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Paper No. ESW2015-21
The research from the 1980s to today have led to The following description of a comprehensive electrical arc
understanding of many of the thermal injuries of 50/60 Hz ac hazard classification system is an overview. In this short paper
arcs, and some of the thermal and kinetic injuries of other it is not possible to present the full details of this system, plus,
sources. The findings from this research will be used to explain there is still a more work to be done. For instance, the reader
the basis for existing thresholds for ac arc injury found in current does not have the user tools in this paper to understand and
standards, and for the basis of thresholds presented for injury determine the parameter values necessary to calculate the
from dc and impulse arcs. Cleary, more research is needed to incident thermal and acoustical boundaries. Nor are the various
better determine thresholds for injury mechanisms less theoretical and empirical models presented here.
understood.
A. Electrical Parameters Determining Injury from Arcs
IV. CURRENT ELECTRICAL SAFETY STANDARDS
Predicting potential thermal and kinetic injury depends highly
In order to provide the basis for an expanded electrical arc on the dynamic nature of the arc. The arc properties and
hazard classification system, it is important to review what behavior is a function of many parameters, including: arc
already exists in electrical safety standards. voltage; current; power; energy; waveform and frequency;
duration of the arc; magnetic forces; electrode geometry and
A. Standards Covering AC Arc Hazards material; boundaries, such as enclosure type, size, geometry
and material; and grounding.
The primary US standards to set thresholds to protect Which parameters are known, which must be calculated, and
workers against thermal ac arc injury is NFPA 70E [52], which which may be unknown, vary as a function of the source,
relies on IEEE 1584 [53] for estimating incident energy. system design, and arc behavior. For example, for 60 Hz facility
arcs, the voltage is always known, and the short circuit current,
and thus short circuit power, is calculated from system
B. Standards Covering DC and Other Arc Flash Hazards impedance from known values such as transformer impedance,
wire impedance, etc. Energy deposited is calculated by
Although the 2012 NFPA 70E [25] added a method of knowing, or estimating, arc time, usually determined by
calculating dc arc flash for battery banks, in Annex D, this overcurrent protection operating times. Several models and
section is not a part of the requirements of the standard. Thus, software packages are available to quantitatively calculate the
there are no national standards, yet, that cover non-facility ac energy value. To this level, the results are rather well known.
arc flash or other arc hazards. But, when we fold in arc behavior as determined by parameters
such as magnetic forces, electrode geometry, enclosure
C. The Future of Arc Hazards geometry, and grounding, there is insufficient theoretical
NFPA 70E and IEEE 1584 focus on managing the arc flash knowledge to quantitatively calculate accurate incident energy,
hazards for 60 Hz ac systems. The focus of this paper and of and thus, thresholds for injury. Even more complex is that arc
future research include accounting for and managing other behavior may dramatically reduce the arc time, through arc
injury mechanisms found in the arc blast, and in developing extinguishing, and the overcurrent operating time, may give an
methods for arc flash analysis of dc, capacitor and battery overly conservative result. Although there are some methods
systems. Research is currently underway nationwide which will for limited theoretical prediction of the arc behavior for certain
add to our body of knowledge in the area. The few arc flash situations, there is no theoretical model to predict the hazards
thresholds used in this comprehensive electrical arc for all cases. As a result, IEEE 1584 and thus NFPA 70E have
classification system for dc, capacitors and batteries are based relied on data taken from testing and measurements to develop
on the concepts of available arc energy and on predicted empirical models. The weakness of the empirical models is that
conversion to other forms of energy. they can only reasonably predict those cases for which tests
have been performed. There are still many cases for which
V. WHAT IS MISSING? there is very limited data, such as some electrode and
enclosure geometries, and for dc and impulse arcs.
The US standards for setting the thresholds for electrical Parameters, such as voltage, short circuit current, power,
hazards have focused on 60 Hz ac electric shock over the past waveform, and arc time, vary substantially when comparing
80 years, and on 60 Hz electric arc flash injury over the past 30 arcs from facility power, battery banks, solar arrays, capacitors,
years. There are, however, many more forms of electrical inductors, and rf sources. Very high voltage does not guarantee
energy (dc, impulse, rf, subrf), and lesser understood an arc hazard (carpet shock is 20 kV), nor does high power, or
mechanisms of injury (such as super sonic acoustic impact, and a long arc time (such as an arc welder). The most important
shrapnel). Missing thresholds in electrical safe work practice common parameter among all arcs is energy, which is
standards lead to a need to account for: necessary to create substantial thermal, acoustic, and kinetic
- arc flash hazards for dc, capacitors, inductors, solar power hazards. Without energy, there is little injury. Although energy
systems, and battery banks. is actually the result of an ac arc flash calculation, using
voltage, current, and time (E = V x I x t) and is necessary to
calculate the arc flash boundary and the incident energy, which
are both based on energy per unit area, it is seldom used as a
threshold for the hazard. To better contrast the arc hazards of This graded approach is very useful to identify hazardous
different waveforms, energy is a key parameter for thresholds in electrical systems, and to develop design and work controls.
