Arc Flash Report | Interstates

Tapping into a renewable natural gas project for the first time, Interstates recently worked with Gevo to build a central biogas purification site and connect it to three different dairies in Northwest Iowa. Interstates provided Gevo with power distribution, PLC design and construction, programming, instrumentation, and heat trace work.

Arc Flash Study Short Circuit Study Coordination Study

By Chris Myers, EIT Jason Wyenberg, PE Brent Kooiman, PE Interstates Sioux Center, Iowa IE Job #:

Summary

On any given day, 5-10 arc flash events occur in the United States. These arc flashes result in over 7,000 burn injuries annually. An arc flash can be caused by human error, equipment failure, aging equipment, failure to maintain equipment, or conductive dust. Keeping your workplace safe and compliant is crucial to the safety of your people and the success of your business. Companies must maintain compliance with the many regulations and standards associated with electrical safety: OSHA Standards 29 CFR, Part 1910 (occupational safety); NFPA Standard 70 (labels); NFPA 70E (workplace practices); IEEE 1584 (calculating arc hazard). A professional arc flash study will identify areas of risk and ensure compliance with standards. The study will determine the level of personal protective equipment (PPE) required when someone is near electrical equipment. The study should also indicate the remediation work necessary to get the PPE level down to an incident energy rating below the desired target. Cost of compliance is unique to each facility; however, a single arc flash event can be far more expensive than maintaining compliance.

Revisions & Table of Contents

Revisions

Revision

Date

Prepared By

Comments

3/21/14

Chris Myers

Issue for review and comment

NOTE: Changes made for the most recent revision will be shown in grey.

Table of Contents

Section 1: Project Overview • Executive Summary • Scope of Work • Clarifications

Section 2: Results •

Recommendations Arc Flash Results Short Circuit Results

• • •

Protective Device Coordination

Section 3: Appendices •

Appendix A: Arc Flash Technical Information • Appendix B: Model One-Lines • Appendix C: Coordination Curves • Appendix D: Model Input Data Report

Section 1: Project Overview

Executive Summary

Air Liquide in Sergeant Bluff, IA The following document presents the results of an Arc Flash Study performed by Interstates Engineering for the . Recommendations were created from these results to minimize or eliminate danger to personnel or electrical equipment in the facility. The Arc Flash results were calculated to determine what personal protective equipment (PPE) is needed at each piece of electrical equipment and show that most of the equipment in the facility has a minimal arc flash hazard. The following pieces of equipment have a high arc flash rating and changes are recommended: ADD INFO HERE. Similarly the short circuit results were calculated to determine the safety of the electrical system equipment if a fault were to occur. Recommendations to increase the short circuit rating for the following equipment have been made in Section 2: ADD INFO HERE. Coordination of protective devices in the facility was also analyzed to determine if the devices are correctly coordinated to trip in the proper order. Coordination problems were prevalent in the facility and recommendations to change the settings or fuses on the following devices have been made in Section 2 : ADD INFO HERE.

Scope of Work

Air Liquide to analyze the electrical system in the facility. A computer model in the SKM POWER TOOLS power analytics software was developed from the information gathered and used to calculate the information needed to create the following reports. The following discussion includes a clarification of the information used during calculations; a presentation of recommendations generated from the results of the study; arc flash results, short circuit results, and coordination results; and supplementary appendices providing additional information about the studies. Any changes to the electrical system of the facility may affect the arc flash ratings of the electrical equipment and invalidate the results of this study. For this reason, it is recommended that the arc flash for the entire facility be re-evaluated on a regular basis not exceeding five years to account for such changes (as specified by NFPA 70E). This Arc Flash Study is being undertaken at the request of

Clarifications

Information Received and Collected

Dan Dana [phone: (712)233-4883; email: ddana@midamerican.com] from MidAmerican on DATE The information used for this arc flash study was collected during an on-site audit performed the week of 2/24/2014 and included information like wire length, size, and type; breaker information and settings; enclosure ratings; and transformer information. Short circuit availability at the service transformers was given to Interstates by . The main service had a short circuit availability of VALUE at LOCATION IN DISTRIBUTION SYSTEM.

