REPORT ON

RELAY CO-ORDINATION
& ARC-FLASH STUDY

FORD INDIA PVT LTD

Sanand- Vehicle Operation

By
LRV Engineering Solutions
Title : Relay Co-ordination & ARC Flash Study
Customer Details

Name : M/s. Ford India Private Limited.

Plant : Vehicle Operation (VO) Plant.

Address : Survey No. 1, Sanand Taluka,

Ahmedabad District, North Kotpura,
Gujarat 382170

Customer Seal &

:
Signature

Supplier Details

Name : LRV Engineering Solutions.

Project No: : LRVES/1744/S/AS/01

Date of Completion : 31-Jan-19

Address : 103.P.S. Sivaswamy Salai,

Mylapore, Chennai,
Tamilnadu, India - 600004.

Supplier Seal &

:
Signature
 ACKNOWLEDGEMENT:

LRV Engineering Solutions takes this opportunity to acknowledge

and thank FORD INDIA PRIVATE LIMITED – Sanand for the trust and
confidence expressed by assigning the responsibility of carrying out the
subject evaluation to verify the present distribution arrangement data of the
Electrical installation at their Sanand facility for enhancing the Safety of
the Installation in terms of Electrical ARC Flash study at this facility.

We take this opportunity to thank the Management of FORD INDIA

PRIVATE LIMITED, for the special thanks to Mr.Baskeran, Mr. Parag,
Mr.Vijayaraj, Mr.Ankit Makwan and their Team for their commitment and
support extended to shape up the data validation.

We appreciate the sincerity with which the Safety and Electrical Team for
the sincerity with which they have participated in the data validation.
 CONFIDENTIALITY STATEMENT:

This document is submitted to M/s. FORD INDIA PRIVATE LIMITED

(FIPL) on the study carried out at the Sanand – Facility by LRV
Engineering Solutions (LRVES) on study carried out on engine facility of
FIPL at North korturpura, Ahmedabad. This document, or any information
contained within it, must not be provided or issued to any third party
without the prior written consent of LRV Engineering Solutions.

This restriction, of course, does not apply to information already known

to FIPL in the compilation of their specifications. In addition, this
restriction does not apply to “copies” for the sole use of internal staff within
FIPL. LRVES reserves the right to request the immediate return of this and
any copies of this document at any time.
In case of any Queries regarding this evaluation, kindly contact the
following.
L.Ravichandran Landline: +91 4442185856.
103, P.S.Sivaswamy Salai, Mobile : +91 9840323271.
Mylapore, Chennai-600004. E-mail : ceo@lrves.com.
Document Authority
Mr. L.Ravichandran.
Document Information
Document Number: LRVES/1723/S/AS/01
Date Issued: February 25th 2018.
Document History
Edition Date of Issue Status Purpose
1 Feb. 25th 2019 Draft Review
INDEX:
1. Introduction
a) System Modeling
b) Short circuit study
c) Arc Flash study
d) Coordination of relays
e) Warning Labels
f) Methods adopted for study
g) Flow Chart for Calculation
h) Main introduction Methods adopted in study
i) Definitions
Table on Limited Approach and Restricted Approach
j) Boundaries
k) Working Distance
l) Table on Classes of Equipment and Typical Working Distances
m) Table on Protective Clothing Characteristics
n) Calculation of Arcing Current
o) Calculation of Incident Energy
2. Section – A, SPP Shop.
3. Section – B, MCB (Utility) Shop.
4. Section – C, STAMPING Shop.
5. Section – D, TCF Shop.
6. Section – E, Paint Shop.
7. Section – F, Body Shop.
Introduction:
M/S. FORD India Private Limited, in line with the Global Practice and the
commitment towards ensuring a Safe Work Environment to the people,
has launched various initiatives and as a part of that it was decided to
carry out the Arc Flash Hazard Analysis for the Electrical Power
Distribution System, in its facility at Chennai with an intention to and
chose to utilize the Services of M/S. LRV Engineering Solutions in carrying
out the above job.

The primary objective of the “Arc Flash Hazard Analysis”, is to identify

the existence of ARC Flash

Hazard in the Electrical Distribution System and carry out engineering

calculations to determine the

- Arc flash boundary,

- The incident energy at the working distance,
- And the type of personal protective equipment to be used within the arc
flash boundary

taking into consideration the design of the overcurrent protective

device and its opening time, including its condition and suggested
maintenance.