this system. This system does cover most of the direct injury mechanisms
Thus, understand that the following proposed electrical arc that could occur from the exposure to electrical arc energy,
flash hazard classification system is necessarily a draft that will including the 4 Categories discussed in Section II-A above with
improve with further testing and theoretical research, and the thermal and kinetic injury. This system, however, does not
development of better empirical and theoretical models. cover all secondary hazards created by electric arcs, including
initiation of facility fire, non ionizing radiation (electric, magnetic,
B. Organization of System – Super Categories and RF fields), ionizing radiation (some X-rays are created from
very high current arcs), chemical hazards (battery materials and
The comprehensive electrical hazard classification system toxic arc gases). Those secondary hazards are not usually
presented here starts by dividing electrical sources and energy covered by electrical safety standards, but by other methods
into 4 “super” or general categories, based on source and and standards.
waveform (refer to the charts in the accompanying Keep in mind that this system attempts to cover ALL hazards
presentation): from arcs, including those that do not have an arc flash hazard.
Category 1 – 50/60 Hz power arcs
1.1 – single phase D. Category 1 – 50/60 Hz Power Arcs
1.2 – three phase Category 1.0 – arcs and sparks without sufficient energy to
Category 2 – DC arcs melt significant metal, short circuit power less than 100 W – no
2.1 – DC power supplies hazard
2.2 – Battery banks Category 1.1 – Single phase arcs, no arc flash boundary, low
2.3 – Solar arrays thermal hazard (< 300 V ac, 100 W ≤ P < 3000 W)
Category 3 – Impulse arcs Hazard – sparks to the eyes
3.1 – Capacitors Category 1.2 – No arc flash boundary, thermal hazards
3.2 – Inductors Hazards – sparks to the eyes, thermal injury from molten
Category 4 – Sinusoidal arcs, not 50/60 Hz power metal in the hands, or current through tools or jewelry
4.1 – subrf – 1 Hz to 3 kHz Category 1.2a – single phase, < 300 V, ≥ 3 kW
4.2 – RF – 3 kHz to 300 GHz Category 1.2b – single phase, ≥ 300 V, ≥ 3 kW
The selection of this General Category depends on source and Note – arc flash hazard analysis must be done
waveform. The first number, X, in a hazard class designation, Category 1.2c – three phase (any), arc flash boundary < 1
X.x gives the General Category. cm, arc flash hazard analysis must be done
Category 1.3 – arc flash boundary greater than 1 cm, incident
2
C. 30 Electrical Arc Hazard Classes energy at 45 cm less than 40 cal/cm
Category 1.3a – vertical electrode geometries
Each of the 4 General Categories, and 9 subcategories are Category 1.3b – horizontal electrode geometries, need to
then broken into a number of Hazard “Classes”, depending on increase incident energy appropriately, may move hazard to
possible injury based on voltage, short circuit current, category 1.4
2
waveform, energy released, electrode geometry, enclosure Category 1.4 – incident energy at 45 cm ≥ 40 cal/cm
geometry, and magnetic forces.
To properly classify electrical energy the worker or work Notes: This draft hazard classification for all arc hazards for
planner must be qualified, and have the ability to determine the ac power (any voltage) includes systems with substantial
necessary information. Current OSHA and NFPA standards thermal and sparks hazards that have no arc flash hazard, such
state that the qualified worker must “be able to determine the as ac welders and arc furnaces
nominal voltage”. This is an example of how the standards
were written with a focus on 60 Hz shock hazards. To properly E. Category 2 – DC Arcs
use this hazard classification system the qualified worker must Category 2.0 – no arc hazard, all dc sources
be able to determine more than just “nominal voltage”. (< 100 W short circuit power, < 1 J energy released, any
With very few exceptions every type and source of electrical voltage)
energy can be placed into one or more of the 30 plus Hazard Category 2.1 – No arc flash boundary, all dc sources
Classes. The classes are color coded to represent the level of Hazard – sparks to the eyes, low thermal hazard
hazard using 5 colors. Colors are not necessary, however, as (100 W ≤ P < 3000 W short circuit power, < 10 J energy
the second number, x, in the Class designation also gives the released, any voltage
hazard ranking. The 5 ranks are: Category 2.2 – No arc flash boundary, thermal and spark
Classes X.0 – Blue – no electrical arc hazard hazards
Classes X.1 – Green – minimal electrical arc hazard, (≥ 3 kW short circuit power, can have any voltage or any
possible minor injury current, but not both V ≥ 100 V dc and I short circuit ≥ 500 A)
Classes X.2 – Yellow – can seriously injure if Hazards – sparks to the eyes, thermal injury from molten
insufficient PPE is worn metal in the hands, or current through tools or jewelry
Classes X.3 – Red – Serious hazard, will seriously Category 2.3 – dc arc flash hazards, arc flash boundary
injure or kill even with PPE, or insufficient PPE is available. greater than 1 cm, incident energy at 45 cm less than 40
2
Classes X.4 – Maroon – There is no PPE available for cal/cm
working close to the source.