Assumptions

The following assumptions were made when performing the arc flash hazard analysis for the Air Liquide, Sergeant Bluff facility:

1. 10300-1 NH3 HIGH STAGE FUSE a.

No fuse data could be found on this and so it was estimated to have the same fuse size as the larger CO2 2 nd STAGE STARTER.

2. 10300-3 DISC NH3 HIGH STAGE a. The AIC rating and momentary rating could not be determined from site data collection or from existing documentation. Both the AIC and momentary ratings have been assumed to be 10 kA.

3. 10515-3 PANEL A XFMR a.

The impedance of the transformer is unknown and so a typical value has used for a 15 kVA transformer. See the data input report in appendix D for details.

4. 10515-5 PANEL A a. The short circuit value could not be determined so a typical value of 10 kA SCR has been assumed.

5. 10516-3 PANEL B a. The short circuit value could not be determined so a typical value of 10 kA SCR has been assumed.

6. 105201-5 PANEL E CIRCUIT BREAKER, 105215-5 PANEL D CIRCUIT BREAKER a.

The quicklag type BA breaker curve is not in the protective device library and has been assumed as a similar thermal magnetic breaker. Specifically, a Westinghouse FDP SERC 100A.

This information was necessary for creating a model of the electrical system, but was not available or accessible at the time of the audit. These were made to model the system as accurately as possible while still providing the worst- case arc flash value for the equipment.

Section 2: Results Recommendations

Recommendations have been provided to eliminate or minimize arc flash hazards, short circuit violations, coordination issues, and NEC violations. Table 1: Recommendations on the following pages provides a brief description of each recommendation; further information may be found in the results sections or appendices. Each recommendation has been given a priority ranking from 0 to 5, based on factors such as personnel safety, electrical equipment safety, and accepted practices in industry. The rankings should be interpreted using the following scale. • A ranking of 5 represents a very urgent item that poses a significant risk to personnel and plant safety. • A ranking of 3 represents an issue that should be discussed and a plan put in place for remediation. • A ranking of 1 represents a low priority issue that should be discussed, but action may not be needed. • A ranking of 0 represents an item included for informational purposes only, no change is needed.

TABLE 1 - RECOMMENDATIONS

RECOMMENDATION NUMBER

RECOMMENDATION TYPE

EQUIPMENT INVOLVED

RECOMMENDED CHANGE

PRIORITY

THE SAME FUSE IS USED FOR BOTH THE MAIN SWGR AND THE SUB-FED 4160 DISCONNECT. THIS COULD LEAD TO THE 4160 MOTORS TRIPPING THE SERVICE RATHER THAN LIMITING IT TO THE BRANCH DISCONNECT. THE MAIN SWGR FUSE SHOULD BE INCREASED (THIS WILL NEED TO BE INVESTIGATED FURTHER TO RECOMMEND A SPECIFIC FUSE) THERE IS MISCOORDINATION BETWEEN AFTER 3 SECONDS, CHANGING THE FUSE TYPE TO A TIME DELAY RATHER THAN STANDARD FUSE ON THE 4160 STARTERS DISCONNECT FUSE WILL LIKELY RESOLVE THE ISSUE. ARC FLASH RECOMMENDATIONS WILL BE REVIEWED WHEN

