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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=1134">Arc Flash at 12kV Variable Voltage Substation - SLAC National Accelerator Laboratory</a></td>
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<h2 style="white-space:nowrap">Statement of Lessons Learned</h2>
<pre>The variable voltage substations (VVS-5) was installed as part of the original SLAC construction (circa 1967). The equipment was maintained according to a 5-year schedule and believed to be safe to operate. It was not considered that 53+ year old air disconnect switches in the VVS may be beyond its useful life.</pre>
<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>On September 15, 2020 High Voltage Electrician (E1) and High Voltage Electrician (E2) were assigned to close and then open 12kV circuits in two variable voltage substations.
E1 and E2 attended the High Voltage (HV) Electrician safety tailgate at 6:30am, lead by the HV Supervisor. They then attended the Sector 10 Area Manager's safety tailgate at 7:00am to gain release for their work. Upon release, E1 donned Category 4 PPE, with the added protection of a 100 cal/cm2 suit, and E2, who was assigned to observe outside the arc flash boundary, was wearing 8 cal/cm2 shirt and pants.
They proceeded to the substations. Circuit VV3 in VVS-6 was energized (closed) at 7:43am and circuit VV1 in VVS-5 was energized (closed) at 10:48am. In both cases E1 closed the 12kV air disconnect switches while E2 observed outside the arc flash boundary. No abnormal issues occurred at either time and both switches operated as expected.
They returned in the early afternoon and E1 opened circuit VV3 in VVS-6 at 1:34pm without incident. They then proceeded to VVS-5 to open circuit VV1.
At the time of the arc flash, E1 was standing in front of the VV1 cabinet, in order to operate the external handle for the VV1 air disconnect switch. E2 stood immediately outside the VVS-5 arc flash boundary (approximately 15 feet away) in order to observe the activity. E2 observed E1 bending slightly when operating the external handle to open the switch. As E1 pushed the external handle downwards to open the switch, E2 heard a "loud boom" and saw flames and smoke shoot from vents at the top of the cabinet. E2 helped E1 out of the alcove. Neither E1 nor E2 were physically injured in this incident.
</pre>
<h2 style="white-space:nowrap">Analysis</h2>
<pre>The arc-flash label on the VV1 cabinet incorrectly stated the flash protection hazard category was Category 1; the flash protection category for VV1 was actually Category 3.
It is SLACs standard practice that High Voltage Electricians wear Category 4 PPE for any switching operations on 12kV equipment that requires the electrician to be within the equipment's arc flash boundary. E2, who was standing ~15 feet away and outside the arc flash boundary, was wearing also wearing 8 cal/cm2 shirt and pants.
The VV1 and VV2 switch components inside the enclosure sustained damage from the arc flash, including melted copper on the main contacts for all three phases, visual damage to the ceramic push rods, and dark soot throughout the cabinet. The enclosure suffered some deformation.
The arc flash incident caused a sitewide 12kV voltage sag of 46.52% of nominal voltage for about 22 cycles. As a result the following impacts occurred:
- The Cryoplant (B905) receives power from circuits VV1 and VV2 and suffered an immediate loss of power. It took two days to restore power to the Cryoplant, interrupting its commissioning activities for the LCLS-II project.
- FACET-II commissioning and start-up was delayed until power to FACET II modulators was restored on September 25, 2020, allowing PPS certification activities to continue thereafter.
- The LCLS beam tripped due to low voltage. Power was restored by 8:00pm that evening, but resulted in a total of 5.3 hours of downtime for LCLS Photon Development programs (machine development) and 7.2 hours of downtime for LCLS users.
- SSRL/SPEAR3 beam tripped due to low voltage, but was restored by 9:11pm. Remaining injector performance issues were resolve the following day. This outage resulted in 6.8 hours lost to the Accelerator Physicsprogram. No users were running at the time of the outage or directly impacted by the incident.
- A variety of secondary and auxiliary infrastructure and science support equipment across the Laboratory tripped off-line due to low voltage.
