RePOrt Of Committee On ElectriCal Equipment Maintenance

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51ELECTRICAL. ,- ' -. ;\;. ,'EEM-iMAINTENANCEEQUIPMENT.,,, y, , ":' , "- .RePOrt of Committee on.ElectriCal Equipment Maintenance,'- Swaffield C o w a n , Ch'airman.FaetorY .Insurance Aesn., 131 Providence Rd., C h a r t t e , NC 28207 (Retli l 12/1/72)Alan Reed, Chairman-Blect, (Dec. i', 1072) "', . Daniel-Wocdbead Co., 3411 Woodhekd Dr., Northbrook, IL 60062 ,.,.(Pep. National Safety CorintH) . ".G e o r g e O. H u n t , Vice Oluzirman . . . .Monssnto Company,'800 N. Lindbergh Blvd., St. Louis, MO 63166 . :(REX/. N F P A Seetional.Committee on F3eetalce] Equipment in 'Chemlcal A t nespheres)- "'". mcha dW. Sh ul,'te - o s . ""'Natl. Electrical Mandlaeturem'Assn., 155 East 44th.St., New Yoik, N Y I0017'A b b o t t H . L u c a s , Elect -ieal Fuse Manua n g e r t , J r . , Low Voltage DistributionNational Electricalfacturers Guild.' . . . . . D o n a l d W. L u t z , Elect ical MsintonanceEnglnecra Assn. C. T . B a x t e r , Industrial a n d Comm reislLighting Equip. Section, National ElecH e n r y S. O r t h , Multi-Amp Institute. "cel ManulacturemAesn.md P k o , Plant Engineering Magazine. " Warren H . G o o k , Western Electric Co., Inc.J . M. P a r k e r , International Brotherhood ofElectrical Workers.Leonard S. Corey, E a s t m a n Kodak Co.R. W. Mummer,Aluminum Co. of A m e r i : Charles J . E i a r t , Nsti0nal Electrical ConC a r l t o n E. SClmad, American Insuran eetrectom Association.A n.C. F. H e d l u n d , Factory Mutual R e s e R. L. Schultz, James G. Biddle Co.Corp.H.Dole S h e e t s , .Procter & Gamble Co.Z. J. K r u z i c , Industrial Control and Systems Section, National Electrical ManuR . F. Sorenson, St. Regis Paper Co. facturers Assn.G . H . S t . On e, Eeso Rescarch a n d EngiL. E. L a F e h r , International Associatibn ofnecring Co.Electrical Inspectors.K. W. S w a i n , National Electrical ManufacRobert J . L a w r t e , McGraw Hill, Inc.turers Assn.W i l l i a m A. W e d d e n d o r f , Western ElectricRichard L. Lloyd, National Electrical CodeCo., Ine.Committee.quipment Section,%BManufoct rers Assn.,"Alternates,,,Robert M. B y r n e , Electrical Fuse Menufseturem Guild (Alternate to A. H.-Lueas)W. L. M c K e t t h a n , W e s t i n g h o u e s , E l e c Corp. (AJternate to C. Bangert, Jr.) Nonvoting. .This Committee R eport is essentially the Recommended Practice for ElectricM Equ!pment Maintenance; NFPA No. 70B-T,which is proposed for tentative adoption.The document has been submitted to letter ballot of the Committee whichconsists of 26 voting members and two alternates. Final comments and suggestions were invited. Of the 26 voting members, 25 have voted affrmatively.There were no negative ballots. Mr. Schaad did not return his ballot.