MAIN SWGR FUSE, 4160 STARTERS DISCONNECT FUSE. SEE TCC CURVE 100-1

COORDINATION

4160 STARTERS DISCONNECT FUSE, 1ST CO2 STARTER FUSE. SEE TCC CURVE 101-1

COORDINATION

ARC FLASH

FINAL UTILITY INFO IS RECEIVED

SHORT CIRCUIT RECOMMENDATIONS WILL BE REVIEWED WHEN FINAL UTILITY INFO IS RECEIVED

SHORT CIRCUIT

Section 2: Results Arc Flash Results

The Arc Flash Study was conducted to find out what personal protective equipment (PPE) is needed at each switchboard, panelboard, control panel, and motor control center. PPE is only needed if the owner chooses to work on the equipment live. A warning tag will need to be clearly visible on each switchboard, panelboard, industrial control panel, and motor control center. The tag will say “WARNING Arc Flash and Shock Hazard Appropriate PPE Required”. Below is an example of the type of tag to be installed on the electrical equipment. The information included on the tag corresponds to the arc flash tag information generated by the software arc flash module. The following pages present Table 2: Arc Flash Tag Information for the equipment that is potentially subject to live work at this facility. Note that the equipment is sorted per the one-line drawings for the electrical system. Below the arc flash tag is an example of the header of Table 2 with indicators of how the information from the table corresponds to the tags installed on equipment in the facility.

A* B

K L M N*

Short

Shock Hazard When Cover is Removed (V)

Controlling Branch Arcing Current (amps)

Cal/cm 2 Flash Hazard at 18"

Circuit Current (amps @ 3P-1/2 cycle)

Flash Hazard Boundary

Fault Duration (seconds)

Clothing Class Number

PPE Level (number of layers)

* Item Not Shown On Arc Flash Tags

Table 2 - Arc Flash Tag Information +

Fault Duration (seconds) +

DESCRIPTION (switchboards, panelboards, industrial control panels, and motor control centers)

Short Circuit Current (amps @ 3P-1/2 cycle)

Controlling Branch Arcing Current (amps)

Shock Hazard When Cover is Removed (V)

One-Line Reference

Flash Hazard Boundary

Limited Approach

Restricted Approach

Prohibited Approach

Glove Class

Cal/cm 2 Flash Hazard at 18"

Clothing Class Number

PPE Level (number of layers)

MAIN SWGR

1379' 9"

465.8

41070

38880

EXTREME DANGER**

PPE NOT AVAILABLE - DE-ENERGIZE EQUIPMENT BEFORE WORKING

4160

5'-0''

2'-2''

0'-7''

E05-1

4160 STARTERS

0.8

40820

39030

0.017

4160

5'-0''

2'-2''

0'-7''

E05-1

1ST CO2 STARTER

0.2

40760

39950

0.004

4160

5'-0''

2'-2''

0'-7''

E05-1

2ND CO2 STARTER

0.2

40700

40050

0.004

4160

5'-0''

2'-2''

0'-7''

E05-1

NH3 HIGH STAGE

0.2

40300

39980

0.004

4160

5'-0''

2'-2''

0'-7''

E05-1

MCC TRANSFORMER

0.8

40810

40410

0.017

4160

5'-0''

2'-2''

0'-7''

E05-1

NORTH MCC

2' 8"

3.1

18380

2120

0.083

480

3'-6''

1'-0''

0'-1''

E05-1

NORTH MCC LINE SIDE

13' 10"

45.6

18380

14080

1.853

EXTREME DANGER**

PPE NOT AVAILABLE - DE-ENERGIZE EQUIPMENT BEFORE WORKING

480

3'-6''

1'-0''

0'-1''

E05-1

Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts) Non-melting or Untreated Natural Fiber (According to ASTM F 1506-00): Shirt (long- sleeve) and Pants (long). Safety Glasses or Goggles, Voltage Rated Gloves with Leather Protectors. Hearing Protection (ear canal inserts)

CO2 DRYER HTR

0.2

6980

0.015

480

3'-6''

1'-0''

0'-1''

E05-2

AVOID CONTACT

RTU

1'6''

N/A

750

N/A

240

3'-6''

E05-2

AVOID CONTACT

OFFICE PNL

1'6''

N/A

930

N/A

240

3'-6''

E05-2

LIFT STATION

0.0

1720

0.01

480

3'-6''

