Objective
To assess arc flash hazards across the electrical distribution network at the Denso India Private Limited manufacturing facility in Chennai, and to provide mitigation measures in compliance with IEEE 1584-2018 and NFPA 70E-2024 standards.
Scope of Work
- Developed a detailed ETAP 22.5 simulation model for the 11 kV and 415 V distribution system.
- Conducted arc flash hazard analysis at LV and MV switchboards.
- Calculated maximum incident energy levels, arc flash boundaries, and fault clearing times.
- Recommended PPE categories based on NFPA 70E-2024.
- Delivered hazard categorization with digital arc flash warning labels.
Key Findings
- Incident energy levels varied significantly with working distance, underlining the need for defined approach boundaries.
- Panels such as BBT-2and ACCP-2 recorded incident energy above 8 cal/cm², requiring Category 3 PPE.
- Fault current analysis highlighted the need to optimize relay settings to reduce clearing times and minimize hazard exposure.
Outcome
The study enabled Denso India to:
- Identify critical high-risk switchboards and prioritize mitigation actions.
- Achieve compliance with IEEE 1584-2018, IEEE 1584.1-2022, and NFPA 70E-2024.
- Strengthen personnel safety through proper PPE selection and boundary labeling.
- Enhance reliability by refining protection coordination and minimizing downtime risks.
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