequences
3. What we know?
4. Analysis is a 3 Step Process
5. Mitigation
6. Equipment
7. Benefits
8. Questions
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

4. November 2015 Prepared by Alan Mason AME Pty
LTD
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TERMS
Arc Fault:
 Is the fault current that travels through air between two
conducting phases or phase to earth with an
uncontrolled release of energy. Generally due to un-
natural causes.
Arc Flash:
 Is a consequence from an Arc Fault but in this subject
is generally understood to also embody all the
consequences of an arc fault.
CAT 0:
 Arc Fault Incident Energy is less than
1.2 cal/cm2 (Heat Energy).
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

5. November 2015 Prepared by Alan Mason AME Pty
LTD
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Arc Fault
Consequences
1. Thermal Burns
2. Electrical Shock
3. Molten Metal
4. Projectiles
5. Blast & Pressure
waves
6. Intense Light (Arc
Flash)
7. Intense Sound
8. Fire
9.Strong Magnetic
Fields
10.Plasma
11.Toxic Gasses
12.Vapours
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

6. November 2015 Prepared by Alan Mason AME Pty
LTD
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Arc Flash
Consequences
Subject to the level of Energy
released the consequences
to :
– a worker will vary from
mild burns to permanent
injury or death.
– equipment may be nil to
catastrophic failure:
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

7. November 2015 Prepared by Alan Mason AME Pty
LTD
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Example: Arc Flash Incident on a
6.6kv Fused Feeder compartment within
the HV Cabinet of an Electric Mining Shovel.
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

8. November 2015 Prepared by Alan Mason AME Pty
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What we know:
Let Through Energy vs Time
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

9. November 2015 Prepared by Alan Mason AME Pty
LTD
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What we know:
Protection Devices vs Time
Shovel Standard
Fast Protection
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

10. November 2015 Prepared by Alan Mason AME Pty
LTD
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What we know:
Arc Fault Current Time Characteristic
Shovel Standard
Fast Protection
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

11. November 2015 Prepared by Alan Mason AME Pty
LTD
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What we know:
Arc Flash Pressure Rise vs &Time
Shovel Standard
Fast Protection
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

12. November 2015 Prepared by Alan Mason AME Pty
LTD
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What we know:
Arc Flash Incident Energy
E ~ k * V * Ibf * t …….…..Eq:1
d2
 Where:
– E = Incident Energy (Cal/cm2)………Heat Energy
– V = System Voltage (kV)
– t = Arcing Time (seconds)
– d = Working distance from Arc (mm)
– Ibf = Bolted fault Current (kA)
– k = Constant
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

13. November 2015 Prepared by Alan Mason AME Pty
LTD
13
Analysis is a
3 Step Process
1. Shovel Single Line Diagram (SLD)
2. Calculate & Analyse
3. Determine CAT 0 measures &
install
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

14. November 2015 Prepared by Alan Mason AME Pty
LTD
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Analysis is a
3 Step Process
Step 1:
Single Line Diagram
PTW
Step 2:
Fault Analysis
IEEE 1584
Step 3
Mitigation
Include details for all:
-Voltages
-Cables (L, CSA, Ez)
-Transformers (kva, Ez)
-Protective Devices
(Type, settings)
-Loads (Motors, etc)
Calculate:
-Bus Fault kA
-Arc Flash Fault kA
-Incident Energy
-Isolation Times
-Arc Flash Boundary
-Arc Flash Category
-Select BUS’s > CAT 0
-Use Hierarchy of Controls
-Reduce Trip times:
• Adjust PD settings
• Select New Equipment
-Recalculate IEEE 1584
-Decide mitigation methods.
-Implement
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

15. November 2015 Prepared by Alan Mason AME Pty
LTD
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Step 1
Step 1:
Single Line Diagram
PTW
Include details for all:
-Voltages
-Cables (L, CSA, Ez)
-Transformers (kva, Ez, tap)
-Protective Devices (Type,
settings)
-Loads (Motors, type) kw, pf
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
UTIL-0001
Init Voltage 1.050 pu
SC Contribution 3P 400.0 MVA
SC Contribution SLG 100.0 MVA
S
XF2-0001
BUS-0001
1780 Amps 3P
1335 Amps SLG
BUS-0002
1636 Amps 3P
1196 Amps SLG
CBL-0002
BUS-0004
14410 Amps 3P
16985 Amps SLG
PD-0001
Frame/Rating 2500.0 A
InterruptingRating 31.5 kA
XLN-0001