1'-0''

0'-1''

E05-2

HTG AND AC

0.1

2190

0.01

480

3'-6''

1'-0''

0'-1''

E05-2

AVOID CONTACT

PANEL A

1'6''

N/A

1210

N/A

240

3'-6''

E05-2

PANEL B

11"

0.5

15260

0.016

480

3'-6''

1'-0''

0'-1''

E05-2

PANEL C

11"

0.5

17160

0.015

480

3'-6''

1'-0''

0'-1''

E05-2

AVOID CONTACT

PANEL E

1'6''

N/A

1250

N/A

240

3'-6''

E05-3

TEMP AIR HNDLR

0.1

2580

0.01

480

3'-6''

1'-0''

0'-1''

E05-3

SOUTH MCC

0.0

16470

14130

0.001

480

3'-6''

1'-0''

0'-1''

E05-1

SOUTH MCC LINE SIDE

15' 9"

56.5

16470

12390

2.557

EXTREME DANGER**

PPE NOT AVAILABLE - DE-ENERGIZE EQUIPMENT BEFORE WORKING

480

3'-6''

1'-0''

0'-1''

E05-1

PELLETIZER #1

0.1

1760

1740

0.021

480

3'-6''

1'-0''

0'-1''

E05-3

PELLETIZER #2

0.1

1760

1740

0.021

480

3'-6''

1'-0''

0'-1''

E05-3

PELLETIZER #3

0.1

1820

1800

0.016

480

3'-6''

1'-0''

0'-1''

E05-3

PELLETIZER #4

0.1

1820

1800

0.016

480

3'-6''

1'-0''

0'-1''

E05-3

PELLETIZER #5

0.1

1920

1900

0.013

480

3'-6''

1'-0''

0'-1''

E05-3

PELLETIZER #6

0.1

1900

1880

0.014

480

3'-6''

1'-0''

0'-1''

E05-3

Section 2: Results Short Circuit Results

The short circuit rating of equipment indicates how much fault current the equipment can safely be subjected to and still maintain proper operation. If the equipment is not rated properly for the available fault current, the equipment could fail during a fault causing equipment and facility damage, plant downtime, or injury. Table 3: Short Circuit Ratings is given on the following pages and shows the comparison between equipment short circuit ratings, available fault current at that location, and a concern rating that matches the rating given in Table 1: Recommendations earlier in this report.

The concern level rating from 0 to 5 is based on an assessment of the difference between the available fault current and component rating.

• A rating of 5 refers to a panel that has been analyzed as substantially under-rated for the available fault current. These situations are high-priority and should be addressed immediately due to their danger for both plant personnel and equipment. • A rating of 3 refers to a device that has been assessed to be medium priority because it is insufficiently rated in comparison to the available fault current. These devices have some risk in a fault situation of sustaining damage or are not rated high enough to accommodate additional load. • A rating of 1 refers to a device that has been assessed to be low priority because it does appear to be sufficiently rated for the available fault current, but there are questions about the rating of the equipment or the available fault current is close to exceeding the rated value.

• A rating of 0 refers to a device that has a short circuit rating high enough to easily handle the available fault current; no changes are recommended in this situation.

Project: Sioux Center Air Liquide SKM Scenario: Base Project Air Liquide Sioux Center, IA

Bus Evaluation Comprehensive Fault Report

Description

Status

Isc

Bus Name

Data State

Calc Isc

Dev Isc

Calc

Dev Mom

Mom

Rating%

Mom_kA

Rating%

Complete Complete Complete Complete Estimated Complete Estimated

MAIN SWITCHGEAR

Fail

41.07

40.00

102.68

52.23

40.00

130.56

10000-5 SWGR [MAIN SWGR]

MAIN SWITCHGEAR

Fail

40.82

40.00

102.06

51.51

40.00

128.78

10000-8 SWGR [4160 STARTERS]