When V ≥ 100 V dc and short circuit current ≥ 500 A dc, an arc Nevertheless, subrf and rf high-power systems need further
flash hazard analysis must be conducted. analysis to adequately characterize arc and arc flash hazards
Hazards – arc flash injury, sparks to the eyes, thermal for workers.
injury from molten metal in the hands, or current through tools
or jewelry VII. APPLICATIONS
Category 2.4 – dc arc flash hazards, incident energy at 45 cm
2
≥ 40 cal/cm Many elements of this new arc hazard classification system
have been under development and review with several efforts,
Notes: This draft hazard classification covers all arc hazards including the NFPA dc task group, DOE, and DOD. The value
(sparks, thermal through jewelry and tools, and arc flash) for all of this new arc hazard classification system can be shown
dc sources. Categories 2.3 and 2.4 may be further subdivided through examples.
into three subcategories, which will be useful in methods of arc
flash analysis. A. Differentiation Between Hazardous and Non-Hazardous
Categories 2.3a or 2.4a – dc power supplies Electric Arcs
Categories 2.3b or 2.4b – battery banks
Categories 2.3c or 2.4c – solar arrays A challenge in the laboratory with many forms of electrical
energy is the differentiation between hazardous electrical
F. Category 3 – Impulse Arcs energy (that which can injure or kill), and nonhazardous
Category 3.0 – negligible energy, no arc hazards, capacitors electrical energy (that which will not injure or kill). One can be
and inductors (< 20 J stored energy) near an electric arc and not be seriously injured (e.g.,
Category 3.1 – minor injury if energy is deposited in jewelry electrostatic discharge arcs). Thresholds are required in the
or tools, noise but likely no injury to ears, avoid contact, advise workplace to establish reasonable boundaries. Clearly,
hearing protection (20 J ≤ E < 100 J stored energy) fatalities and serious injuries must be prevented. What level of
Category 3.2 – no arc flash hazard, sparks, thermal hazard injury is acceptable? And how much can one count on work
from deposition in tools or jewelry, ear hazards (100 J ≤ E < 1 control and worker qualification to protect the worker during
kJ stored energy) exposure? The answers to these questions are often quite
Category 3.3 – arc flash hazard, substantial ear hazard, subjective.
st
sparks (1 kJ ≤ E < 100 kJ stored energy), PPE is available for Minor injury might include 1 degree burns, sparks on the
these hazards skin, ear discomfort, etc. At what level do we need eye
Category 3.4 – dominant hazard is acoustic energy for protection for sparks? At what level do we need hearing
capacitors and arc flash hazard for inductors, there is no protection. What is the limit of leather gloves for thermal
sufficient PPE (≥ 100 kJ stored energy stored energy) hazards? Some energized work with arc hazards is common
(e.g., welding), others should be discouraged (e.g., 480 V).
Notes: This proposed hazard classification does NOT
account for the shock hazards for high voltage capacitors. The B. Clarification of Types of Thermal Injuries
shock hazards will likely dominate and keep the worker outside
the arc hazards, except for Category 3.4 capacitors, where the There has been a general lack of appreciation for the thermal
acoustic hazard may stretch past the shock hazards. hazards of high current arcs, which cannot sustain an arc flash.
For all Category 3.x, can be subdivided into The welder is well trained for this hazard, but not the
3.xa capacitors homeowner working on their car battery. This hazard is not
3.xb inductors clearly stated in NFPA 70E.
since the exact injury mechanisms and hazard analyses will There is confusion and varying opinion on how electrical
be different. energy is converted into radiant and convective thermal energy.
Some have claimed that up to 90% of facility arc flash energy is
G. Category 4 – Sinusoidal arcs, not 5060 Hz power radiant energy. However, the physics of arcs does not support
Category 4a – Subrf arcs (1 – 3 kHz) this. Currently, a conservative approach to arc flash analysis
Category 4b – RF arcs (3 – 300 GHz) and PPE selection attempts to protect the worker against both,
There are few systems with substantial power in the range of without knowing the type and percentage. As our measurement
subrf (1 – 3 kHz) except for 400 Hz power systems for aircraft techniques and models improve for short and long arcs, we will
and military, and low frequency induction furnaces. In general, better understand the ratio of thermal hazards from radiant
addressing arc hazards will be similar to methods used for energy vs. convective energy. This may lead to specialized
50/60 Hz ac. PPE for certain classes of arcs.