16. November 2015 Prepared by Alan Mason AME Pty
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TSS
@ 914 mm
PPE Category 0
Trail Cable
Fuse 200 A
690v
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
433v Bus
0.1 Cal/cm^2
@ 61 mm
PPE Category 0
MCC CB 415v
L&P CB 415v
CBL-0007
MCC 415v
@ 457 mm
PPE Category 0
CBL-0008 CBL-0011
Controls CB 200v
Controls
@ 457 mm
PPE Category 0
L7 Controls
UTIL-1
L&P 415v
@ 457 mm
PPE Category 0
CBL-4
HV Cab Output
@ 914 mm
PPE Category 0
6.6kv Contactor
Arc Flash Relay B0
AFR B4
AFR B5 BUS-40 @ 914 mm
PPE Category 0
CBL-26
PD-0046
BUS-0042 MCC
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
PD-52
CBL-27
MTRI-1
BUS-0043
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0028
PD-53
CBL-29
MTRI-2
BUS-0044
@ 457 mm
PPE Category 0
PD-54
CBL-30
MTRI-3
BUS-45
@ 457 mm
PPE Category 0
PD-55
CBL-31
MTRI-4
BUS-46
@ 457 mm
PPE Category 0
PD-56
CBL-32
MTRI-5
BUS-47
@ 457 mm
PPE Category 0
PD-7
CBL-33
L10
CBL-0036
BUS-0051 Light & Power
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0060PD-0061PD-0062PD-0063
CBL-0037 CBL-0038 CBL-0039 CBL-0040
L11
BUS-0052
@ 457 mm
PPE Category 0
L12
BUS-0053
@ 457 mm
PPE Category 0
L13
BUS-0054
@ 457 mm
PPE Category 0
L14
BUS-0055
@ 457 mm
PPE Category 0
S
P
XF2-6 TSS
BUS-0056
111.4 Cal/cm^2
@ 914 mm
PPE Category Dangerous!
AFR B7
CBL-0041
BUS-0057
@ 914 mm
PPE Category 0
CBL-0042
CBL-0045
BUS-0061
@ 457 mm
PPE Category 0
CBL-0048
BUS-0064
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
S
P
XF2-7 Main Tx
BUS-0066
@ 914 mm
PPE Category 0
TS
P
XF3-4 Aux Tx
BUS-0067
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
MTRI-0008 MTRI-0009 MTRI-0010 MTRI-0011 MTRI-0012 MTRI-0013 MTRI-0014 MTRI-0015
BUS-0076
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0065
PD-0066
PD-0067 PD-0068
BUS-0078
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0050
PD-0069
PD-0070 PD-0071
BUS-0079
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0051
PD-0072
PD-0073 PD-0074
BUS-0080
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0052
PD-0075
PD-0076 PD-0077
BUS-0081
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0053
PD-0078
PD-0079 PD-0080
BUS-0082
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0054
CBL-0055
BUS-0083
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
BUS-0084
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0081
BUS-0085
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0082
BUS-0086
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0083
BUS-0087
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0084
BUS-0088
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0085
BUS-0089
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0086
BUS-0090
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0087
BUS-0091
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0056 CBL-0057
CBL-0058
CBL-0059
CBL-0060
CBL-0061
CBL-0062
CBL-0063
CBL-0064
CBL-0065
CBL-0066 CBL-0067 CBL-0068 CBL-0069 CBL-0070 CBL-0071 CBL-0072 CBL-0073
PD-0089 QTTM
Fuse 200 Amp
BUS-0095
@ 914 mm
PPE Category 0
BUS-0096 @ 914 mm
PPE Category 0
CBL-0075
CBL-0076
BUS-0098
@ 914 mm
PPE Category 0
CBL-0077
PD-0092
Fuse 200 A0
CBL-0078
Shovel Single Line
Diagram
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
Step 1

17. November 2015 Prepared by Alan Mason AME Pty
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Step 2
Step 2:
Fault Analysis
IEEE 1584
Calculate:
-Bus Fault kA
-Arc Flash Fault kA
-Incident Energy
-Isolation Times
-Arc Flash Boundary
-Arc Flash Category
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

