Case Study: Innovating Safety in High Voltage Arc Flash Analysis for a Leading Energy Company

Key Achievements

• 8.3% reduction in maintenance and operational costs through enhanced safety protocols.
• 15% increase in operational efficiency due to comprehensive modernization.
• 7% under budget for comprehensive hardware, software, and safety upgrades.

Introduction

This project involved conducting an arc flash study to estimate incident energy for substation equipment operating at voltages higher than 15 kV. Since the industry standard IEEE 1584-2018 only applies to equipment rated at or below 15 kV, our team utilized IEEE Std. C2 and Arc Pro software to extend the analysis to higher voltage systems. This approach allowed the client, a major energy company, to ensure compliance with safety regulations and provide workers with accurate protection guidelines for high-voltage equipment.

The client is a leading energy company in North America that operates extensive infrastructure, transporting natural gas across a vast network of pipelines. The company’s innovative operations required a robust safety solution to mitigate risks associated with high-voltage electrical systems.

Opportunity to Improve Operations

The main challenge stemmed from the absence of established guidelines for arc flash studies on equipment operating above 15 kV. Industry standards like IEEE 1584-2018 provide data only for equipment up to 15 kV, leaving the client with limited means to assess arc flash boundaries and determine safety protocols for their high-voltage systems.

Without quantified incident energy values for substation equipment, workers were unable to safely perform their tasks, posing significant operational and safety risks. The client sought a customized solution to calculate incident energy and establish clear safety protocols for workers operating near energized high-voltage equipment.

Our Solution

Our engineering team devised a comprehensive solution that included the following elements:

• Leveraging IEEE C2 and Arc Pro Software: We applied the IEEE C2 standards and used Arc Pro software to extrapolate incident energy values for higher voltage systems, filling the gaps left by the industry standards.
• Custom Spreadsheet Tools: We developed custom spreadsheet tools to back-calculate additional incident energy values beyond those specified in the IEEE C2 standard, allowing for a more comprehensive analysis of high-voltage equipment.
• ETAP Fault Calculations: ETAP software was used to determine fault currents and fault clearing times, which were integrated into our custom tools to evaluate incident energy levels for each piece of substation equipment.

This approach enabled us to deliver accurate and actionable safety data, meeting the client’s requirements while addressing the unique challenges posed by their high-voltage infrastructure.

Key Results

• Improved Safety Compliance: Workers now have access to precise incident energy values, allowing them to wear appropriate PPE when working near high-voltage equipment.
• Cost Savings: The project was completed under budget, with additional drafting work included as a result of process optimization after the first site analysis.
• Updated Safety Protocols: The client’s safety standards were updated to include procedures for working with high-voltage equipment, significantly improving workplace safety.

Looking Ahead

Our innovative approach to high-voltage arc flash studies has set a new standard for safety in the energy sector. As regulatory pressures increase and the demand for enhanced safety protocols grows, more companies are expected to adopt similar practices. The client plans to revisit and update the arc flash study in five years, ensuring continued safety compliance.