NFPA and its

Implications on
Electrical Inspections

Presented by:
Martin Robinson
CEO
IRISS, Inc.

Incident Pyramid
1
10

Fatality

Disabling Injuries

100
1 000
10 000
100 000
Commonly used update to the Safety Pyramid: W.H. Heinrich, 1931

Recordable Injuries

1st Aid Cases

Near-miss Incidents

Hazardous Tasks

Arc Flash Pyramid

1

Fatality
Incurable Burns Over of Body

20

Burn Injuries

Arc Flash Incidents

85

Data derived from research by CapSchell, Inc.

Arc Flash Incident Pyramid

1

10
100
1 000
10 000
100 000

Comparison

Fatality
Disabling Injuries

1
6

Recordable Injuries
1st Aid Cases
Near-Miss Incidents

20

85

Hazardous Tasks

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
Worlds 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

NFPA 70B
Recommended Practice for Electrical Equipment Maintenance

Committee established 1968

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

2006 Edition
Enhanced Focus on Safety
Importance of Baseline Performance Data
How to Apply RCM (Reliability Centered Maintenance)

NFPA 70B
Recommended Practice for Electrical Equipment Maintenance

2010 Edition
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)

Chapter 4:
Why an Effective Electrical Preventive Maintenance
(EPM) Program Pays Dividends

Dependability can be engineered and built

into equipment, but effective maintenance is
required to keep it dependable.

Chapter 11: (previously Chapter 21)

Testing and Test Methods

Infrared inspections of electrical systems are beneficial

to reduce the number of costly and catastrophic
equipment failures and unscheduled plant shutdowns.
(Infrared inspections) can reduce typical visual
examinations and tedious manual inspections and
are especially effective in long-range detection
situations.

Chapter 11:
Testing and Test Methods

Inspection Cycles
Up to Quarterly where warranted by
Loss Experience
New Installation
Environmental Changes
Changes in operational or Load Conditions

Chapter 11:
Calls for Maximum Possible Loading

Open For Direct View of Components

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

NFPA 70E Standard for

Electrical Safety in the
Workplace

NFPA 70E
Standard For Electrical Safety in the
Workplace

Committee Established 1976

To assist OSHA in developing electrical
safety standards

2007 OSHA stated that it will:

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

NFPA 70E
Fundamental Principal Upon Which 70E and
OSHA are Based

Control Risk Wherever Practical:

Eliminate the Hazard

Reduce the Risk by Design
Apply Safeguards
Implement Administrative Controls
Use PPE

When is 70E Applicable?

Workers Exposed to Energized Electrical
Conductors or Circuit Parts
Risk-Increasing Behavior
Reason to Believe that Equipment Could
Experience a Sudden Change in State

Exposed

RiskIncreasing

Hazard
/Risk

NFPA 70E
Removal of Bolted Covers

Yes

Yes

Opening Hinged Covers

Yes

Yes

CB Operation with Enclosure Doors Open

Yes

Yes

CB Operation with Enclosure Doors Closed

No

Yes

Performing Thermography Outside the Restricted Area

Yes

No

Reading a Panel Meter While Operating a Meter Switch

No

No

Metal Clad Switchgear 1 kV to 38 kV

NFPA 70E
Hazard/Risk
Category

Min. Arc
Rating

Clothing Description

Non-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

Arc-rated FR shirt & FR pants or FR coverall

4 cal/cm2

Arc-rated FR shirt & FR pants or FR coverall

8 cal/cm2

Arc-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

Arc-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

n/a

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)
Panel Removal

Suit up for Live Works

30 minutes

30 Minutes

2 x Electricians
1 x RCM Engineer

2 x Electricians

Move to Next Panel

Time For Live Inspection

1 hour 6 minutes
(excludes PPE Suit-up Time)

Infrared Scan
10 Minutes
1 x RCM Engineer

Panel Refit
30 minutes

All

2 x Electricians

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)

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 =

Operation

Total

$200.00

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

Cost Analysis of Energized RCM Survey Using IR Windows

Operation

Man Hours

Total Man Hours

Rate ($/hr)

RCM Engineer PPE Suit-up

$150

$0

Electrician PPE Suit-up

$125

$0

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

Operation

Total

$00.0

Man Hours

Total Man Hours

Rate ($/hr)

Cover Removal

$125

$0

RCM Inspection

0.15

0.5

$150

$22.50

Cover Replacement

$125

$0

RCM Engineer Waiting Time

$150

$0

Electrician Waiting Time

$125

$0

Manpower Costs Per Inspection of 1 Electrical Panel =

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

Year 1 Manpower Costs Per Inspection of 1 Electrical Panel =

Total

$22.50
190.00

$212.50

5 Year Cost Benefit Analysis

Period

Cumulative Cost Without

IR Windows

Cumulative Cost Using

IR Windows

$ Savings Per
Inspection

Total %
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%

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

Cost Analysis For Paper Mill

Scenario:
Paper Mill X currently have 150 pieces of primary switchgear
that they inspect annually (due to intrusive nature of the
inspection).

The RCM inspections (Ultrasound and Infrared) are currently

completed ENERGISED in line with the requirements of NFPA70E
& 70B. (full PPE and Strict guidelines on how inspections are
completed)
Inspection is completed by 2 Plant Electricians ( required for panel
removal) 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

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

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

Cost Analysis of Energized RCM Survey Using IR Windows

Operation

Man Hours

Total Man Hours Rate ($/hr)

Total

RCM Engineer PPE Suit-up

$150

$0

Electrician PPE Suit-up

$125

$0

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

Operation

Man Hours

Total Man Hours Rate ($/hr)

$0
Total

Cover Removal

$125

$0

RCM Inspection

15.0

15.0

$150

$2,250.00

Cover Replacement

$125

$0

RCM Engineer Waiting Time

$150

$0

Electrician Waiting Time

$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

5 Year Cost benefit: Cost Analysis

Period

Cumulative Cost Without

IR Windows

Cumulative Cost Using

IR Windows

$ Savings Per
Inspection

Total %
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%

Example shows a saving of $332,350.00 over a 5

year period (89%) for 150 cable compartments
in a Medium Voltage Electrical Panels

Increased Inspection Frequency Analysis

5 Year Cost 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%

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.

Working with Infrared Windows Installed

Working with Ultrasound Ports Installed

Working with U/Sound Ports and IR Windows

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

Companies Looking To Improve Profitability, Uptime And Safety Should

Study The Recommendations In The NFPA 70B Standard For Electrical
Preventive Maintenance.
It Is Significant That The Standards Value Infrared Inspections As A Critical
Part Of An EPM Program.
Infrared Inspection Windows Provide A Way For The Companies To Comply
With The Recommendations For Inspection Processes.

NFPA And OSHA Agree That Electrical Equipment Should Not Be Opened
Unless It Is De-energized.
Infrared Inspection Windows Will Help Companies To Comply With
Standards.

Visit www.iriss.com and

download your free copy of:

10 Things you Need to Know

About Infrared Windows

Questions??