The primary interest for arc and arc flash hazards in the rf
range (above 3 kHz) are the MW level power converters C. Better Thresholds for Acoustic Hazards
(rectifiers and inverters) associated with dc power transmission.
It is unlikely, however, that workers will be exposed to arc and Studies for the acoustic hazards of arcs have focused on the
arc flash hazards since (a) there are many hazards (e.g., shock 50/60 Hz facility arc. Preliminary studies show that rise time
and rf fields) that keep worker away from the equipment when may make a significant difference for impulse arc acoustic
operating, and (b) fast acting, overcurrent protection is required injury. Further study is warranted to understand the difference
to prevent major equipment damage, limiting energy deposited between subsonic and super sonic injury.
in a failure.
D. Selection of PPE Based on Injury The NFPA 70E dc ask group worked over six years and
contributed several new sections on dc to the 2012 and 2015
Selection of PPE is based on the injury to be prevented. versions of NFPA 70E, including the dc shock approach
Initially, PPE is chosen rather conservatively, not really boundary table, the dc arc flash calculation method in Annex D,
understanding the mechanisms of injury. However, as we and the task tables for work on battery banks.
better understand the energy conversion mechanisms, we will Much of the information on ac facility arc flash hazards and
better understand the types and amounts of incident energies, some of the data for dc arc flash hazards came from efforts
and be better able to choose the right PPE for the possible under the IEEE 1584 committee, and the collaborative effort
injuries. Understanding incident conductive, convective, and between NFPA and IEEE on arc flash hazards.
radiative thermal energy; slow rise time and fast rise time And finally, information from acoustical impulse injury was
acoustic energy; sparks and molten metal ejected; and shrapnel contributed by the Army Research Laboratory as a part of the
will help us to better design and choose PPE for all classes of effort of the DOD Electrical Safety Working Group.
arc hazards.
X. REFERENCES
E. Further Studies Needed
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[35] M. Wactor, G.H. Miller, J. Bowen, M. Capelli-Schellpfeffer,
“Modeling of the pressure wave associated with arc fault”, Lloyd B. Gordon graduated from Texas Tech University in
IEEE PCIC Conf. Rec., pp. 333-341,Sept. 2000. 1981 with a PhD in Electrical Engineering. He started his
[36] T.E. Neal, R.F. Parry, “Shrapnel, Pressure, and Noise”, research career at Lawrence Livermore National Laboratory
IEEE Industry Applications Magazine, pp. 49- (DOE), conducting research in topics of pulsed power
53,May/June 2005. engineering, plasma physics and dielectric engineering from
[37] M. Akazaki, K. Muraoka, M. Hamamoto, “Studies of 1981 to 1986. From 1986 to 1991 he was in the Department of
Atmospheric Impulse Arcs Using Two-Wavelength Laser Electrical Engineering at Auburn University, and from 1991 to
1998 was in the Department of Electrical Engineering at the
University of Texas at Arlington. Since 1998 he has been at
Los Alamos National Laboratory (DOE). Dr. Gordon has 25
years of experience in experimental high-energy research, 39
years of experience as an educator and trainer, and has
focused his efforts on R&D electrical safety over the past 19
years. He has lectured to and trained over 50,000 scientists
and engineers throughout the DOE and DOD complex over the
past 20 years in R&D Electrical Safety. Dr. Gordon is currently
the Chief Electrical Safety Officer at Los Alamos National
Laboratory (LANL), chairs the ISA committee on Electrical
Safety Standards for High Power R&D Systems, is the LANL
representative for the DOE’s Energy Facility Contractors
Operating Group (EFCOG), chairs the EFCOG Electrical Safety
Workshop (2004 – 2014), is a member of the IEEE 1584, Guide
to Arc Flash Calculations committee, and manages the
DOE/EFCOG Center of Excellence for Electrical Safety. He
may be contacted through the Center website at
http://www.lanl.gov/safety/electrical/.
Nicole Graham graduated from Los Alamos High School in
May 2014 with high honors. She is currently studying at the
University of New Mexico in Albuquerque in the fields of
Mechanical Engineering and Biology. Nicole plans to continue
her graduate education in biomedical engineering. Nicole has
been a student intern at Los Alamos National Laboratory since
May 2013, and works closely with the principle author on all
aspects of the management of electrical safety.