NFPA and its

Implications on

Electrical Inspections

Presented by:Martin Robinson

CEO

IRISS, Inc.

Incident Pyramid

Fatality

Disabling Injuries

Recordable Injuries

1st Aid Cases

Near-miss Incidents

Hazardous Tasks

1

100 000

10

100

1 000

10 000

Commonly used update to the Safety Pyramid: W.H. Heinrich, 1931

Arc Flash Pyramid

Data derived from research by CapSchell, Inc.

Fatality

Incurable Burns Over ½ of Body

Arc Flash Incidents

1

6

20

85

Burn Injuries

Arc Flash Incident Pyramid

Fatality

Disabling Injuries

Recordable Injuries

1st Aid Cases

Near-Miss Incidents

Hazardous Tasks

1

100 000

10

100

1 000

10 000

1

6

20

85

Comparison General EHS Arc Flash

Near-Miss : Fatality 10 000 : 1 85 : 1

Near Miss : Disabling Injury 10 000 : 1 85 : 6

Injury : Fatality 1 000 : 1 20 : 1

Established 1896

World’s Leading Advocate Of Fire Prevention

Over 300 Codes And Standards

Worldwide Influence

Expert Consensus To Create Standards

NEC (NFPA 70) National Electric Code

NFPA 70B Recommended Practice For Electrical Equipment Maintenance

NFPA 70E Standard For Electrical Safety In The Workplace

National Electric Code (NEC)

NFPA 70

Established 1897 by efforts of Insurance, Architectural, Electrical and allied interests

Electrical Design, Installation & Inspection

NOT to address Maintenance or Workplace Safety

NFPA 70B Recommended Practice for Electrical

Equipment Maintenance

• Recommended Practice for Electrical Equipment Maintenance

NFPA 70B

• To address “preventative maintenance of electrical systems and equipment used in industrial-type applications with the view of reducing loss of life and property.”

Committee established 1968

• Enhanced Focus on Safety

• Importance of Baseline Performance Data

• How to Apply RCM (Reliability Centered Maintenance)

2006 Edition

• Recommended Practice for Electrical Equipment Maintenance

NFPA 70B

• Reorganization of document, including grouping of related topics plus consolidation of testing information

• New material on emergency preparedness and electrical system and equipment restoration

• New recommendations on how to conduct outsourcing of electrical equipment maintenance

• New information on failure modes effects and criticality analysis (FMECA)

2010 Edition

• Why an Effective Electrical Preventive Maintenance (EPM) Program Pays Dividends

Chapter 4:

“Dependability can be engineered and built into equipment, but effective maintenance is

required to keep it dependable.”

• Testing and Test Methods

Chapter 11: (previously Chapter 21)

• “(Infrared inspections) can reduce typical visual examinations and tedious manual inspections and are especially effective in long-range detection situations.”

“Infrared inspections of electrical systems are beneficial to reduce the number of costly and catastrophic equipment failures and unscheduled plant shutdowns.”

• Testing and Test Methods

Chapter 11:

• Up to Quarterly where warranted by

• Loss Experience

• New Installation

• Environmental Changes

• Changes in operational or Load Conditions

Inspection Cycles

• Calls for “Maximum Possible Loading”

Chapter 11:

• But 70B, 70E and OSHA 1910 all call for an electrically safe work condition whenever possible

Open For Direct View of Components

NFPA 70E Standard for Electrical Safety in the

Workplace

• Standard For Electrical Safety in the Workplace

NFPA 70E

• To assist OSHA in developing electrical safety standards

Committee Established 1976

• “Draw heavily from Aspects of 70E and NEC in a rare revision of 1910.303 Subpart S”

2007 OSHA stated that it will:

• Fundamental Principal Upon Which 70E and OSHA are Based

NFPA 70E

• Eliminate the Hazard

• Reduce the Risk by Design

• Apply Safeguards

• Implement Administrative Controls

• Use PPE

Control Risk Wherever Practical:

• Workers Exposed to Energized Electrical Conductors or Circuit Parts

• Risk-Increasing Behavior

• Reason to Believe that Equipment Could Experience a Sudden Change in State

When is 70E Applicable?