18. November 2015 Prepared by Alan Mason AME Pty
LTD
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TSS
@ 914 mm
PPE Category 0
Trail Cable
Fuse 200 A
690v
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
433v Bus
0.1 Cal/cm^2
@ 61 mm
PPE Category 0
MCC CB 415v
L&P CB 415v
CBL-0007
MCC 415v
@ 457 mm
PPE Category 0
CBL-0008 CBL-0011
Controls CB 200v
Controls
@ 457 mm
PPE Category 0
L7 Controls
UTIL-1
L&P 415v
@ 457 mm
PPE Category 0
CBL-4
HV Cab Output
@ 914 mm
PPE Category 0
6.6kv Contactor
Arc Flash Relay B0
AFR B4
AFR B5 BUS-40 @ 914 mm
PPE Category 0
CBL-26
PD-0046
BUS-0042 MCC
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
PD-52
CBL-27
MTRI-1
BUS-0043
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0028
PD-53
CBL-29
MTRI-2
BUS-0044
@ 457 mm
PPE Category 0
PD-54
CBL-30
MTRI-3
BUS-45
@ 457 mm
PPE Category 0
PD-55
CBL-31
MTRI-4
BUS-46
@ 457 mm
PPE Category 0
PD-56
CBL-32
MTRI-5
BUS-47
@ 457 mm
PPE Category 0
PD-7
CBL-33
L10
CBL-0036
BUS-0051 Light & Power
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0060PD-0061PD-0062PD-0063
CBL-0037 CBL-0038 CBL-0039 CBL-0040
L11
BUS-0052
@ 457 mm
PPE Category 0
L12
BUS-0053
@ 457 mm
PPE Category 0
L13
BUS-0054
@ 457 mm
PPE Category 0
L14
BUS-0055
@ 457 mm
PPE Category 0
S
P
XF2-6 TSS
BUS-0056
111.4 Cal/cm^2
@ 914 mm
PPE Category Dangerous!
AFR B7
CBL-0041
BUS-0057
@ 914 mm
PPE Category 0
CBL-0042
CBL-0045
BUS-0061
@ 457 mm
PPE Category 0
CBL-0048
BUS-0064
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
S
P
XF2-7 Main Tx
BUS-0066
@ 914 mm
PPE Category 0
TS
P
XF3-4 Aux Tx
BUS-0067
0.1 Cal/cm^2
@ 457 mm
PPE Category 0
MTRI-0008 MTRI-0009 MTRI-0010 MTRI-0011 MTRI-0012 MTRI-0013 MTRI-0014 MTRI-0015
BUS-0076
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0065
PD-0066
PD-0067 PD-0068
BUS-0078
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0050
PD-0069
PD-0070 PD-0071
BUS-0079
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0051
PD-0072
PD-0073 PD-0074
BUS-0080
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0052
PD-0075
PD-0076 PD-0077
BUS-0081
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0053
PD-0078
PD-0079 PD-0080
BUS-0082
0.4 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0054
CBL-0055
BUS-0083
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
BUS-0084
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0081
BUS-0085
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0082
BUS-0086
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0083
BUS-0087
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0084
BUS-0088
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0085
BUS-0089
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0086
BUS-0090
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
PD-0087
BUS-0091
0.2 Cal/cm^2
@ 457 mm
PPE Category 0
CBL-0056 CBL-0057
CBL-0058
CBL-0059
CBL-0060
CBL-0061
CBL-0062
CBL-0063
CBL-0064
CBL-0065
CBL-0066 CBL-0067 CBL-0068 CBL-0069 CBL-0070 CBL-0071 CBL-0072 CBL-0073
PD-0089 QTTM
Fuse 200 Amp
BUS-0095
@ 914 mm
PPE Category 0
BUS-0096 @ 914 mm
PPE Category 0
CBL-0075
CBL-0076
BUS-0098
@ 914 mm
PPE Category 0
CBL-0077
PD-0092
Fuse 200 A0
CBL-0078
Shovel PTW SLD
showing
Arc Flash CAT Levels
and
Incident Energy
levels.
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
Step 2

19. November 2015 Prepared by Alan Mason AME Pty
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Step 2: Arc Flash Locations
with E>1.2cal/cm2
LIGHT & POWER
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

20. November 2015 Prepared by Alan Mason AME Pty
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Step 3
Step 3
Mitigation
-Select BUS’s > CAT 0
-Use Hierarchy of Controls
-Reduce Arc Fault Isolation
times:
• Adjust PD settings
• Select New Equipment
-Recalculate IEEE 1584
-Decide mitigation methods
-Installation
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

21. November 2015 Prepared by Alan Mason AME Pty
LTD
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Step 3: PPE and Arc Flash CAT
related to Incident Energy E
25 to 4040Cotton underwear
+ Fire Retardant
Shirt & Pants +
Multilayer Flash suit
4
8 to 2525Cotton underwear
+ Fire Retardant
Shirt & Pants + Fire
Retardant coverall
3
4 to 88Cotton underwear
+ Fire Retardant
Shirt & Pants
2
1.2 to 44Fire Retardant Shirt
& Pants
1
0 to 1.21.2Cotton underwear0
Incident
Energy E
range
cal/cm2
Min Arc
Rating of
PPE
cal/cm2
General PPE
Clothing
Description
Hazard
Risk
CAT

