Cat 0 shovel Alan Mason
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25th annual Electrical Engineering Safety Seminar 2015
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Cat 0 shovel Alan Mason
- 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 3 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 4 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 5 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 6 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 7 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 LTD 8 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 9 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 10 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 11 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 12 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 14 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 15 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 LTD 16 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 LTD 17 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 18 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 LTD 19 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 LTD 20 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 21 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 LTD 22 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 23 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 24 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 LTD 25 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
- 26. November 2015 Prepared by Alan Mason AME Pty LTD 26 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 LTD 27 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 LTD 28 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 LTD 29 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
- 30. November 2015 Prepared by Alan Mason AME Pty LTD 30 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 LTD 31 QUESTIONS 25th Electrical Engineering Safety Seminar – Alan Mason – AME Pty Ltd – November 2015