NFPA 70E

Metal Clad Switchgear 1 kV to 38 kV

Exp

ose

d

Ris

k-In

cre

asin

g

Haz

ard

/R

isk

Removal of Bolted Covers Yes Yes 4

Opening Hinged Covers Yes Yes 3

CB Operation with Enclosure Doors Open Yes Yes 4

CB Operation with Enclosure Doors Closed No Yes 2

Performing Thermography Outside the Restricted Area Yes No 3

Reading a Panel Meter While Operating a Meter Switch No No 0

NFPA 70EHazard/Risk

Category Clothing DescriptionMin. Arc Rating

0Non-melting, flammable materials (i.e., untreated cotton, wool, rayon, or silk, or blends of these materials) with fabric weight of less than 4.5 oz/yd2

n/a

1 Arc-rated FR shirt & FR pants or FR coverall 4 cal/cm2

2 Arc-rated FR shirt & FR pants or FR coverall 8 cal/cm2

3Arc-rated FR shirt & pants or FR coverall, and arc flash suit selected so that the system arc rating meets the required minimum

25 cal/cm2

4Arc-rated FR shirt & pants or FR coverall, and arc flash suit selected so that the system arc rating meets the required minimum

40 cal/cm2

Table 130.7(C)(11)

“The collective experience of the task group is that in most cases closed doors do not provide enough protection to eliminate the need for PPE for instances where the state of the equipment is known to readily change (e.g., doors open or closed, rack in or rack out).”

- 70E: 130.7(C)(9) FPN No. 2

IR Window and Ultrasound Port Cost

Benefit Analysis

Electrical Panel Removal Man-hours• 3 Man Live Electrical RCM Team consists of:

– 2 x Electrical Engineers:

– 2 x Electricians for panel removal

– 1 x RCM Engineer (Contracted)

Suit up for Live Works

30 Minutes

•2 x Electricians

•1 x RCM Engineer

Panel Removal

30 minutes

•2 x Electricians

Infrared Scan

10 Minutes

•1 x RCM Engineer

Panel Refit

30 minutes

•2 x Electricians

Move to Next Panel

•All

Time For Live Inspection 1 hour 6 minutes

(excludes PPE Suit-up Time)

NFPA 70E

Example of Category 3 or 4 PPE

Cost Analysis of Energized RCM Survey Removing Panels

Operation Man Hours Total Man Hours Rate ($/hr) Total

Cover Removal 0.5 1.0 $125 $125.00

RCM Inspection 0.1 0.1 $150 $15.00

Cover Replacement 0.5 1.0 $125 $125.00

RCM Engineer Waiting Time 1.0 1.0 $150 $150.00

Electrician Waiting Time 0.1 .2 $125 $25.00

Manpower Costs Per Inspection of 1 Electrical Panel = $450.00

Total Manpower Costs Per Inspection of 1 Electrical Panel = $650.00

Operation Man Hours Total Man Hours Rate ($/hr) Total

RCM Engineer PPE Suit-up 0.5 0.5 $150 $75.00

Electrician PPE Suit-up 0.5 1.0 $125 $125.00

Manpower Costs Per PPE Suit-up As Per NFPA 70E = $200.00

Cost Analysis of Energized RCM Survey Using IR Windows

Operation Man Hours Total Man Hours Rate ($/hr) Total

Cover Removal 0 0 $125 $0

RCM Inspection 0.15 0.5 $150 $22.50

Cover Replacement 0 0 $125 $0

RCM Engineer Waiting Time 0 0 $150 $0

Electrician Waiting Time 0 0 $125 $0

Manpower Costs Per Inspection of 1 Electrical Panel = $22.50

Cost of IRISS VPFR 75 (3 inch diameter) Infrared Inspection Window 190.00

Year 1 Manpower Costs Per Inspection of 1 Electrical Panel = $212.50

Operation Man Hours Total Man Hours Rate ($/hr) Total

RCM Engineer PPE Suit-up 0 0 $150 $0

Electrician PPE Suit-up 0 0 $125 $0

Manpower Costs Per PPE Suit-up As Per NFPA 70E = $00.0

5 Year Cost Benefit Analysis

Example shows a saving of nearly $3,000.00 over a 5 year period (91%) for 1 cable compartment in

a Medium Voltage Electrical Panel

PeriodCumulative Cost Without

IR WindowsCumulative Cost Using

IR Windows$ Savings Per

InspectionTotal % Saving

Year 1 $650.00 $212.50 $437.50 67%

Year 2 $1,300.00 $235.00 $1,065.00 82%

Year 3 $1,950.00 $257.50 $1,692.50 87%

Year 4 $2,600.00 $280.00 $2,320.00 89%

Year 5 $3,250.00 $302.50 $2,947.50 91%

Cost Analysis For Paper Mill

Scenario:

Paper Mill “X” currently have 150 pieces of primary switchgearthat they inspect annually (due to intrusive nature of theinspection).

