ARC FLASH HAZARD EVALUATION FOR A 10-MVA SUBSTATION

WITH A RELAY PROTECTION DESIGNED BY

SUNERTECH CORPORATION

TRISSHA MARIE ESCONDE ZAMORA

SUBMITTED TO THE FACULTY OF THE

DEPARTMENT OF ELECTRICAL ENGINEERING
COLLEGE OF ENGINEERING AND AGRO-INDUSTRIAL TECHNOLOGY
UNIVERSITY OF THE PHILIPPINES LOS BAOS
IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE
DEGREE OF

BACHELOR OF SCIENCE IN ELECTRICAL ENGINEERING

(Major in Power Engineering)

JUNE 2017

This field practice manuscript can be accessed:

By the general public -

Only after consultation with the author/adviser -
Only by those bound by confidentiality agreement Yes

Signature of Student: _________________

Signature of Field Practice Adviser: _________________
 TABLE OF CONTENTS

PAGE

TITLE PAGE i
APPROVAL PAGE
BIOGRAPHICAL SKETCH
ACKNOWLEDGEMENT
TABLE OF CONTENTS ii
LIST OF TABLES vi
LIST OF FIGURES vii
LIST OF APPENDICES viii
LIST OF APPENDIX TABLES ix
LIST OF APPENDIX FIGURES x
EXECUTIVE SUMMARY xi
1. INTRODUCTION 1
1.1 Background of the Field Practice 1
1.2 Significance of the Field Practice 2
1.3 Objectives of the Field Practice 3
1.4 Scope and Limitations of the Field Practice 3
1.5 Time and Place of the Field Practice 4
2. THEORETICAL BACKGROUND 5
2.1 Arc-Flash 5
2.2 Arc-Flash Hazard Analysis 7
PAGE

System Operating Modes 8

Bolted Fault Current 9
ANSI/IEEE Based Short-Circuit Analysis on ETAP 10
Arc-Fault Current 13
Working Distance 13
Incident Energy 15
Flash Protection Boundary 17
2.3 Methods of Reducing Arc-Flash Hazards 19

Avoiding Arc Flash Incidents 20

Reducing Incident Energy 22
Protective Relaying 23
Personal Protective Equipment 25
3. MATERIALS AND METHODS 27
3.1 Data Gathering 28
3.2 Short-Circuit Analysis on ETAP 12.6.0 28
Modeling of the 10 MVA Substation on ETAP 28

2
 Definition of the System Modes of Operation 30

Determination of the Bolted Fault Currents 31

3.3 Incident Energy and Flash Protection Boundary Calculation and 32
Evaluation

Circuit Breaker Opening Times 33

Working Distance 34
PAGE

IEEE 1584-2002 Spreadsheet Calculator 34

4. RESULTS AND DISCUSSION 37
4.1 Short Circuit Analysis using ETAP 12.6.0 37
Study Case A: Normal Operation 37
Study Case B: TFS 38
Study Case C: TFS+1FS 39
Study Case D: TFS+2FS 41
Study Case E: TFS+3FS 42
Study Case F: TFS+4FS 43
Study Case G: TFC+1FS 44
Study Case H: TFC+2FS 45
Study Case I: TFC+3FS 46
Study Case J: TFC+4FS 47
4.2 Incident Energy and Flash Protection Boundary Calculation 48
using IEEE Std. 1584-2002 Spreadsheet Calculator

Arcing Fault Current Calculation 49

Incident Energy Calculation 50
Flash Protection Boundary Calculation 51
4.3 Analysis of the Incident Energy and Arc Flash Boundary 52
Calculations

5. SUMMARY AND CONCLUSION 58

6. RECOMMENDATION 60

PAGE

7. REFERENCES 61
APPENDICES 64
APPENDIX TABLES 65
APPENDIX FIGURES 88

3
4
 LIST OF TABLES

TABLE PAGE

2-1 Requirements for Arc-flash Calculation according to IEEE Std. 1584- 8

2002

2-2 Standards used for the short-circuit analysis on ETAP 11

2-3 Protective relays and their ANSI device number 25
3-1 Study case modes of operation for the short-circuit analysis 31
3-2 Power circuit breaker operating times 33
3-3 Class of equipment corresponding its typical bus gaps and working 34
distance

3-4 Hazard/Risk Category and recommended PPE per incident energy 35

4-1 Summary of bolted fault currents in BUS 1 and BUS 2 48
4-2 Bolted Fault Currents during Study Case A: Normal Operation 49
4-3 Incident energy, flash protection boundary, and hazard category of 53
BUS 1

