NFPA 70B and the Importance

of Electrical Predictive
Maintenance

PRESENTED BY
Bhanu Srilla
Director  of  Product  Marke0ng  
Grace  Engineered  Products,  Inc.  
Learning Objectives

1.  Review NFPA 70B Maintenance Requirements

2.  Identify various failure points in electrical systems

3.  Observe temperature monitoring in critical applications

4.  Compare IR inspections vs. continuous monitoring

Downtime Costs by Industry Sector

§  Average    Revenue  Loss:  ~$1.0  Million/Hour  

§  Predic0ve  Maintenance  can  o>en  be  the  
lower-­‐cost  op0on  
§  Predic0ve  Maintenance  o>en  results  in  
longer  intervals  between  maintenance  
Fires triggered due to Electrical
faults/malfunction

§  Non-­‐Home  structures  involving  electrical  equipment  malfunc0on  or  failure  

§  ~37%  of  the  accidents  between  midnight-­‐  8  AM  
§  March  and  November  months  
Fires involving Lighting and Power
Distribution Equipment

5
Key Drivers for Electrical Maintenance
Programs

§  Regulatory    

§  Safety    
§  Cost  Management  

§  Service  Con0nuity  

 OSHA & NFPA

§  29  CFR  1926.431,  Subpart:  K  –  NFPA  70B  

§  29  CFR  1926.331  –  335,  Subpart:  S  -­‐  NFPA  

70E  

§  OSHA  training  requirements  have  

maintenance  component  

§  OSHA  defers  to  manufacturers  required  

maintenance  schedules  
 NFPA 70B: “Personnel Safety”

§  Personnel  safety  is  very  important  when  performing  maintenance  

§  7.1.3.1  Some  of  the  considera0ons  in  Ar0cle110  of  NFPA  70E:  
§  (1)  Training  requirements  (see  110.2)  
§  (2)  Electrical  safety  program  (see  110.1)  
§  (3)  Use  of  electrical  equipment  (see  110.4)  
§  7.1.3.2  Some  Considera0ons  in  Ar0cle  120  of  NFPA  70E:  
§  (1)  Verifica0on  of  an  electrically  safe  work  condi0on  (see  120.1)  
§  (2)  De-­‐energized  electrical  equipment  that  has  lockout/  tagout  devices  applied(see  120.2)  
§  (3)  Temporary  protec0ve  grounding  equipment  (see  120.3)  
 NFPA 70E: “Properly Installed and
Maintained”

Ar8cle  130.1(A)(4)  Normal  Opera8on.  Normal  opera0on  of  electric  equipment  shall  
be  permieed  where  all  of  the  following  condi0ons  are  sa0sfied:  
(1)  The  equipment  is  properly  installed.  
(2)  The  equipment  is  properly  maintained.  
(3)  The  equipment  doors  are  closed  and  secured.  
(4)  All  equipment  covers  are  in  place  and  secured.  
(5)  There  is  no  evidence  of  impending  failure.  
 

 
 Preventive Vs Predictive Maintenance

§  Based  on  Periodic  checks  and   §  Full  asset  Visibility  
inspec0ons   §  Cost  Effec0ve  
§  Doesn’t  consider  the  asset  wear   §  Predict  failures  using  data  
§  Availability  of  0me  and  trained   §  Increase  asset  life  cycle  
personnel   §  Planned  Down0me  
  §  Increase  Reliability  
 
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Predictive Maintenance

§  Risk  reduc0on  is  the  primary  

driver  

§  Predic0ve  Maintenance  can  

o>en  be  the  lower-­‐cost  op0on  

§  Predic0ve  Maintenance  

some0mes  results  in  longer  
intervals  between  
maintenance  
 NFPA 70B 2016 Edition Highlights

§  Torque  Recommenda0ons    

§  Loose  connec0ons  
§  Proper  termina0on  torque  values  
§  Overhea0ng,  Intermieent  Open  Circuits  
and  electrical  arcs  

§  Baeery  Tes0ng  and  Maintenance  

§  Greater  detail  on  baeery  tes0ng    
§  Safety  considera0ons  for  persons  
performing  maintenance  
Critical Facility Electrical Equipment

§  Generators  
§  UPS  &  Baeeries  
§  Transformers  
§  Busways  
§  HVAC  systems  
§  Transfer  Switches  
§  MV/LV  switchgear  
Risk Control Hierarchy