The RCM inspections (Ultrasound and Infrared) are currentlycompleted “ENERGISED” in line with the requirements of NFPA70E& 70B. (full PPE and Strict guidelines on how inspections arecompleted)

Inspection is completed by 2 Plant Electricians ( required for panelremoval) and 1 Contract RCM Engineer.

Inspections currently take approximately 150 hrs (3 weeks)

Cost Analysis of Energized RCM Survey Removing Panels

Operation Man Hours Total Man Hours Rate ($/hr) Total

Cover Removal 0.5 150.0 $125 $18,750.00

RCM Inspection 0.1 15.0 $150 $2,250.00

Cover Replacement 0.5 150.0 $125 $18,750.00

RCM Engineer Waiting Time 1.0 150.0 $150 $22,500.00

Electrician Waiting Time 0.1 30.0 $125 $3,750.00

Manpower Costs of 150 Electrical Panels = $66,000.00

Total Manpower Costs Per Inspection of 1 Electrical Panel = $74,400.00

Operation Man Hours Total Man Hours Rate ($/hr) Total

RCM Engineer PPE Suit-up 0.5 0.5 $150 $75.00

Electrician PPE Suit-up 0.5 1.0 $125 $125.00

Manpower Costs Per PPE Suit-up As Per NFPA 70E = $200.00

21 Days, 2 suit-ups per day (42 total dress-outs = 63.0 hrs) $8,400.00

Cost Analysis of Energized RCM Survey Using IR Windows

Operation Man Hours Total Man Hours Rate ($/hr) Total

Cover Removal 0 0 $125 $0

RCM Inspection 15.0 15.0 $150 $2,250.00

Cover Replacement 0 0 $125 $0

RCM Engineer Waiting Time 0 0 $150 $0

Electrician Waiting Time 0 0 $125 $0

Manpower Costs Per Inspection of 1 Electrical Panel = $2,250.00

Cost of IRISS VPFR 75 IR Windows and VP12 Ultrasound Ports = $28,500.00

Year 1 Manpower Costs Per Inspection of 1 Electrical Panel = $30,750.00

Operation Man Hours Total Man Hours Rate ($/hr) Total

RCM Engineer PPE Suit-up 0 0 $150 $0

Electrician PPE Suit-up 0 0 $125 $0

Manpower Costs Per PPE Suit-up As Per NFPA 70E = $0

Example shows a saving of $332,350.00 over a 5 year period (89%) for 150 cable compartments

in a Medium Voltage Electrical Panels

5 Year Cost benefit: Cost Analysis

PeriodCumulative Cost Without

IR WindowsCumulative Cost Using

IR Windows$ Savings Per

InspectionTotal % Saving

Year 1 $74,400.00 $30,750.00 $43,650.00 59%

Year 2 $148,800.00 $33,000.00 $115,800.00 78%

Year 3 $223,200.00 $35,250.00 $187,950.00 84%

Year 4 $297,600.00 $37,500.00 $260,100.00 87%

Year 5 $372,000.00 $39,750.00 $332,350.00 89%

5 Year Cost Analysis:

Using Ultrasound Ports and IR windows allows you to increase your inspection frequency by a factor of 4 and the 5 year program cost is less than

the original Annual “Energized” inspection methodologies.

Increased Inspection Frequency Analysis

Inspection Frequency

Cumulative Cost Using IR Windows

$ Cumulative Savings

Total % Saving

Annual $39,750.00 $332,350.00 89%

6 Monthly $51,000.00 $321,100.00 86%

4 Monthly $62,250.00 $309,850.00 83%

3 Monthly $73,500.00 $298,600.00 80%

Working with Infrared Windows Installed

Working with Ultrasound Ports Installed

• Remove High-Risk Behavior

• Maintain Enclosed & Guarded Condition

• Fully Loaded Inspections

• Access to Un-Inspectable Gear

• Efficient Surveys

• Control Risk to Personnel, Plant & Processes

• Eliminate >99% of Arc Triggers During Inspection

Working with U/Sound Ports and IR Windows

Infrared Inspection Windows Will Help Companies To Comply With Standards.

NFPA And OSHA Agree That Electrical Equipment Should Not Be Opened Unless It Is De-energized.

Infrared Inspection Windows Provide A Way For The Companies To Comply With The Recommendations For Inspection Processes.

It Is Significant That The Standards Value Infrared Inspections As A Critical Part Of An EPM Program.

Companies Looking To Improve Profitability, Uptime And Safety Should Study The Recommendations In The NFPA 70B Standard For Electrical

Preventive Maintenance.

Visit www.iriss.com and download your free copy of:

“10 Things you Need to Know About Infrared Windows”

Questions??