1ST STAGE CO2 STARTER/DISCOFail

40.76

50.00

81.52

51.44

50.00

102.89

10100-3 DISC [1ST CO2 STARTER]

2ND STAGE CO2 STARTER/DISCOFail

40.70

50.00

81.40

51.38

50.00

102.76

10200-3 DISC [2ND CO2 STARTER]

NH3 HIGH STAGE STARTER/DISCFail

40.30

10.00

403.03

50.05

10.00

500.48

10300-3 DISC [NH3 HIGH STAGE]

MAIN SWITCHGEAR

Fail

40.81

40.00

102.02

51.46

40.00

128.65

10500-3 SWGR [MCC TRANSFORMER]

10516-3 PNL [PANEL B]

PANEL B

Fail

15.26

10.00

152.62

0.00

Section 2: Results Protective Device Coordination

The coordination study calculates how the overcurrent protective devices (fuses, breakers, relays, etc.) in the system will interact with each other under various overload or fault conditions. Table 4: Breaker and Fuse Coordination Settings gives the settings of protective devices found in the facility and recommendations where applicable. Protective device curves, where given, are noted by a separate page numbering system in Table 4 and can be found in Appendix C: Coordination Curves. See Table 1: Recommendations for more information on recommendations involving changes in coordination settings.

Project: Sioux Center Air Liquide SKM Scenario: Base Project Air Liquide Sioux Center, IA

Protective Device Setting Report

Prot Dev

Manufacturer

Type

Frame

Sensor

LTPU

LTD

STPU

STD

INST

INST_Delay

10000-4 FUSE [MAIN SWGR]

RBA, RDB-400, 2.4-34.5kV E-Rated

CUTLER-HAMMER

400.0

10100-1 FUSE [1ST CO2 STARTER]

GOULD SHAWMUT

A480R, 5.5kV R-Rated

200.0

10200-1 FUSE [2ND CO2 STARTER]

GOULD SHAWMUT

A480R, 5.5kV R-Rated

170.0

10300-1 FUSE [NH3 HIGH STAGE]

GOULD SHAWMUT

A480R, 5.5kV R-Rated

170.0

Section 3: Appendices B: Model One-Lines

Included is the one-line drawing of the electrical system as modeled in the power analytics software package used for the Arc-Flash study. This model is used for the arc flash and short circuit calculations in addition to being the base model for the coordination analysis.

10000-1 UTIL [UTILITY] 4160.0 V

SC Contribution 3P 300. 0 M VA SC Contribution SLG 30.0 MVA

10000-2 XFMR [UTILITY]

0.0 kVA 12470 V 4160 V Z% 0.0000 %

10000-3 CBL [MAIN SWGR] 5" Non-Magnetic 4/0 AWG/kcmil 100% 140.0 ft 10000-4 FUSE [MAIN SWGR] Frame/Rating 400.0 A InterruptingRating 20.0 kA

10000-5 SWGR [MAIN SWGR] 600.0 A 4160.0 V 3 PH 40.0 kASCR 10500-1 CBL [MCC TRANSFORMER] N/A

10000-6 CBL [4160 STARTERS] N/A

Non-Magnetic 4/0 AWG/kcmil MV 15.0 ft

10000-7 FUSE [4160 STARTERS] Frame/Rating 400.0 A InterruptingRating 20.0 kA

10500-2 FUSE [MCC TRANSFORMER] Frame/Rating 200.0 A InterruptingRating 19.0 kA

10000-8 SWGR [4160 STARTERS] 600.0 A 4160.0 V 3 PH 40.0 kASCR

10500-3 SWGR [MCC TRANSFORMER] 600.0 A 4160.0 V 3 PH 40.0 kASCR

10300-1 FUSE [NH3 HIGH STAGE]

10200-1 FUSE [2ND CO2 STARTER]

10100-1 FUSE [1ST CO2 STARTER]