System Modeling:
The Software employed for carrying out the Analysis is “Electrical design
Software ETAP 18.1 by Operation Analytics Inc. USA”.

Network Modelling was carried out for the entire Power Distribution
System from 220 kV to 415 V level, comprising HT and LT Switchgears,
Transformers, Busduct, Cables & Busbars, etc. All the parameters for each
device have been embedded on to the model. This Network model is
reproduced in the report.
Short Circuit Study:
In the Network Model the 220kV, 33KV, 3.3KV and 415 V Busbars are
designated and Short Circuit Study was conducted as per - IEC60909
Method.
The Sourced fault considered at 220KV level for carrying out the Short
Circuit Analysis is 78090 MVA sec and the results are tabulated in Table.

Arc Flash Study:

The various Busbars at 33KV, 3.3KV and 415V levels are designated in the
Network Model and Arc Flash Study has been carried out and the results
are tabulated in Table “Arc flash Hazard Analysis Table” as per IEEE1584.

The Arc Flash study results consist the following:

1. Bus Name as per Network Model
2. Protective device name as per Network Model
3. LL voltage in kV
4. Three Phase Bolted Fault Current in Amps
5. Branch current in Amps
6. Three Phase Arcing Current in kA at 100%
6. Fault duration time in sec
7. Name of Protective Device
8. Protective device rating
9. Grounded or not grounded
10. Type of Equipment
11. Gap in mm
12. Max Arc Flash boundary in cm
13. Working distance in cm
14. Three phase Energy (Cal/cm2)
15. Required IEEE1584 PPE Class

As a part of Arc Flash study,

3 Phase Arc Current at 100 % and 85%, based on 3 phase bolted
Fault current is calculated. Typical calculation is given in sheet.
 3 Phase Energy based on Arc Current and 3 phase fault duration are
calculated. Typical calculation is given sheet.
In some of the bus bars the Energy levels are beyond the acceptable
limits.
Our objective is to reduce the energy level, for this we have to reduce the
Arc Current or duration of fault. It is not possible to reduce the Arc
current as it depends on circuit Impedance, which is fixed, for any given
circuit based on its elements like cable, transformer and source.
Therefore, only alternative is to reduce the duration of fault. Duration of
fault can be modified by selecting the time setting of the tripping of the
relevant Breaker or the Relay. By modifying the existing settings of the
relays and breakers without affecting basic settings, reduction in the
duration of the sustenance of the fault could be achieved. In case of fuses,
duration of the tripping time could be reduced by selecting the fuses of
lower rating taking due care of the load current. The existing settings are
in order for normal short circuit currents. However, in some feeders,
for 85 % of Arcing current the operating time of the
relay/breaker is very high which will have an influence on the Energy.
Coordination of relays
The settings of the relays/breakers are modified to achieve faster
tripping even at 85 % of Arcing currents. Appropriate settings for the
relay and the Breakers are furnished in the tables separately. Time current
Characteristic curves for different Paths are also furnished.
Warning Labels
Based on the revised settings the “ARC Flash Labels” have been
generated for each Bus and device as per Ford Asia Pacific Regional
format.
Conclusion
After modification of the settings for the relays/breakers with revised
values proposed, the energy levels at various Bus bars of 33kV, 3.3KV and
415V are within the acceptable level as per IEEE1584.
Methods adopted for doing the study.
1. The available SLD and data sheets provided by M/S.FORD India Private
Limited were reviewed.
2. Also, the details of the Switchgears and cable of the plant were
received.
3. System study modelling was prepared as per the data with the help of
the tool "ETAP 18.1" an Electrical design Software Application.
4. Flow of short circuit fault currents in every branch of system and
Busbar was generated
5. Based on the short circuit current report generated above, device
capacity, and cable rating, the settings for various protective devices was
proposed.
6. TCC for various paths was prepared. Studied the curves generated, re
arranged the settings to avoid any fouling of curves.
7. Arc flash report prepared. Studied the report and re arranged the
settings to reduce the arc flash energy to minimum.
8. Flow chart for calculations of arc flash hazard is shown below.
9. Compiled the study reports into different sections.
10. Divided the report into sections for easy understanding
implementation.
Flow Chart for Calculation of Arc Flash Hazard
Main introduction Methods adopted in study
Report on SPP Shop
SPP Shop substation having two Transformers -01 & 02
Report on SPP Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels

Report on MCB (Utility) Shop

MCB (Utility) Shop substation having four Transformers -01, 02, 03 & 04.
Report on MCB (Utility) Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels
Report on Stamping Shop
Stamping Shop substation having five Transformers -01, 02, 03, 04 & 05
and 5 Nos of BBT which has been connected to each transformers.
Report on Stamping Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels

Report on TCF Shop

TCF Shop substation having three Transformers -01, 02 & 03.
Report on Stamping Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels
Report on Paint Shop
Paint Shop substation having eight Transformers -01, 02, 03, 04, 05, 06, 07
& 08 and 7BBT which is connected to the associated transformers.
Report on Stamping Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels

Report on Body Shop

Body Shop substation having Eight Transformers -01, 02, 03, 04, 05, 06, 07
& 08 and 14BBT which is connected to associated transformers.
Report on Stamping Shop will include the following:
• Single Line Diagram
• Reference documents
• Device Details.
• Single Line Diagram for this section
• Short circuit Current details at various busbars
• Setting details for ACBs and MCCBs under this section
• Setting details for Relays under this section
• Arc flash Hazard Analysis Table
• Time current characteristic curves for important paths
• Comments and observations
• Labels
DEFINITIONS:
Definitions from the Ford Electrical Safety standard:
Arc Flash Hazard Analysis: engineering calculations to determine the arc
flash boundary, the incident energy at the working distance, and the type
of personal protective equipment that people within the arc flash
boundary shall use.
Electrical Power Distribution Systems: systems and associated
equipment for the generation, transmission, conversion, and distribution
of electrical power. This includes all equipment from the incoming utility
through the substation to the buss duct system (including buss plug fuses
or circuit breakers). This also includes any electrical equipment directly
fed from a substation breaker, such as transformers, motor control
centers and direct-fed power distribution panels (PDPs). Equipment
downstream from buss plugs (including PDPs fed from buss plugs) or
downstream from direct-fed motor control centers or PDPs are usually
not considered to be part of the electrical power distribution system
Definitions from NFPA 70E 2015
Arc Flash Hazard: A dangerous condition associated with the possible
release of energy caused by an electric arc.
Arc Flash Risk Assessment: An arc flash risk assessment that determines if
an arc flash hazard exists, and if so the appropriate safety-related work
practices, the arc flash boundary and the PPE to be used within the arc
flash boundary, taking into consideration the design of the overcurrent
protective device and its opening time, including its condition of
maintenance.
Boundary, Arc Flash: When an arc flash hazard exists, an approach limit
at a distance from a prospective arc source within which a person could
receive a second degree burn if an electrical arc flash were to occur.
Boundary, Limited Approach: An approach limit at a distance from an
exposed energized electrical conductor or circuit part within which a
shock hazard exists.
Current-Limiting Overcurrent Protective Device: A device that, when
interrupting currents in its current-limiting range, reduces the current
flowing in the faulted circuit to a magnitude substantially less than that
obtainable in the same circuit if the device were replaced with a solid
conductor having comparable impedance.
Incident Energy Analysis: A component of an arc flash risk assessment
used to predict the incident energy of an arc flash for a specified set of
conditions.
Motor Control Center: An assembly of one or more enclosed sections
having a common power bus and principally containing motor control
units.
Overcurrent: Any current in excess of the rated current of equipment or
the ampacity of a conductor. It may result from overload, short circuit, or
ground fault
Overload: Operation of equipment in excess of normal, full-load rating,
or of a conductor in excess of rated ampacity that, when it persists for a
sufficient length of time, would cause damage or dangerous
overheating. A fault, such as a short circuit or ground fault, is not an
overload.
Short-Circuit Current Rating: The prospective symmetrical fault current at
a nominal voltage to which an apparatus or system is able to be
connected without sustaining damage exceeding defined acceptance
criteria.
Single-Line Diagram: A diagram that shows, by means of single lines and
graphic symbols, the course of an electric circuit or system of circuits and
the component devices or parts used in the circuit or system
The boundaries are defined in NFPA, and the following synopsis is relevant
here (Figure). The flash protection boundary is the distance at which the
threshold of second - degree burns can occur and the incident energy
release is 1.2 cal/cm 2).
This is the boundary that is calculated by computer - based programs and
IEEE Guide equations. Inside the boundary, the energy level will be higher.
This boundary should not be crossed by anyone, including a qualified
person, without wearing the required PPE, (Table). The PPE outfits are
designed to minimize the risk of sustaining energy
Greater than 1.2 cal/ cm 2. That is, the threshold of second - degree burns
can still occur even with appropriate PPE, and these burns are considered
curable.
Unqualified persons, that is, those not specifically trained to carry out the
required tasks, are safe when they stay away from the energized part of a
certain distance, which is
 Table: Limited Approach and Restricted Approach Boundaries
System voltage Range (Phase to Phase) Restricted Approach Boundary
Less than 50 V Not specified
50-300 V Avoid contact
301-750V 0.3m
751V-15kV 0.7m
15.1-36kV 0.8m
36.1-46kV 0.8m
46.1-72.5kV 1.0m
72.6-121kV 1.02m
138-145kV 1.15m
Source: NFPA 70E

