Introduction
Covol was recently approached by a major UK manufacturer operating within the chemical and process sector. The company manages a complex electrical network across its production sites, where safety, reliability, and system resilience are vital to day-to-day operations.
An earlier Arc Flash Assessment highlighted several switchboards and distribution panels with high levels of incident energy. In simple terms, if a fault were to occur, these boards could release dangerous amounts of energy, putting both personnel and equipment at risk.
The client needed to understand how best to reduce this risk in a way that was both practical and financially viable. That’s where Covol stepped in, to carry out a feasibility study aimed at exploring potential mitigation solutions before any investment was made.
The Challenge
When we reviewed the initial assessment data, it was clear that some of the site’s switchboards carried energy levels beyond the recommended safety limits. Installing new protection relays across such a large network, however, would be a significant investment.
Our role was to determine whether the investment of installing new protection relays could reduce the incident energy levels at the high incident energy switchboards to a safe and manageable level. The challenge lay in understanding exactly how much difference this would make, and whether it justified the cost and disruption of installation.
Our Approach
To help the client make an informed decision, our engineering team proposed a feasibility study to simulate the potential benefits of installing Terasaki protection relays at the client’s low-voltage high incident energy switchboards. Modern protection relays have more selectability regarding protection settings, which allows for faster operation during a fault whilst maintaining coordination with upstream protection relays. This significantly reduces the time an arc flash can occur and, as a result, the total incident energy released.
Using the site’s existing electrical model within SKM Power Tools, we updated the network to include the new protection relays. Our engineers then ran detailed simulations to test their impact on incident energy across the system.
This included:
- Analysing the fault current behaviour at key distribution points.
- Choosing protection setting that coordinate with upstream devices
- Comparing baseline results with simulated results using Terasaki’s protection relays.
- Identifying if the upgrades would bring the high incident energy switchboards to a manageable level.
Throughout this process, we worked closely with the client’s own electrical engineers, ensuring that every recommendation was backed by real data and could be implemented without unnecessary network changes.
The Findings
The study produced strong, measurable results. The updated electrical model showed a significant drop in incident energy across most of the boards previously flagged as high risk. In short, the proposed solution worked, delivering a major improvement in safety performance without requiring full-scale system replacement.
The outcome gave the client the confidence to move forward with a focused installation plan, targeting only the boards where the new protection relays made the desired impact of bringing the high incident energy switchboards to a safe and manageable level. This balanced approach provided both cost efficiency and enhanced protection for operators.
Results at a Glance
- Safer Operations: Verified reductions in arc flash energy at critical boards.
- Cost-Effective Solution: Focused investment in the areas that mattered most.
- Technical Confidence: Decisions backed by clear data and simulation results.
- Collaborative Process: Smooth coordination between Covol engineers and site teams.
Conclusion
This feasibility study is a great example of how data-led engineering can guide smart decision-making. Instead of committing to a full network upgrade, the client gained clarity, confidence, and a safer working environment, all based on accurate modelling and expert analysis.
At Covol, we believe electrical safety isn’t just about compliance; it’s about understanding how systems behave under real-world conditions and helping clients make informed choices.
Our engineers continue to support industrial and manufacturing clients with Arc Flash Assessments, Protection Coordination Studies, and Electrical Design Reviews, always focused on safety, performance, and long-term value.
Get in touch with our expert team to learn more about how we can help you. Or why not sign up for our upcoming Arc Flash and Protection Coordination webinar?