10400-1 FUSE [SPARE] Frame/Rating 0.0 A

Frame/Rating 170.0 A InterruptingRating 50.0 kA

Frame/Rating 150.0 A InterruptingRating 50.0 kA

Frame/Rating 200.0 A InterruptingRating 50.0 kA

InterruptingRating 0.0 kA

10300-2 CBL [NH3 HIGH STAGE] N/A

10200-2 CBL [2ND C O2 STARTER] BUSWAY Busway 3000 AWG/kcmil Class B 4.0 ft

10100-2 CBL [1ST CO2 STARTER] BUSWAY Busway 3000 AWG/kcmil Class B 2.0 ft

10400-2 CBL [SPARE] BUSWAY Busway 3000 AWG/kcmil Class B 8.0 ft

10500-4 CBL [MCC TRANSFORMER] 3 1/2" Magnetic 1/0 AWG/kcmil 133% 40.0 ft

Non-Magnetic 4/0 AWG/kcmil MV 15.0 ft

10300-3 DISC [NH3 HIGH STAGE] 100.0 A 4160.0 V 3 PH 10.0 kASCR

10200-3 DISC [2ND CO2 STARTER] 600.0 A 4160.0 V 3 PH 50.0 kASCR

10100-3 DISC [1ST CO2 STARTER] 600.0 A 4160.0 V 3 PH 50.0 kASCR

10400-3 DISC [SPARE] 0.0 A 4160.0 V 3 PH 0.0 kASCR

P 10500-5 XFMR [MCC TRANSFORMER]

750.0 kVA 4160 V 480 V Z% 5.7700 %

10300-4 CBL [NH3 HIGH STAGE] N/A

10200-4 CBL [2ND C O2 STARTER] N/A

10100-4 CBL [1ST CO2 STARTER] N/A

Non-Magnetic 4 AWG/kcmil MV 35.0 ft

Non-Magnetic 2 AWG/kcmil MV 121.0 ft

Non-Magnetic 4/0 AWG/kcmil MV 153.0 ft

10500-6 TAPS [MCC TRANSFORMER] 0.0 A 480.0 V 3 PH 0.0 kASCR

10520-1 CBL [SOUTH MC C] 2" Magnetic 4/0 AWG/kcmil THHN 52.0 ft 10520-2 CB [SOUTH MCC] Frame/Rating 600.0 A InterruptingRating 30.0 kA

10510-1 CBL [NORTH MCC] 2" Magnetic 4/0 AWG/kcmil THHN 47.0 ft 10510-2 CB [NORTH MCC] Frame/Rating 800.0 A InterruptingRating 30.0 kA

10300-5 MTR [NH3 HIGH STAGE] 400.0 hp NumMotors 1

10200-5 MTR [2ND CO2 STARTER] 800.0 hp NumMotors 1

10100-5 MTR [1ST CO2 STARTER] 1000.0 hp NumMotors 1

10520-3 MCC [SOUTH MCC] 600.0 A 480.0 V 3 PH 65.0 kASCR

10510-3 MCC [NORTH MCC] 800.0 A 480.0 V 3 PH 65.0 kASCR

E05-01 MAIN SWGR Base Project March 19, 2014

Air Liquide Sioux Center, IA

Section 3: Appendices C: Coordination Curves

The coordination study calculates how the overcurrent devices in the system will interact with each other under various overload or fault conditions. On the graphs, current is shown on the horizontal axis and time is on the vertical axis. Note that each curve is plotted at a reference voltage of 480V even though some devices may be rated for higher or lower voltages. Progressing from left to right on the horizontal axis, the fault or overload current is increased. Trip times are calculated by finding the correct fault or overload condition on the horizontal axis, and moving vertically upward until a protective device curve is intercepted. These trip times can be adjusted either by making changes to the settings on the adjustable breakers or by using a different size and style of fixed-magnitude breaker or fuse. By adjusting these trip times, the system can be coordinated so that if a fault does occur, the fewest pieces of equipment possible are shut down. Example: If a fault would happen at a motor, you would want the individual breaker or fuse in the starter bucket to open and shut that motor down. You would not want the main breaker to open and shut down the entire MCC. Proper settings minimize the probability of this occurring. A listing of the settings and sizes of the breakers included in this study can be found in Table 4 – Breaker and Fuse Coordination Settings . Not all curves are shown in this appendix because there were no coordination issues or no recommendations made for changes to coordination settings.

