Electrical

IR Scanning, Arc Flash & Other Maintenance

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Switchgear Maintenance

IR Scanning

Arc Flash Study

NFPA-70E

Performed: Every 1 - 3 Years

Performed: Once Every 5 years

Performed: Annually

Performed: Every 5 years or as infrastructure changes

Electrical

IR Scanning, Arc Flash & Other Maintenance

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Reasons For IR Scanning

Detect problems you never knew you had IR scanning can identify failure modes not detected by liquid testing and can add the clarity needed to address anomalies that liquid testing does uncover. By analyzing substation thermal images, it is possible to detect:

• Overloading
• Unbalanced loads
• Low liquid levels
• Defects or issues in cooling systems and radiators
• Oil circulation issues
• Malfunctioning temperature or level gauges
• Hot spots
• Loose or faulty connections
• Load tap changer (LTC) and no-load tap changers (NLTC) 

Overview of IR Scan Process

IEEE Standard 1584-2002 provides a calculation model that can be used to quantify arc flash hazard levels. The most effective arc flash safety programs incorporate “safety by design” or other mitigation techniques. This includes performing an Electrical Hazard Analysis, including an evaluation of both shock and arc flash hazards, when workers are going to be exposed to energized equipment operating at 50V or more.

When is an IR Scan Required?

• IR Scanning is typically performed once per year
  
• Energized equipment operating at 50V or more

What Factors in the Cost of an IR Scan?

The cost of a study isn't a one-size-fits-all answer, but it's shaped by several key factors relevant to your facility:

• Scope and Complexity:
  
  • Amount of Equipment: The sheer number of transformers, switchgear, and other components directly influences the time and effort involved, affecting the cost
  • Accessibility of Equipment: Easily accessible equipment simplifies data collection, while hard-to-reach components can increase time and cost
• Depth of reporting generated following the IR Scan

Electrical

IR Scanning, Arc Flash & Other Maintenance

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Page 3 of 4

Reasons For Arc Flash Study

While arc flash studies are essential for regulatory compliance with NFPA 70E, their benefits extend far beyond mere adherence to standards. Companies can significantly enhance workplace safety, minimize equipment downtime, and reduce insurance costs by conducting comprehensive arc flash studies.

Understanding and mitigating arc flash hazards through detailed risk assessments and appropriate protective measures not only protect workers from injuries but also safeguard critical assets and infrastructure. Moreover, proactive management of arc flash risks demonstrates a commitment to employee welfare and fosters a culture of safety within the organization.

Overview of Arc Flash Study Process

An arc flash risk assessment comprises several critical steps to assess and mitigate arc flash hazards within a facility accurately:

• Data Collection: Gathering pertinent information about the power system, including electrical equipment specifications, single-line diagrams, and fault current data.
• Short Circuit Calculations: Analyzing the available short-circuit current levels to determine the maximum potential fault currents in the system
• Incident Energy Calculations: Estimating the incident energy levels at various points within the electrical system to assess the severity of potential arc flash events
• Arc Flash Boundary Determination: Defining the safe distance from the arc flash source where the incident energy falls below the threshold for causing second-degree burns
• PPE Selection: Recommending appropriate personal protective equipment based on the calculated incident energy levels and arc flash boundary distances
• Report Generation: Compiling the findings and recommendations into a comprehensive report, including hazard analysis results, equipment labeling requirements, and PPE recommendations
  

When is an Arc Flash Study Required?

In critical environments like commercial buildings, industrial plants, manufacturing facilities, and healthcare centers, ensuring the safety of workers and property is paramount. Arc flash hazards demand proactive mitigation strategies.

Mandatory Compliance:

• NFPA 70E® Standard: The National Fire Protection Association mandates an arc flash hazard analysis every five years (Section 130.5). This reassesses potential dangers and guides safety protocols
• OSHA Regulations: While not explicitly requiring studies, OSHA's General Duty Clause (29 CFR 1910.132) emphasizes protecting workers from known hazards. Arc flash falls under this category, making studies essential for compliance.

Beyond Compliance:

• Significant System Changes: Any major alterations to your electrical system, like adding / removing equipment, changing wiring configurations, or altering protective device settings, trigger the need for a fresh study. These modifications can alter arc flash risks, requiring updated assessments.
  

Enhanced Safety Measures:

• Even if your study meets the five-year mark, consider revisiting it if you've experienced near misses or safety concerns related to electrical equipment
• Proactive evaluation helps identify and address potential issues

Insurance Requirements:

• Some insurance companies may require up-to-date arc flash studies as a condition for coverage
• This ensures informed risk management and reduces potential liabilities
  

What Factors in the Cost of an Arc Flash Study?

The cost of a study isn't a one-size-fits-all answer, but it's shaped by several key factors relevant to your facility:

• Scope and Complexity:
• Size and Type of Facility: Larger facilities with more complex electrical systems naturally require more extensive studies, impacting the cost
• Amount of Equipment: The sheer number of transformers, switchgear, and other components directly influences the time and effort involved, affecting the cost
• Accessibility of Equipment: Easily accessible equipment simplifies data collection, while hard-to-reach components can increase time and cost

Additional Considerations:

• Starting Information Availability: Having accessible single-line diagrams, equipment specifications, and other relevant data can streamline the process, potentially lowering costs
• Electrical Workers Utilization: Studies factoring in worker exposure during specific tasks can add complexity, impacting the cost
  
• Travel and Logistics: Location and any travel requirements for the engineer can influence the overall cost
• Remember, while upfront study costs might seem significant, they pale in comparison to potential consequences of an arc flash incident, including worker injuries, equipment damage, production downtime, and legal ramifications
  

Electrical

IR Scanning, Arc Flash & Other Maintenance

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Page 4 of 4

Reasons For Switchgear Maintenance

Switchgears are much like computer systems collecting dust and producing low heat which causes rodents to nest inside the equipment. This leads to a need for cleaning, lubricating and tightening fittings. Torque wrenches are used to tighten to specifications in the OEM manual. 

Without continued service maintenance dust / debris buildup can cause power failure and outages to occur much more frequently. 

Overview of Switchgear Maintenance

Level 1 - Frequency of 12 - 18 Months

• Project management for coordination of shutdown
• Coordination with utility for equipment shutdown and lockout
• Visual inspection of mechanical components, electrical components, and gauges / indicators (damage, corrosion, moisture, clearances, anchoring)
• Vacuum interior of panels (exterior as needed)
• Wipe down exterior and interior of panels with lint-free cloth and alcohol
• Inspect alignment, grounding, and all connections
• Torque all bolted bus and cable connections to manufacturer specification
• Clean, lubricate and exercise applicable dynamic or articulated components
  Controlled restart of equipment
  
• Document all deficiencies identified and the status of any repair actions

Level 2 - Frequency of 24 - 36 Months

• Perform insulation resistance testing to verify bus integrity
• Contact resistance testing to verify joint connections on bus and protective device connectivity between bus and load
• Perform protective relay and circuit breaker testing (secondary injection testing where applicable)