In high-energy environments like Oil & Gas facilities, electrical safety can never be an afterthought. Yet, many plants operate for years without a proper Arc Flash Analysis, putting both assets and personnel at serious risk.

This case study walks you through a realistic scenario in a crude oil processing plant, where our team at Elegrow Technology identified and mitigated a hidden arc flash hazard before an accident could occur.

The Site: Crude Oil Processing Unit, Western India

• Installed Load: 6.5 MW
• Voltage Levels: 33 kV / 11 kV / 415 V
• Power Sources: Dual 33 kV grid supply + 2 MVA standby diesel gensets
• Key Areas Studied: MCC panels, switchrooms, motor feeders, and field panels
• Problem Statement: Safety audit triggered after a minor arc flash incident during maintenance

Initial Observations

Upon arrival, our team noted:

• No arc flash labeling on panels
• Protection relays had generic settings – not optimized for clearing time
• No available documentation on incident energy or PPE categorization
• Operators used standard flame-resistant overalls, unaware of actual risk levels
• MCCs were being accessed live during testing and calibration

Incident Energy Calculations – Key Findings

Using IEEE 1584–2018 methodology and field data, we simulated arc flash scenarios across critical panels.

Example Results from One LT Panel:

Note: At 10.8 cal/cm², a person standing in front of the panel without proper PPE could suffer second-degree burns in under one second.

What We Did: Corrective Measures & Optimization

Our solution was built around both safety and system performance.

1. Relay Setting Review:
   Optimized instantaneous and short-time settings to reduce clearing time from 580 ms → 180 ms.
2. Panel Categorization:
   Grouped panels into PPE zones and calculated incident energy for each—ranging from <1.2 to >8 cal/cm².
3. Arc Flash Labels:
   Installed custom warning labels with energy levels, approach boundaries, and PPE class.
4. Training & SOPs:
   Conducted workshops with maintenance teams on arc-rated PPE, safe approach distances, and risk zones.
5. Preventive Maintenance:
   Recommended thermography and breaker servicing cycles based on criticality index.

Impact of Changes – Before vs After

Lessons for the Industry

• Arc flash isn’t just a compliance formality – it’s a life-critical analysis.
• Even new systems can carry hidden arc flash hazards due to delayed breaker response, coordination gaps, or high available fault currents.
• Proper arc flash labeling and PPE zoning not only protect lives but also help in passing client audits and insurance compliance.

How Elegrow Can Help

We specialize in Arc Flash Analysis, Protection Coordination, and Electrical Safety Audits for high-risk industries like Oil & Gas, Petrochemicals, Pharma, and Steel.

Using IEEE 1584, ETAP/DIgSILENT tools, and on-site data collection, we deliver practical, actionable reports that enhance system safety without disrupting operations.

📩 Need a review of your plant’s arc flash risk?

Book a technical free call – email at info@elegrow.com