Recommendations for new breaker settings have been made and are shown as a second entry in Table 4 – Breaker and Fuse Coordination Settings .

CURRENT IN AMPERES

0.5

1000

Name 10000-4 FUSE [MAIN SWGR] Manufacturer CUTLER-HAMMER Type RBA, Frame/Model RBA, RDB-400, 400E Trip 400.0 A Settings Phase 400.0 Amps RBD-400, 2.4-3kV E-Rated

100

Name 10000-7 FUSE [4160 STARTERS] Manufacturer CUTLER-HAMMER Type RBA, RDB-400, 2.4-34.5kV E-Rated Frame/Model RBA, RDB-400, 400E Trip 400.0 A Settings Phase 400.0 Amps

Name 10500-2 Manufacturer CUTLER-HAMMER Type RBA, RDB-200, 2.4-34.5kV E-Rated Frame/Model RBA, RDB-200, 200E Trip 200.0 A Settings Phase 200.0 Amps FUSE [MCC TRANSFORMER ]

0.10

0.01

100-1 MAIN SWGR FUSES

Reference Voltage: 4160 March 19, 2014

Base Project

Section 3: Appendices D: Input Report

The input report details the various components in the model. This appendix can be used to recover or recreate the model used to generate this report.

Project: Sioux Center Air Liquid Air Liquide Sioux Center, IA

DAPPER Fault Analysis Input Report (English)

Utilities

Contribution

Bus

In/Out

Nominal

-------- Contribution Data --------

PU (100 MVA Base

From Name

Name

Service

Voltage

Duty Units

X/R

R PU X PU

3P:

Pos:

10000-1 UTIL [UTILITY]

BUS-0001

4,160

300 MVA

8.00

0.041

0.331

Zero:

0.331

2.646

SLG:

30 MVA

8.00

Motors

# of Motors

--------- Contribution Data --------

Contribution From Name

Bus Name

In/Out Service

Nominal Voltage

PU (100 MVA Base)

Base kVA

Xd"

X/R

R PU

X PU

10100-5 MTR [1ST CO2 STARTER

BUS-0005

4,160

1,002.69

0.1692

10.00

1.687

16.870

10200-5 MTR [2ND CO2 STARTE

BUS-0006

4,160

802.15

0.1692

10.00

2.109

21.088

10300-5 MTR [NH3 HIGH STAGE

BUS-0007

4,160

401.08

0.1692

10.00

4.217

42.175

10509-1 MTR [MCC NORTH LOA

10510-3 MCC [NORTH MCC]

480

11.03

0.1692

10.00

17.040

170.406

10518-1 MTR [FRICK BOOSTER]

10510-3 MCC [NORTH MCC]

480

200.54

0.1692

10.00

8.435

84.351

105203-4 MTR [PELLETIZER 1]

105203-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105204-4 MTR [PELLETIZER 2]

105204-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105205-4 MTR [PELLETIZER 3]

105205-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105206-4 MTR [PELLETIZER 4]

105206-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105207-4 MTR [PELLETIZER 5]

105207-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105208-4 MTR [PELLETIZER 6]

105208-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105209-4 MTR [PELLETIZER 7]

105209-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105210-4 MTR [PELLETIZER 8]

105210-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105211-4 MTR [PELLETIZER 9]

105211-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105212-4 MTR [PELLETIZER 10]

105212-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105213-4 MTR [PELLETIZER 11]

105213-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105214-4 MTR [PELLETIZER 12]