</pre>
<h2 style="white-space:nowrap">Recommended Actions</h2>
<pre>A SLAC Field Construction Manager located in the vicinity of VVS-5 notified Security of an explosion at Sector 10, and requested EMT support. After assisting E1, E2 secured and locked the VVS-5 alcove, then called the Facilities Operations Center and the Accelerator Control Room to report the incident. Security EMTs responded to the site to provide immediate assistance to both E1 and E2. Security EMTs left the scene by 1:57pm.
The Main Gate notified the SLAC Duty Officer of the arc flash incident and the Electrical Safety Officer (ESO). The Duty Officer (who was off site due to COVID restrictions) remotely issued an initial incident notification email at 2:05pm and proceeded to the site to assist with post-event activities.
SLAC Facilities & Operations (F&O) electrical teams responded and isolated the circuits, stabilized power, locked out the VV1 and VV2 12kV circuits (that feed VVS-5) at the MasterSubstation and otherwise ensured the incident site was safe.
Due to COVID protocols, E1 and E2 were provided a medical assessment the next day via phone, rather than in person,.
A causal analysis investigation was issued a prohibition on energized operations of all VVS 12kV switches pending completion of the and implementation of corrective actions.
SLAC will review existing arc flash labels on all VVS 12kV switches to verify they are correct and will update any labels found to have errors prior to release of the prohibition on energized operations.
</pre>
<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre></pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">12/8/2020 2:55:18 PM by Bailey, Mary Jo</h5>
<pre>Submitted to those current in:
SAF603: Understand the basics of electrical safety
SAF603N: NFPA-70E BASIC ELECTRICAL SAFETY
SAF603N1: Understand the dangers from Arc Flash</pre>
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<legend>Summary</legend>
<table>
<tr class="row">
<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">1134</td>
</tr>
<tr class="row">
<td class="label" nowrap>Status:</td>
<td class="dataval">OK</td>
</tr>
<tr class="row">
<td class="label" nowrap>Doc ID:</td>
<td class="dataval">2020-JLAB-1134</td>
</tr>
<tr class="row">
<td class="label" nowrap>Priority:</td>
<td class="dataval">Caution</td>
</tr>
<tr class="row">
<td class="label" nowrap>Safety Related:</td>
<td class="dataval">YES</td>
</tr>
<tr class="row">
<td class="label" nowrap>Originator:</td>
<td class="dataval">Bailey, Mary Jo</td>
</tr>
<tr class="row">
<td class="label" nowrap>Issued:</td>
<td class="dataval">12/8/2020 2:51:58 PM</td>
</tr>
<tr class="row">
<td class="label" nowrap>Approved By:</td>
<td class="dataval">Bailey, Mary Jo</td>
</tr>
<tr class="row">
<td class="label" nowrap>Approved On:</td>
<td class="dataval">12/8/2020 2:55:18 PM</td>
</tr>
<tr class="row">
<td class="label">Source:</td>
<td class="dataval">
OTHER
</td>
</tr>
<tr class="row">
<td class="label" nowrap>Location:</td>
<td class="dataval">Other</td>
</tr>
<tr class="row">
<td class="label" nowrap>Cost Savings:</td>
<td class="dataval"></td>
</tr>
<tr class="row">
<td class="label" nowrap>Contact:</td>
<td class="dataval">Ralph R. Kerwin, (650) 926-2095 SLAC National Accelerator Laboratory</td>
</tr>
<tr class="row">
<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">482</td>
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<tr class="row">
<td class="label" nowrap>Sent Emails:</td>
<td class="dataval">0</td>
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<td class="label" nowrap>Viewings:</td>
<td class="dataval">1 times</td>
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<li>SAF603: Understand the basics of electrical safety</li>
<li>SAF603N: NFPA-70E BASIC ELECTRICAL SAFETY</li>
<li>SAF603N1: Understand the dangers from Arc Flash</li>
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