ARC FLASH HAZARD ANALYSIS

By Mike Lang
Principal Field Engineer

I. ARC FLASH HAZARD ANALYSIS IS REQUIRED

OSHA’s 29 CFR Part 1910.132(d) states:

The employer shall assess the workplace to determine if hazards are present, or are likely to be present,
which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely
to be present, the employer shall:

1910.132(d)(1)(i)
Select, and have each affected employee use, the types of PPE that will protect the affected
employee from the hazards identified in the hazard assessment;

1910.132(d)(1)(ii)
Communicate selection decisions to each affected employee; and,

1910.132(d)(1)(iii)
Select PPE that properly fits each affected employee.

Additionally 29 CFR Part 1910.335 calls for the employer to provide

“…electrical equipment that is appropriate for the specific parts of the body to be protected and for the
work to be performed…” when employees are called upon to work wherever there is a potential
electrical hazard.

NFPA 70E Standard for Electrical Safety in The Workplace is viewed by OSHA as an industry consensus
standard that can be used by employers as guides to making the assessments required by OSHA
standards. Section 110.8(B)(1) of NFPA 70E requires that an electrical hazard analysis be performed to
ensure that workers are properly protected whenever they work on or near equipment that is not in an
“electrically safe condition.” This includes work required to deenergize the equipment. Refer to Article
120 for guidance on putting equipment in an electrically safe condition.

Part of an electrical hazard analysis is an arc flash hazard analysis. According to NFPA 70E Section 130.3,
the goal of arc flash hazard analysis is to identify:

The Flash Protection Boundary, defined in Article 130.3(A) as “an approach limit at a distance
from exposed live parts within which a person could receive a second degree burn if an
electrical arc flash were to occur.”

The proper personal protective equipment (PPE) and protective

clothing necessary, based on an incident heat energy calculation for
the working distance for the task to be performed, as described in
Article 130.3(B) and Article 130.7. The results of the incident energy
calculations are typically expressed in cal/cm2.

Appropriate safety related work practices.

NFPA 70E cites two approaches to proper PPE selection: an analytical method and a table-based
method. Performing an arc flash hazard analysis by an analytical method provides the additional benefit
of an in-depth look at your electrical system. The results of the analysis can be used to reduce arc flash
energies, improve overall system performance, reduce downtime, and better manage costs.

II. USING AN ANALYTICAL METHOD TO SELECT PPE Figure 1: PPE for Hazard/Risk
Category 2 (right) and 4 (left).
{Courtesy of WH Salisbury Co.}
Appendix D of NFPA 70E and the IEEE Standard 1584™-2002, Guide for Performing Arc Flash Hazard
Calculations, provide guidance on performing an arc flash hazard analysis. IEEE 1584 identifies a
systematic, nine-step approach for performing a comprehensive arc flash hazard analysis.

Since fault current and time are two of the most important variables in the calculations, the process
begins with a short circuit study to determine the available “bolted” fault current at each location in the
system. Arcing fault currents are less than the maximum bolted fault current and must be estimated. Let
through data must be obtained for current limiting overcurrent protective devices. Clearing times for all
other overcurrent protection device must be obtained to accurately predict the duration of the arc fault
current. See the following section for additional details and other factors that affect arc flash energies.

A choice of formulas for calculating the Flash Protection Boundaries and incident energy can be found in
NFPA 70E and IEEE 1584. Note that IEEE 1584 contains separate equations for calculating the dramatic
reduction in arc flash energies possible with certain current limiting fuses. Using these fuses can
significantly reduce the energy delivered to an arc fault and thus the category of PPE workers are
required to wear. See Arc Flash Notes 2 and 4 for additional information.

If a worker is required to be within the Flash Protection Boundary, PPE must be selected for the
expected incident energy calculated during the analysis. Protective clothing must be chosen so that the
clothing rating in cal/cm2 is greater than the calculated incident energy. When this rating is determined
by testing according to appropriate ASTM standards, the clothing should, in most cases, protect the
majority of the worker’s body from receiving 2nd degree burns.

NFPA 70E 130.7(C) contains extensive information and guidelines on the selection of PPE for work where
electrical hazards are present. These sections include protection of head, face, neck , chin, eyes, body,
arms, hands, feet, and legs. Section 130.7(C)(13) covers arc flash protective equipment in more detail.

NFPA 70E provides Table 130.7(C)(11) for general information for selecting clothing based on
Hazard/Risk Categories. These categories are referred to
frequently in selecting PPE. Note that with the exception
for Category 0, Flame-Resistant (FR) clothing of adequate
rating is required for all workers that must be within the
Flash Protection Boundary. As the table indicates, layering
is typically required to achieve higher ratings. Non-FR
synthetic fiber clothing, including blends of synthetic
fibers with cotton, is prohibited for all layers because it
not only easily ignites but can melt into workers flesh -
even as an under layer. For a discussion about APTV and Table 1: Typical Protective Clothing Characteristics
taken from Table 130.7 (C) (11) from NFPA 70E
EBT. see the note to the table in NFPA 70E.
Working on energized components, and hence selection of PPE should be the last alternative
considered. As such, PPE should be viewed as the last line of defense for protecting workers.

III. THE NINE STEPS OF ARC FLASH HAZARD ANALYSIS

Step 1: Collect System and Installation Data.

The data needed for an arc flash hazard analysis is similar to that needed for a short circuit and
coordination study. It is essential to model the system in detail to get a reasonable assessment
of the arc flash hazard. For many facilities, this will mean collecting all the data needed to build
an up-to-date one-line diagram.