105214-3 ENC [PELLETIZER

480

10.03

0.1692

10.00

168.695 1,687.015

105216-1 MTR [RECO BOOSTER

10520-3 MCC [SOUTH MCC]

480

200.54

0.1692

10.00

8.435

84.351

# of Motors

--------- Contribution Data --------

Contribution From Name

Bus Name

In/Out Service

Nominal Voltage

PU (100 MVA Base)

Base kVA

Xd"

X/R

R PU

X PU

105217-1 MTR [SOUTH MCC LO

10520-3 MCC [SOUTH MCC]

480

3.01

0.1692

10.00

93.719

937.231

Cables

Qty /Ph

------ Cable Description ------

Per Unit (100 MVA Base)

Cable Name

From Bus To Bus

In/Out Service

Length Feet

Size Cond. Type

Duct Type Insul

R pu

jX pu

10000-3 CBL [MAIN

BUS-0001

4/0 Copper

Non-Magnetic XLPE

0.0258

0.0198

Pos:

140

SWGR]

Zero:

0.0950

0.0561

10000-5 SWGR [MAIN SWGR] 10000-5 SWGR [MAIN SWGR] 10000-8 SWGR

4/0

Copper

Non-Magnetic EPR

0.0027

0.0017

Pos:

10000-6 CBL [4160

STARTERS]

Zero:

0.0044

[4160

3000 Copper

Busway Epoxy

0.0000

0.0005

Pos:

10100-2 CBL [1ST CO2 STARTER]

10000-8 SWGR

[4160 STARTERS] 10100-3 DISC

0.0002

0.0029

Zero:

[1ST CO2

4/0

Copper

Non-Magnetic EPR

0.0560

0.0294

Pos:

10100-4 CBL [1ST CO2 STARTER]

10100-3 DISC [1ST CO2 STARTER] BUS-0005

153

0.0889

0.0746

Zero:

3000 Copper

Busway Epoxy

0.0001

0.0011

Pos:

10200-2 CBL [2ND

10000-8 SWGR

CO2 STARTER]

[4160 STARTERS] 10200-3 DISC

0.0004

0.0059

Zero:

[2ND CO2

2 Copper

Non-Magnetic EPR

0.1412

0.0273

Pos:

10200-4 CBL [2ND

10200-3 DISC

121

[2ND CO2 BUS-0006

CO2 STARTER]

Zero:

0.2245

0.0694

4/0 Copper

Non-Magnetic EPR

0.0055

0.0034

Pos:

10300-2 CBL [NH3

10000-8 SWGR

HIGH STAGE]

[4160 STARTERS] 10300-3 DISC

Zero:

0.0087

0.0088

[NH3 HIGH

4 Copper

Non-Magnetic EPR

0.0649

0.0085

Pos:

10300-4 CBL [NH3

10300-3 DISC [NH3 HIGH BUS-0007

HIGH STAGE]

Zero:

0.1003

0.0217

10400-2 CBL

10000-8 SWGR

Out

3000 Copper

Busway Epoxy

0.0001

0.0022

Pos:

[SPARE]

[4160 STARTERS] 10400-3 DISC

Zero:

0.0008

0.0117

[SPARE]

10500-1 CBL [MCC TRANSFORMER]

10000-5 SWGR [MAIN SWGR] 10500-3 SWGR

4/0

Copper

Non-Magnetic EPR

0.0027

0.0017

Pos:

Zero:

0.0044

[MCC

10500-4 CBL [MCC TRANSFORMER]

10500-3 SWGR

1/0

Copper

Magnetic XLPE

0.0296

0.0140

Pos:

[MCC BUS-0051

Zero:

0.1001

0.0396

4/0 Copper

Magnetic PVC

0.4352

0.3379

Pos:

10510-1 CBL [NORTH MCC]

10500-6 TAPS [MCC 10510-3 MCC [NORTH MCC]

Zero:

1.3715

0.8323

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