Client Background & Needs
A large industrial client was in the early stages of an electrical safety improvement project. As part of this initiative, they required clear and accurate arc flash labelling for their distribution boards, detailing:
- Arc flash levels
- Working distances
- PPE (Personal Protective Equipment) requirements
Previously, the client had relied on manual calculations using assumed values and worst-case fault levels. This approach produced overly conservative results, suggesting higher-than-necessary PPE requirements and indicating that equipment ratings were being exceeded.
To ensure accuracy and reduce unnecessary costs, we were contracted to perform a full arc flash analysis across the site and produce accurate, compliant labelling.
Challenges & Approach
The key challenges included:
- Outdated Data: Previous calculations used assumed values rather than real site data.
- Safety Concerns: The client was concerned about the potential risk of excessive arc flash levels.
- Cost Management: Overly conservative calculations had driven up PPE costs unnecessarily.
To address these challenges, we conducted a comprehensive site visit to gather critical information, including:
- Transformer specifications
- Cable lengths
- Equipment ratings
- Distribution board cubicle dimensions
- Protection devices and their settings
This detailed data collection allowed us to create a comprehensive power system model that accurately represented the site’s electrical infrastructure — from high voltage incomers to low voltage final distribution circuits.
Implementation & Solution
Using the collected data, we developed a detailed electrical model and conducted an arc flash analysis in accordance with IEEE 1584 standards. This process calculated:
- Incident energy levels
- Arc flash boundaries
- Safe working distances
- PPE requirements
From these results, we produced accurate and clear arc flash labels for distribution boards, switchgear, and MCCs. These labels provided clear guidance for staff working on or near live equipment.
Additionally, we recommended:
- A tailored PPE matrix to optimise staff protection while reducing excessive PPE costs.
- Adjustments to protection settings to reduce overall incident energy levels.
- Design recommendations for arc flash detection and quenching devices to further enhance site safety.
Results & Impact
- The client gained clear, accurate arc flash information for all distribution boards.
- The improved calculations reduced PPE requirements, resulting in cost savings without compromising safety.
- The tailored PPE matrix simplified safety procedures, ensuring staff could follow clear guidance in different working conditions.
- Adjustments to protection settings lowered the risk of high-energy incidents, improving site-wide safety.
- The client received a detailed roadmap for future upgrades, including arc flash detection and quenching systems for additional risk reduction.
Conclusion & Key Takeaways
This project demonstrated the value of accurate arc flash analysis and the importance of site-specific data over assumed values. By combining precise calculations with practical recommendations, we delivered a solution that improved both safety and cost efficiency.
Our expertise in power system modelling, arc flash assessment, and protective device coordination ensured the client achieved a safer working environment while reducing unnecessary PPE expenditure.
If your business is looking to improve electrical safety or ensure compliance with IEEE 1584, Pendulum Power Consultants can provide expert guidance and tailored solutions to meet your needs.