22. November 2015 Prepared by Alan Mason AME Pty
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Step 3:Protective Devices
with adjustable settings
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

23. November 2015 Prepared by Alan Mason AME Pty
LTD
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Step 3:Speed of
Fault Current Isolation
 Demonstrate change of CAT level with time of Arc
isolation using :
– 1.0 sec Standard CB & Fuse protection
– 0.14 sec Standard CB/Relay protection
– 0.065 sec Standard + Arc Flash Systems
– 0.004 sec Standard + AFS + UFES
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

24. November 2015 Prepared by Alan Mason AME Pty
LTD
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00016.6kv TSS LV OutputTSS
00016.6kv Main Tfr PrimaryHV Cab Output
0001208v Aux Tfr CB Cabinet OutputControls
00016.6kv HV Cabinet InputBUS-40
00016.6kv HV Cabinet ContactorBUS-0096
0111415v Light & Power Cabinet InputBUS-0051 L&P
0011415v Machine House Blower 1BUS-0043
0111415v MCC Cabinet InputBUS-0042 MCC
0012433v Aux Tfr CB Cab MCC SupplyMCC 415v
0012433v Aux Tfr CB Cab L&P SupplyL&P 415v
0012433v Aux Tfr CB Cabinet Supply433v Bus
0013208v Aux Tfr CB SupplyBUS-0067
0124690v Drive Inverter InputBUS-0082
0124690v Drive Inverter InputBUS-0081
0124690v Drive Inverter InputBUS-0080
0124690v Drive Inverter InputBUS-0079
0124690v Drive Inverter InputBUS-0078
0114690v Main Tfr Secondary690v
013Dangerous!690v Drive Inverter DC Bus 1BUS-0084
012Dangerous!690v Drive Inverter DC Bus 2BUS-0076
012Dangerous!690v ABB ACS800 Drive InputBUS-0064
Dangerous!Dangerous!Dangerous!Dangerous!66kv TSS HV SupplyBUS-0056
Scenario3
0.004 Sec
Scenario2
0.065 Sec
Scenario1
0.140 Sec
Base Project
1.0Sec
LocationComponent
Step 3: IEEE 1584 Arc Flash CAT Calculation Results

25. November 2015 Prepared by Alan Mason AME Pty
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Step 3:
INSTALLATION BLOCK
DIAGRAM - UFES.
SHOWING:
Earth Switch:
1 x UFES (3 x PSU’s)
Arc Flash Relays:
1 x QRU100
2 x REA101
2 x REA107
Arc Flash Sensors:
1 x Fibre optic Sensor
12 x AFS Point Sensors
Circuit Breaker:
1 x 12kv GE SecoVac VCB

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Operational Sequence
of events with UFES:
1. Arc Flash occurs.
2. Light Sensor sees Arc Flash.
3. Light signal trips Pick-up AFR.
4. Pick-up AFR sends Trip signal to UFES Trip Relay.
5. UFES Trip Relay sends Trip signals to UFES and VCB.
6. UFES shorts Fault Current to Earth in 0.004sec from flash
(Arc Fault extinguished).
7. VCB trips and opens supply 0.060 - 0.080 sec to remove
bolted 3 ph Short Circuit.
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

27. November 2015 Prepared by Alan Mason AME Pty
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Installed
Arc Flash Equipment
UFES Trip Relay
+ UFES (3 PSU’s)
+ Light Sensors
High speed
Light Sensor
Arc Flash relays
6.6kv VCB (Non
Withdrawable)
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015

28. November 2015 Prepared by Alan Mason AME Pty
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UFES
3 x PSU’s
VCB
ARC
FLASH
RELAYS
6.6kv HV Cabinet (Front) 6.6kv HV Cabinet (Rear)
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
Installed Arc Flash Equipment

29. November 2015 Prepared by Alan Mason AME Pty
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Other Arc Flash Mitigating Items
Stand-off
deflector Panels
Arc Flash Relays for 18
Light Point Sensors
Pressure Relief
Valve with Pilot
Wire Switch
6.6kv Lower Isolator Box
6.6kv Cable Reeler Slipring
Box
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
Installed Arc Flash Equipment

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The BENEFITS of using an AFS + UFES are:
1. Arc Flash Fault Current nearly eliminated.
2. CAT 0 (<1.2cal/cm2) obtained.
3. Safest arc flash protection to personnel.
4. Nil damage to Shovel electrics.
5. Shovel down time minimal to nil.
6. Production delay eliminated.
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015
In Conclusion

31. November 2015 Prepared by Alan Mason AME Pty
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QUESTIONS
25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015