§  Our  Goal  must  be:    

1.  Elimina0on    

2.  Engineering  Controls  

 
PPE  must  be  your  last  line  of  defense  
 
 
Loose Connections & Temperature Rise

§  Load  Condi0ons  

§  Duty  Cycles  

§  Mechanical  wear  and  stress  

§  Incorrect  crimping  of    connec0ons  

§  Improper  cable  training  

§  Thermal  expansion  &  contrac0ons  

§  Vibra0ons  and  Harmonics  

 NFPA 70B Code Reference

§  Loose  Connec8ons  &  Temperature  Rise:    

§  Sec8on  17.9:  Loose  Connec8ons.  Loose  connec0ons  are  the  most  common  cause  of  excessive  heat.  
Periodic  maintenance  checks  should  involve  checking  for  loose  connec0ons  or  evidence  of  
overhea0ng…”  

§  Section 15.2.15.1: “Temperatures over design levels for prolonged periods can reduce the electrical life of
organic insulating materials…”

§  Section 15.2.15.2: Localized heating (hot spots) can sometimes occur and can be masked because the
overall temperature of the surroundings…”

§  Section 11.7.5.6: “Section 9 and table 10.18 of the ANSI/NETA/MTS, Standard for Maintenance Testing
Specifications for Electrical power distribution equipment and systems suggests temperature
benchmark….”
§  Temperature differences of 1° C to 3°C indicate possible deficiency and warrant investigation
§  Temperature differences of 4° C to 15°C indicate deficiency; repairs should be made as time permits
§  Temperature differences of 16°C and above indicate major deficiency; repairs should be made immediately.”

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 NFPA 70B Code Reference
 
Thermography Programs:

§  Section: 11.17.1.1: “Infrared inspections should be performed by qualified and trained personnel who
have an understanding of infrared technology, electrical equipment maintenance…”
 
§  Sec8on  11.17.3.1:  “Infrared  inspec0ons  require  special  measures  and  analysis.  Equipment  enclosed  for  safety  or  
reliability  can  be  difficult  to  scan  or  to  detect  radia0on  from  within.  Special  precau0ons,  including  the  removal  of  
access  panels,  might  be  necessary  for  sa0sfactory  measurements…”  
 
§  Sec8on  11.17.5:  Inspec6on  frequency  and  procedures  “Rou6ne  infrared  inspec6ons  of  energized  electrical  systems  
should  be  performed  annually  prior  to  shut  down.  More  frequent  infrared  inspec6ons,  for  example,  quarterly  or  
semi-­‐annually,  should  be  performed  where  warranted  by  loss  experience,  installa6on  of  new  electrical  equipment,  
or  changes  in  environmental,  opera6onal  or  load  condi6ons.”  

§  Sec8on  11.17.5:  Inspec0on  frequency  and  procedures  “Rou0ne  infrared  inspec0ons  of  energized  electrical  systems  
should  be  performed  annually  prior  to  shut  down.  More  frequent  infrared  inspec0ons,  for  example,  quarterly  or  
semi-­‐annually…”  
 
 
 
 NFPA 70B Code Reference
Sensing,  Indica8ng  &  Control  Systems  in  Maintenance  of  Electrical  Equipment  
Subject  to  Long  Intervals  Between  shutdowns:  
 
§  Applies  to  both  low  and  medium  voltage  systems  
§  Sensing,  Indica0ng  and  Control  Systems  
 
Sec8on  12.4.5.1:  The  need  for  and  frequency  of  inspec0on  and  maintenance  are  determined  by  the  effect  on  
safety,  plant  opera0ons,  and  the  severity  of  service.  Also,  some  components  can  be  readily  isolated,  while  others  
can  be  inspected  only  during  plant  or  process  shutdowns.  
 
Sec8on  12.4.5.2:  Visual  inspec0on  either  by  plant  operators  during  normal  opera0ons  or  as  part  of  a  scheduled  
inspec0on  can  assist  in  detec0on  of  deficiencies  such  as  loose  connec0ons,  overhea0ng,  and  excessive  vibra0on.  
 