Working Distance:
Working distance is defined as the closest distance to a worker’s body
excluding hands and arms. IEEE 1584 Guide specifies required working
distances (Table 1.6). For the 15 - kV switchgear, it is 36 in, while for a
480V MCC, it is 18 in. A larger working distance reduces the incident
energy and therefore the HRC. Recommendations of IEEE for the working
 distances are followed in the calculations. The working distance does
exclude hands and arms, which will be much closer to the seat of arc. It is
the vital organs like eyes, chest, and heart that are at the working distance
from the seat of the arc. This assumes that a worker does not stick his
head inside the switchgear door.
Table: Classes of Equipment and Typical Working Distances
Classes of Equipment Typical Working Distance
15 kV switchgear (mm) 910
5 kV switchgear 910
Low voltage switchgear 610
Low voltage MCCs and panel 455
boards
Source: NFPA 70E

Table: Protective Clothing Characteristics

Hazard Range of calculated Arc Rating of
Clothing Description
Category Incident Energy PPE, cal/cm2
Non-melting, flammable materials, that is,
untreated cotton, wool, rayon, or silk, or
0 0 ≤ E ≤ 1.2 N/A
blends of these materials, with a fabric
weight of 4.5 oz/yd 2
Arc - rated clothing, minimum arc rating of 4
1 1.2 < E ≤ 4 4
cal/cm 2
Arc - rated clothing, minimum arc rating of 8
2 4<E≤8 8
cal/cm 2
Arc - rated clothing selected so that the
3 system rating meets the required minimum 8 < E ≤ 25 25
arc rating of 25 cal/cm 2
Arc - rated clothing selected so that the
4 system rating meets the required minimum 25 < E ≤ 40 40
arc rating of 40 cal/cm 2
Source: NFPA 70E

Table: Incident Energy Category as per Ford India Norms.

Hazard Range of calculated
Category Incident Energy
0 0 ≤ E ≤ 1.2
2 1.2 < E ≤ 8
4 25 < E ≤ 40
 CALCULATION OF ARCING CURRENT
Arcing Current below 1kV:
To calculate the arcing current for systems operating less than 1 kV two
equations are used.
Equation-1 calculates the exponent of the arcing current Ia
Log10 Ia = K+ 0.662(Log10 (Ibf) +0.0966 V+0.000526 G+0.5588 V (Log10
(Ibf)-0.00304 G (Log10 (Ibf).
Where,
V = System voltage in kV
G = Conductor gap in mm
Ibf = Bolted three phase symmetrical short circuit current in kA
K = -0.153 for open air arcs and -0.-097 for arcs in a box
Log 10 = Log base 10
Ia = Arcing current

Equation-2 determines the arcing current by raising the number 10 to the

power of Log10Ia as found in in equation-1

Ia = 10 log10Ia

Arcing Current above 1Kv:

For voltages greater than 1 kV, the following equation can be used

Log10 Ia =0.00402+0.983 X Log10 Ibf

Ia = 10 log10Ia
Example 01:
For Voltage Less than 1Kv:

Bolted Three phase symmetrical short circuit

= 38.0681
current Ibf in kA
System voltage V = 0.433
Conductor gap in mm G = 25
Configuration Box –swg. K = -0.097

Therefore,
Log10 (Ibf) = Log10 (38.068).
= 1.580560061.
Log10 Ia = K+ 0.662(Log10 (Ibf) +0.0966 V+0.000526 G+0.5588 V (Log10
(Ibf)-0.00304 G (Log10 (Ibf).
= -0.097+ (0.662 X 1.580560061) + (0.0966 X 0.433) +
(0.000526 X 25) + (0.5588 X 0.433X1.580560061)-(0.000304 X
25 X1.580560061).
= 1.26661889 1.266619
1.26661889
Ia = 10
= 18.47646527 kA.