For facilities with a recent short circuit study, it may mean:

Extending the existing study to include control equipment.
Refining a study that omitted impedances to ensure calculations of the highest possible short
circuit currents. Worst-case arc flash energies may be achieved with lower fault currents if
clearing times for overcurrent protective devices are considerably longer.
Suggested data collection forms are included in the IEEE guide, as are other useful tips on
collecting data from your system and your utility.

Step 2: Determine System Modes of Operation.

The IEEE 1584 guide provides examples of different modes of operation, including operation
with more than one utility feed, tie breakers opened or closed, and generators running. This
information is important in determining the different short circuit currents that might be
available to each location for the different modes. As noted in Step 1, the highest available fault
current may not yield the worst-case arc flash energy, since the worst-case energy also depends
on the opening time of the overcurrent protection devices.

Step 3: Determine Bolted Fault Currents.

Calculate the bolted fault currents from the data gathered in Step 1 and Step 2. Refer to IEEE Std
141-1993 (IEEE RedBook™) for details on methodology pertaining to these calculations. The
typical method is to enter the data into a commercially available software program that allows
you to model your system and easily switch between modes of operation.

Step 4: Determine Arc Fault Currents.

The bolted fault current calculated for each point in the system represents the highest possible
fault current expected to flow to that point. In the case of an arcing fault, the current flow to the
fault will be less, due to the added impedance of the arc. It is important to adequately predict
these lower current levels, especially if the overcurrent protective devices are significantly
slower at these reduced levels, as these situations have been known to provide worst-case arc
fault hazards.

Step 5: Find Protective Device Characteristics and Duration of Arcs.

 IEEE 1584 offers guidance on using the time-current curves of overcurrent protective devices
including how to handle average-melt-time-only curves and relay-operated circuit breakers, for
example. For certain types of current limiting fuses, time-current curves are not required,
because their characteristics have been incorporated into the final Flash Protection Boundary
and incident energy equations.

Step 6: Document System Voltages and Classes of Equipment.

Factors that affect arc energies, such as bus gap and voltage, are required for IEEE 1584
equations. A table is provided with typical bus gaps for various equipment up to 15kV.

Step 7: Select Working Distances.

Typically, this is assumed to be the distance between the potential arc source and the worker’s
body and face. Incident energy on a worker’s hands and arms would likely be higher in the event
of an arcing fault because of their closer proximity to the arc source. Typical working distances
for various types of equipment are suggested in a table.

Step 8: Determine Incident Energy for All Equipment.

The analyst will need to choose equations based upon voltage level, type of overcurrent
protective device and equipment. In addition to the current limiting fuse equations, the IEEE
guide provides other equations that call for the data described above. These calculations
provide heat energy densities in either cal/cm2 or joules/cm2, values necessary in selecting
appropriate PPE and FR clothing. Because of the complexity and number of manual calculations
possible, software is recommended to complete this step. Most software gives you a choice of
equations, including three other incident energy equations identified in Appendix D of NFPA
70E. Factors affecting the choice of equations include: type of equipment, voltage levels, and
protective devices. A spreadsheet-type calculator is included with IEEE 1584 and can be useful
for sample calculations and small systems.

Step 9: Determine Flash Protection Boundary for All Equipment.

Instead of solving for cal/cm2 at a given working distance, this
equation solves for a distance at which the incident heat energy
density would be 1.2 cal/cm2 (or 5.0 joules/cm2). Due to the same
reasons mentioned in Step 8, software is also recommended for this
calculation.

IV. USING THE TABLE METHOD TO SELECT PPE

NFPA 70E also offers Table 130.7(C)(9)(a) as an acceptable method for selecting protective clothing and
other PPE. In order to do so, you must be certain that the parameters of your electrical system are
covered by these tables and their various footnotes.
The steps required to select PPE with the table method are:

 Identify the type of equipment that will be accessed while not in an electrically safe condition.
 Confirm that fault current limits identified in 130.3(A) for flash protection boundary apply. If the
available fault current is less than 50,000A and the clearing time is less than 6 cycles (300kA
cycles) then the default Flash Protection Boundary of 4 feet can be used.
 Confirm that the notes of Table 130.7(C)(9)(a) regarding available fault current and clearing
times apply to the application.
 Locate the equipment and task to be performed within Table 130.7(C)(9)(a), .
 Identify the Hazard/Risk Category and the need for Voltage Rated gloves and tools.
 Identify the required Flame-Resistant (FR) clothing and other personal protective equipment
using Table 130(C)(10), Protective Clothing and Personal Protective Equipment Matrix.

An excerpt of Table 130.7(C)(9)(a) is shown below in Figure 2 for selecting the proper PPE for testing
voltage in a 480V motor control center that is protected by a circuit breaker with a clearing time of 2
cycles for the available fault current of 25,000A. Since the fault current is less than the 65,000A
identified in Note 2 and the clearing time is within the approved range, the table is acceptable. For this
situation the Hazard/Risk Category is 2* and both
voltage rated gloves and tools are required.

Referring to Table 130(C)(10) reveals that Hazard/

Risk Category 2* requires the following:
 A short sleeve T-shirt and long pants made
from untreated natural fiber or other fiber Figure 2: Hazard/Risk Category Classifications
that is nonmelting per ASTM F1506-00. excerpted from NFPA 70E Table 130.7(C)(9)(a).
 An outer layer of a FR long sleeve shirt and
FR pants. Alternatively FR coveralls are allowed.
 The “2*” requires the use of a double layered arc flash rated hood.
 Other PPE identified includes a hard hat, safety glasses (or goggles), hearing protection, leather
gloves and leather work shoes.

See NFPA 70E 130.7 for more information on the requirements for PPE and FR clothing.
Use of current limiting fuses may reduce the level of PPE required. See Arc Flash Note 2.