Safe-T-Rack Arc Flash Dangers And Remote Racking Systems for Power Circuit Breakers

1. Safe-T-Rack Arc Flash Dangers And Remote Racking Systems for Power Circuit Breakers www.Safe-T-Rack.com

2. Remote Solutions LLC Who we are: • Manufacturer solely dedicated to design and manufacturing leading edge C/B racking systems and products. • Remote racking and switchgear application experts What we make: • Fully automated remote racking systems (SRH & SRN). • Remote breaker operation devices • Accessories

3. Remote Solutions – Why Are We Different?4 Major Reasons Alignment Philosophy - Use the switchgear as a reference and align only once. “Human Proof” - Establish a “chain of rejection” to prevent human error. Ease of Use & Switchgear Damage Prevention - Create elements that make operators want to use the system and prevent damage to switchgear as a result of using remote racking equipment. Maximum Portability & Scalable Platform

4. Electrical Incident Statistics1 • Electrical incidents rank sixth among all cause of work related deaths in the US • Average of 4,000 non-disabling and 3,600 disabling electrical contact injuries annually in the US. • One person is electrocuted in the workplace every day. • Over 20,000 workers are sent to burn centers each year with electrical related burn injuries • An Arc Flash Blast occurs 5-10 times each day in the US. 1EC&M Magazine - Preventing Arc Flash Incidents in the Workplace

5. 5 Changes of State • Racking a breaker onto primary stabs • Racking a breaker off of primary stabs • Breaker charging • Closing a circuit breaker • Opening a circuit breaker

6. Failure Facts • An arc flash incident is always the result of at least one of the five change of states. • OEMs did not generally design switchgear to allow for survivability of human operators when performing switchgear related tasks. • Regulations and standards are typically developed as a result of tragic incidents and are often written in blood.

7. Regulations and Standards • OSHA 29 CFR 1910 – OSHA is the enforcer – Now recognized arc-flash as a work place hazard • NFPA 70E – 2009 – The “how to” standard. Provides guidance on specific steps that must be taken to comply with the more general OSHA standards. This regulation specified that arc-flash study must be completed by Jan. 1, 2009 • Other significant design codes and standards: • IEEE 1584 – Provides steps required to perform calculation of incident energy from which decisions about appropriate PPE are made. Takes into account the role of the over current protective device. • ANSI/NFPA 70-2002 • National Electric Code • NESC

8. Sound 142db @ 2 feet. Sound of a Jet Engine at 30 meters Eardrum rupture: ~720 lbs./ft2 Skin Temp Face & Hands >437°F Skin temp under shirt 122°F Pressure on chest, >2160 lbs./ft2 Lung Damage: ~1728-2160 lbs./ft2 Forces at Work

9. Arc Flash Event

10. Recommended Requirements for Remote Racking Systems • System Must • Have ability to increase operator distance • Rack breaker in and out of a cubicle • Integrate PI management • System Must • Be a true closed door design when possible • Limit equipment damage due to excessive mechanical racking forces

11. Recommended Requirements for Remote Racking Systems Cont’ • System Must • Be easy to operate and account for the “Human Factor”. • Be modular and portable. • Be adaptive to old and new breaker designs. • System Must • Not modify original breaker controls or wiring. • Give positive indication of breaker status and position. • Standardize the way a breaker is racked • Monitor tilt angle of vertically racked breakers

12. SRN and SRH Product Line Overview SRN Vertical Lift Racking System SRH Horizontal Racking System SR/SRN SRH SR, SRN, SRH Accessories P2 – Universal Training and Installation Exit/Continue

13. SRN Product Line Overview SR/SR-N Vertical Lift Racking System • This product is a remote racking design made specifically for GE Magneblastmedium voltage vertical lift circuit breakers • Patented LimiTilt ® design minimizes tilted breaker related equipment damage • Systems control and protection eliminates costly racking motor failure. • Does not modify original controls. • Backward compatible with original design motor. • Universal application for M26/ M36 breakers.

14. GE Vertical Lift M26 / M36 Original Design • Slide clutch manual engagement • Slide clutch manual hold-to-use • Slide clutch manual disengagement STR ® Design • One piece construction • Positively coupled manual engagement • Automatic lock and hold • Remotely operated clutch release

15. GE Vertical Lift M26 / M36 Original Design • Elevating motor receptacle and power source • Raise & lower limit switches STR ® Design • J Box taps power source & provides new motor receptacle • J Box taps directly into limit switch circuits and eliminates control wire modifications

16. GE Vertical Lift M26 / M36 Original Design • Elevating motor controlled by clutch lever limit switch & raise/lower limits • Elevating motor direction controlled by toggle switch • Motor circuit fuse protection STR ® Design • Motor controlled by 20 amp, DC3 rated, electrical & mechanical interlocked, reversing contactor • Motor direction with switching time delay provided by control box • Control box has adjustable motor jam, thermal overload, short circuit protection and discrete control circuit fuses

17. GE Vertical Lift M26 / M36 Original Design • Relies on human operator to monitor for adverse breaker operation. STR ® Design • Monitors tilt angles of breaker-in-motion • Limits extent of tilted breaker related damage

18. GE Vertical Lift M26 / M36 Original Design • Elevating motor controlled by operating personnel at the breaker • Racked-in breaker operating mechanism charges upon release of slide clutch lever • Circuit breaker open & close SB control switch located on compartment door STR ® Design • Operating personnel remotely control motor by a full function pendant • Operator pendant controller remotely releases slide clutch allowing the breaker to charge • Optional pendant controller can remotely open & close the circuit breaker