Therefore,
100% Arcing Current = 18.79397 kA.
85% of Arcing Current = 15.97487 kA
Example 02:
For Voltage Greater than 1Kv:

Bolted Three phase symmetrical short circuit

= 14.1552
current Ibf in kA
System voltage V = 11
Conductor gap in mm G = 153
Configuration Box –swg. K = -0.097

Therefore,
Log10 (Ibf) = Log10 (14.155).
= 1.150909874.
Log10 Ia = 0.00402+0.983 X Log10 Ibf
= 0.00402+0.983 X 1.516641125.
= 1.494878226. 1.135365.
1.494878226
IA = 10
= 31.25202953 kA.
Therefore,
100% Arcing Current = 13.6573 kA.
85% of Arcing Current = 11.6087 kA
 CALCULATION OF INCIDENT ENERGY

As per NEPA 70E incident Energy is defined as the amount of Energy

impressed on a surface, a certain distance away from the source
generated during an electrical arc event.
The incident energy calculation depends on the magnitude of short-circuit
current and over current device's clearing time.
Two equations are used to determine the normalised incident energy
based on a normalised 2 foot working distance and 0.2 second device
clearing time. The first equation is used to determine the log of the
normalised incident energy, Ea.
Log10 Ea =k1+K2+1.081 x Log10 Ia+0.0011G.

Where,
Incident energy (joules/cm ) normalised to 2 foot working
Ea =
distance and 0.2 second clearing time
k1 = -0.792 for open air arcs,-0.555 for arcs in a box
k2 = 0 for ungrounded systems,-0.113 for grounded system
G = conductor gap in millimeter

The second equation requires raising number 10 to the power of Log10 Ea

E = 10 log10 Ea a

The third equation is to convert the calculated incident energy to

calories/cm² at the specific working distance and device clearing time
E = 4.184 Cf Ea [t/0.2] [610x /Dx] [0.24]
Where,
E = Incident of energy in cal/cm2
Cf = Calculation factor

Ea = Incident energy normalised to 2 foot working distance and

0.2 second clearing time
t = arcing time in seconds from time current curve
D = working distance in mm
x = distance exponent
0.24 = conversion to calories /cm2

The typical working distance used for panels, switchboards and motor
control centers is 18 inches.
The X distance exponent depends on the type of equipment being studied,
for medium voltage switch gear the x factor is 0.973 and 1.641 for low
voltage switchgear.
Example 01:
For Voltage Less than 1Kv:
k1- arc in a box = -0.555
k2-Grounded system = -0.113
G- conductor gap in = 25
mmArcing current
Ia- = 18.477
Log10 Ia = log 10(18.477)
= 1.266631

Log10 Ea = k1+K2+1.081 x Log10 Ia+0.0011G.

=-0.555-0.113+ (1.081x1.266631) + (0.0011x 25).
= 0.728728.

E = 10 log10 Ea a
=100.728728
=5.35461.

E = 4.184 Cf Ea [t/0.2] [610x /Dx] [0.24]

Cf- calculation factor = 1.5
Ea-Incident of energy calculated above = 5.355
t- trip time = 0.181
x-distance exponent = 1.641
D-working distance = 455

= 4.184 x 1.5 x 5.35461 x [0.181/0.2]x [6101.641 /4551.641] x [0.24].

= 4.184 x 1.5 x 5.35461 x 0.905x 1.6178 x 0.24.
= 11.7516.
For Voltage Greater than 1Kv:
k1- arc in a box = -0.555
k2-Grounded system = -0.113
G- conductor gap in = 153
mmArcing current
Ia- = 13.657
Log10 Ia = log 10(13.657)
= 1.135355

Log10 Ea = k1+K2+1.081 x Log10 Ia+0.0011G.

=-0.555-0.113+ (1.081x1.135355) + (0.0011x 153).
= 0.727619.

E = 10 log10 Ea a
=100.727619
=5.34096.

E = 4.184 Cf Ea [t/0.2] [610x /Dx] [0.24]

Cf- calculation factor = 1.0
Ea-Incident of energy calculated above = 5.34096
t- trip time = 0.481
x-distance exponent = 0.973
D-working distance = 910

= 4.184 x 1.0 x 5.34096 x [0.481/0.2]x [6100.973 /9100.973] x [0.24].

= 4.184 x 1.0 x 5.34096 x 2.405 x 0.677 x 0.24.
= 8.73225.