4-4 PPE requirement for BUS 1 54

4-5 Incident energy, flash protection boundary, and hazard category of 54
BUS 2

4-6 PPE requirement for BUS 2 56

4-7 Summary of maximum incident energy and flash protection boundary 57

5
 LIST OF FIGURES

FIGURE PAGE

2-1 Arc flash event in a control panel with dummy 5

2-2 Representation of a) 3-phase bolted fault 9
and b) bolted line-to-line fault

2-3 Visual representation of working distance 14

2-4 Visual representation of the flash protection boundary 18
2-5 Different approach boundaries 21
3-1 Flowchart for the evaluation of the substations arc-flash hazaard 27
3-2 Edit Mode in the Mode toolbar of ETAP 12.6.0 29
3-3 Single Line Diagram for the short-circuit analysis on ETAP 12.6.0 29
3-4 Short-Circuit Analysis Mode in the Mode Toolbar of ETAP 12.6.0 31
3-5 ANSI Short Circuit Toolbar 32
4-1 Short-circuit analysis for Study Case A: Normal Operation 37
4-2 Short-circuit analysis for Study Case B: TFS 38
4-3 Short-circuit analysis of Study Case C: TFS + 1FS 40
4-4 Short-circuit analysis of Study Case D: TFS + 2FS 41
4-5 Short-circuit analysis of Study Case E: TFS + 3FS 42
4-6 Short-circuit analysis of Study Case F: TFS + 4FS 43
4-7 Short-circuit analysis of Study Case G: TFC + 1FS 44
4-8 Short-circuit analysis of Study Case H: TFC + 2FS 45
4-9 Short-circuit analysis of Study Case I: TFC + 3FS 46

FIGURE PAGE

4-10 Short-circuit analysis of Study Case J: TFC + 4FS 47

4-11 Incident energy and arc flash boundary of BUS 1 with 56
respect to the number of feeders per study case

4-12 Incident energy and arc flash boundary of BUS 2 with 57

respect to the number of feeders per study case

6
 LIST OF APPENDIX TABLES

APPENDIX
TABLE PAGE

1-1 Power Grid Rating 66

1-2 Substation Circuit Breaker Ratings 66

1-3 Distribution Feeder Ratings 66

1-4 Substation Current Transformer Ratios 67

1-5 Substation Bus Rating 67
2-1 Study Case A: Normal Operation Input Data 68
2-2 Study Case A: Normal Operation Results 69
3-1 Study Case B: TFS Input Data 70
3-2 Study Case B: TFS Results 71
4-1 Study Case C: TFS + 1FS Input Data 72
4-2 Study Case C: TFS + 1FS Results 73
5-1 Study Case C: TFS + 2FS Input Data 74
5-2 Study Case C: TFS + 2FS Results 75
6-1 Study Case C: TFS + 3FS Input Data 76
6-2 Study Case C: TFS + 3FS Results 77
7-1 Study Case C: TFS + 4FS Input Data 78
7-2 Study Case C: TFS + 4FS Results 79
8-1 Study Case C: TFC + 1FS Input Data 80
8-2 Study Case C: TFC + 1FS Results 81

APPENDIX
TABLE PAGE

9-1 Study Case C: TFC + 2FS Input Data 82

9-2 Study Case C: TFC + 2FS Results 83
10-1 Study Case C: TFC + 3FS Input Data 84
10-2 Study Case C: TFC + 3FS Results 85
11-1 Study Case C: TFC + 4FS Input Data 86
11-2 Study Case C: TFC + 4FS Results 87

7
 LIST OF APPENDIX FIGURES

APPENDIX
FIGURE PAGE

1 10 MVA Substation Single Line Diagram 86

2 13.8 kV Switchgear Single Line Diagram 87
3 IEEE Std. 1584-2002 Spreadsheet Calculator Input Sheet 88
4 IEEE Std. 1584-2002 Spreadsheet Calculator Calculation Result 89
Sheet

5 Certification of Completion from Sunertech Corporation 90

8
 EXECUTIVE SUMMARY

ZAMORA, TRISSHA MARIE E. College of Engineering and Agro-Industrial

Technology, University of the Philippines Los Baos. June 2017. Arc Flash Hazard
Evaluation for a 10-MVA Substation with a Relay Protection Designed by Sunertech
Corporation.

Major Adviser: Asst. Prof. Elvin D. Dulce

In this study, arc flash hazard analysis was performed on a 10-MVA substation

with a relay protection designed by Sunertech Corporation. This was done to determine

the maximum incident energy of the system buses and identify the required personal

protective equipment (PPE). The method used was based on IEEE Standard 1584-2002:

Guide for Performing Arc Flash Hazard Calculations. To determine the available bolted

fault current on the buses and protective devices, short-circuit analysis was performed

using ETAP 12.6.0 considering 10 modes of operation which were based on the number

of feeders in operation. The obtained bolted fault currents were used as input for the

IEEE 1584-2002 spreadsheet calculator to compute for the maximum incident energy and

flash protection boundary of the system buses. The calculations on the spreadsheet

calculator resulted to a maximum incident energy of 7.7 cal/cm 2 for the 69 kV bus and

2.0 cal/cm2 for the 13.8 kV bus, both during Study Case A: Normal Operation, with

4645.1 mm and 1518.4 mm as Arc-flash Protection Boundaries, respectively. Based on

the computed incident energies, the Hazard/Risk Category of the buses were identified as

Category 1 for the 69 kV bus and Category 0 for the 13.8 kV bus. The required PPE for

each bus depending on the level of hazard/risk was determined based on the Hazard/Risk

category defined by NFPA 70E Standard for Electrical Safety in the Workplace.