Sec8on  12.4.5.3:  Sensing,  indica0ng,  and  control  devices  can  be  divided  into  two  categories:  primary  elements  and  
secondary  
elements.  
(1)  Primary  elements  are  elements  in  contact  with  the  process  medium  directly  or  indirectly  and  that  might  or  might  
not  be  isolated  from  the  process  medium.  
(2)  Secondary  elements  are  transminng,  recording,  or  controlling  devices.  Some  are  normally  in  use  and  thus  
receive  an  automa0c  day-­‐to-­‐day  check.  Some  are  remotely  located  or  infrequently  used  and  require  a  check  at  
regular  intervals.  
 NFPA 70B Code Reference
Busways  &  Electrical  Joints  
Low Voltage Busway – (600 Volts)

§  Section 20.4.1.1 – Feeder Busway

§  Section 20.4.1.2 – Plug-in bus way

Section 20.4.1.3 Metal-Enclosed Busway (5 kV to 15 kV)

Section 20.4.2 Electrical Joints

Section 20.4.2.1 Infrared inspection of busway joints can
reveal loose connections

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 Thermography and it’s challenges

§  Thermography  Programs  

§  Open-­‐door  Thermography  

§  Annually/  Semi-­‐annually    

§  Closed-­‐door  Thermography  

§  IR  windows    

§  More  frequent  (Monthly)  

 
Trends in temperature monitoring

§  Con0nuous  monitoring  

§  Fixed  IR  Cameras  

§  RFID  Sensors    

§  Magne0c  sensors  

 
 Fiber-optic Non-Conductive Sensing

LED  tunnels  through  polymer  fiber,  reflects  off  probe  8p  compound  and  a]enua8on  is  
measured  at  the  HSM  module.  

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Ease of Installation

§   Ability  to  perform  concurrent  maintenance  

§  Perform  maintenance  on  redundant  systems  
§  Aeain  the  reliability/availability  criteria  
Potential Failure Points Example

Visibility  Barriers   Low  Voltage  

Compartment  

All  Poten8al  Failure  Points  

(PFP’s)  should  be  known  for  
op8mal  predictability  

Infrared  imaging  has  limita8ons  

with  Field  of  View  (FOV)  

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Application Ideas

Main  Incoming  
Termina8ons   Low  Voltage  MCC  

MV  MCC  
Other Application Ideas

Ambient   Space  Heater  

 Open Door Thermography vs Continuous
Monitoring
Scenario:  Industrial  facility  using  thermography  contractors  on  a  semiannual  basis  for  open  door  inspec8ons  to  meet  insurance  
requirements.  
 
For  this  example,  we  considered  a  manufacturing  facility  required  to  inspect  ten  electrical  panels  with  six  cri0cal  connec0ons  in  each  panel  totaling  sixty  
inspec0on  points.  A  typical  open  door  inspec0on  of  this  magnitude  requires  two  thermographers  and  a  facility  electrician.  
Electrical  Panels:  10,  Cri8cal  connec8ons  in  each  panel:  6,  Total  points  inspected:  60  No.  of  Electricians:  1,  No.  of  Thermographers:  2,  No.  of  
inspec8ons:  1
IR Windows vs Continuous Monitoring

Scenario:  Industrial  facility  has  iden8fied  cri8cal  panels  to  be  inspected  and  is  evalua8ng  the  installa8on  of  IR  windows  and  using  in-­‐house  
personnel  to  minimize  the  exposure  to  high  incident  energy  and  reduce  outsourced  thermography  contractor  costs.  
 
For  this  example,  we  considered  a  manufacturing  facility  that  iden0fied  nine  electrical  panels  with  three  cri0cal  connec0ons  in  each  panel    
totaling  to  twenty  seven  inspec0on  points.  A  typical  closed  door  inspec0on  requires  at  least  one  3”  round  IR  window  installed  in  every  panel  
to  inspect  three  connec0ons  that  result  in  installa0on  of  nine  IR  windows.  
Electrical  Panels:  9,  Cri8cal  connec8ons  in  each  panel:  3,  Total  points  inspected:  27,  No.  of  inspec8ons:  4
Networking

§  Stand Alone Unit

§  TCP/IP

§  Serial Topology (Daisy Chain)

§  Modbus RTU
§  Plant-wide Integration
§  SCADA/ DCS Systems
§  Local Power Management System

§  Star Topology

§  Ethernet IP
§  Plant-wide Integration
§  SCADA/ DCS Systems
§  Local Power Management System
Comparison of Open Door / IR Windows /
Continuous Monitoring
Summary
Questions?

 
 
Thank  you!