19. GE Vertical Lift M26 / M36 Original Design • Elevating motor RPM of 400 or 600 depending on breaker size/weight • Motor approximately ½ HP rated • Motor mounted direction selector (toggle switch) not rated to start or stop the elevating motor STR ® Design • Local and remote elevating motors are 450 RPM for use with all size/weight breakers helps to limit coasting. • Local and remote elevating motors are 1.1 HP rated • Local motor equipped with hesitation toggle switch prevents accidental reverse plugging and is rated to start and stop motor

20. GE Vertical Lift M26 / M36 Original Compartment With STR ® SRN Cubicle Kit

22. SRN and SRH Product Line Overview SRN Vertical Lift Racking System SRH Horizontal Racking System SR/SRN SRH SR, SRN, SRH Accessories P2 – Universal Training and Installation Exit/Continue

23. SR-H Product Overview • PLC-based universal system controller • Racks both low-voltage and medium voltage breakers • Fully portablesystem • True closed-door racking system where possible • Reduces operator induced equipment wear

24. SR-H Universal Horizontal Racking System System Controller Features • Controller operates with any SRH tool through an innovative HMI touch screen interface. • Battery backup provides failsafe racking in the event of an input power failure. • Selectable automatic breaker travel, SABT ™ • Emergency stop at any time during racking. • Flexible architecture allows for expansion to any breaker type.

25. SR-H Drive Motor and Transmission Tool Features • Drive Motor • Heavy duty 1.1HP motor that allows for continuous duty without compromising performance. • Quick-connect stainless steel bayonet coupling with thumb-lock for easy transmission changes. • Transmission Tools • No-tools-required interchangeable transmissions • Smart transmission identifies itself so controller can load the appropriate racking parameters • Torque-limited output dependant on breaker type prevents racking hardware damage due to applying too much torque • Digital encoder confirms linear travel and zero-speed output

26. SR-H Drive Mounting Brackets • SRH system can be used with a wide variety of different circuit breakers through the use of different portable door-mounted cubicle adaptor plates. • Various cubicle adaptor plate designs with disparate features including positive interlock actuating mechanisms, gimbal-mounted transmission collars, positioning guides and insertion locks • Portable drive mounting brackets incorporates breaker interlock automation where applicable.

27. SR-H ABB K-Line Drive Mounting Brackets • These are the mounting brackets for the K-Line Safe-T-Rack system. • The thrusting transmission connects to these brackets in order for the system to engage the K-Line horizontal racking mechanism. K600 – K2000 K3000 – K 4000

28. SR-H Racking Software • SRH racking software is configured for each specific switchgear manufacturer’s breaker types and can be field upgraded through an Ethernet port for additional breaker types.

29. SR-H Software Features

30. SR-H Software Features

31. SR-H Software Features

32. SR-H Software Features

33. SR-H Software Features

35. SRN and SRH Product Line Overview SRN Vertical Lift Racking System SRH Horizontal Racking System SR/SRN SRH SR, SRN, SRH Accessories P2 – Universal Training and Installation Exit/Continue

36. Accessories SR & SRN SR-H

37. Original Design Local Motor Elevating motor RPM of 400 or 600 depending on breaker size/weight Motor approximately ½ HP rated Motor mounted direction selector (toggle switch) not rated to start or stop the elevating motor STR ® Design Local and remote elevating motors are 450 RPM for use with all size/weight breakers helps to limit coasting. Local and remote elevating motors are 1.1 HP rated Local motor equipped with hesitation toggle switch prevents accidental reverse plugging and is rated to start and stop motor GE M26 / M36 – LOCAL MOTOR

38. TIMING TESTER • Circuit Breaker Contact Timing tester. • Used for quick validation of breaker operating times. • Single Operating Dial and simple user interface.

39. INSTALLATION TOOL KIT • For SR / SRN Cubicle Kit Installations - • Includes ISO 20 and ISO 40 slug Buster punches. • Necessary Drill Bits and installation adjustment tools.

40. INSTALLTION TOOLS • SRN Voltage Tester – • Used in SRN installations to verify: • AC or DC Voltage • Voltage level • Correct Pin Configuration

41. CONTROL PANEL MOUNTING BRACKET • Used to mount SR and SRN Control panels to Cubicle end sections or walls. • Includes necessary unistrut fittings and hardware to mount a control panel and cable storage hanger.

42. SR / SRN CABLE HANGER • SR/ SRNN Cable Hanger mounts below the SRN controller, or on a wall for SR applications. • Rated to hold both the SRN control and SRN Pendant Cables.

43. CUBICLE REPAIR KIT • GE M26/M36 cubicle repair hardware kit includes; • Replacement Limit Switches, Clutch Return Springs, Drive Chain and slide clutch.

44. GE M26/M36 GEN 3 TO GEN 4 CONVERSION KIT • All hardware, wiring and instructions necessary to convert a M26/M36 Generation 3 cubicle to a Generation 4 cubicle

45. GE M26/M36 GEN 2 TO GEN 4 CONVERSION KIT • All hardware, wiring and instructions necessary to convert a M26/M36 Generation 2 cubicle to a Generation 4 cubicle. • This kit includes a replacement motor platform assembly.

46. SR-N REMOTE TO LOCAL JUMPER • Designed specifically for the Nuclear Industry to quickly convert the SRN remote racking system to a configuration that use the original OEM local motor.

47. SR / SRN Portable and Cubicle Kits

48. Accessories SR-H EXIT/CONTINUE

49. SRN and SRH Product Line Overview SRN Vertical Lift Racking System SRH Horizontal Racking System SR/SRN SRH SR, SRN, SRH Accessories P2 – Universal Training and Installation Exit/Continue

50. SR-H Installation Templates • SRH Install templates • Used to ensure correct alignment of the SR-H transmission drive shaft on the cubicle door. • Required for all SR-H installations.