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
• 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
• 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
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)
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%
• 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”