52EEM-2E X P L A N A T I O N OF R E P O R TSince this Committee reports to the Association through the ArationMElectrical Code Correlating Committee, this report was also submitted tothem for letter ballot.Over a period of many years, the need for guidance to promotethe safety of persons and property through effective electrical equip.ment maintenance has been increasingly evident. In the fall of1967 the Board of Directors of the National Fire Protection Avsoeiation authorized the formation of an Ad Hoe Committee onElectrical Equipment Maintenance to determine the need for thedevelopment of a suitable document on this subject. In reachingits affirmative decision early in 1968, the Ad Hoe Committee pointedout many reasons why it believed the National Electrical Code waanot the proper document in which to cover the maintenance ofelectrical equipment. However, the high frequency of electricalaccidents attributed to lack of maintenance, which results annuallyin numerous fatalities and serious injury as well as high monetarylosses of property, caused the Committee to advise that it was asubject requiring prompt attention.In June 1968 the Board of Directors authorized the formationof a new NFPA Committee on Electrical Equipment Maintenancehaving the following scope:" T o develop suitable texts relating to preventive maintenanceof electrical systems and equipment used in industrial-type appli.cations with the view of reducing loss of life and property. Thepurpose is to correlate generally applicable procedures for pre.ventive maintenance that have broad application to the morecommon classes of industrial electrical systems and equipmentwithout duplicating or superseding instructions which manufae.turers normally provide. Reports to the Association through theCorrelating Committee of the National Electrical Code Committee."With this background the Committee was organized in December 1968. Its large and very active membership has seen fewchanges in personnel since its inception. It should be pointed outthat the members are individually highly qualified and collectivelythe committee representation includes equipment manufacturers;installers; inspectors; safety, labor, and insurance organizations;users of the equipment; maintenance contractors and engineers;representatives of the National Electrical Code Committee andother NFPA Committees; and specialists. All committee membershave made a fine contribution to this endeavor.

ELECTRICAL EQUIPMENT MAINTENANCE53Recommended Practice forELECTRICAL EQUIPMENT MAINTENANCENFPA No. 70B.T, 1973HISTORYThe Board of Directors of the National Fire Protection Associationin the fall of 1967 authorized the formation of an Ad Hoc Commit tee on Electrical Equipment Maintenance to determine the needfor the development of a suitable document on this subject. Thepurpose of the document would be to give recommendations onthe maintenance of various types of electrical installations, apparatus, and equipment usually found in industrial and large commercial type installations. Various highly diversified interests andorganizations were invited to participate.At a meeting of the Ad Hoc Committee held J a n u a r y 10, 1968,in New York, with 31 representatives attending, it was pointedout t h a t several requests had been made to the National ElectricalCode Committee to include maintenance recommendations in theNEC. T h e subject had been discussed by the Correlating Committee of the National Electrical Code Committee and the decision was made that the Code was not the proper documentin which to cover the maintenance of electrical equipment. 1LIowever, the high frequency of electrical accidents attributed to lackof maintenance, which result annually in numerous fatalities andserious injuries as well as high monetary losses of property, causedthe committee to recognize that it was a subject requiring attention.It was noted that electrical safety information breaks downlogically into four main subdivisions: (1) design or product standards; (2) installation standards (as covered by the National Electrical Code and the National Electrical Safety Code; (3) maintenance recommendations; and (4) use instructions. T h e problemwas to explore whether something more should be done in theinterest of electrical safety on the maintenance of electrical equipment and what form activity in this field should take.It was recognized that much has been done to enunciate maintenance needs for specific types of equipment by the equipmentmanufacturers, and that guidance is available on the generalsubject from a number of sources. However, it was also felt desirable to bring together some of the general guidelines in a singledocument under the NFPA procedure. The stature of the document would also be enhanced if it could in some way become associated with the National Electrical Code. T o this end, a tenta-

54HISTORY70B--3tire scope was drafted for presentation to the Board of Directorsof the National Fire Protection Association with a recommenda.tion that an NFPA Committee on Electrical Equipment Mainte.nance be authorized.O n June 27, 1968 the NFPA Board of Directors authorized theestablishment of an NFPA Committee on Electrical EquipmentMaintenance with the scope statement indicated below (whichwas subsequently amended to include the last sentence): " T o de.velop suitable texts relating to preventive maintenance of elec.tdcal systems and equipment used in industrial-type applicationswith the view of reducing loss of life and property. T h e purpose isto correlate generally applicable procedures for preventive mainte.nance that have broad application to the more common classes ofindustrial electrical systems and equipment without duplicatingor superseding instructions which manufacturers normally provide.Reports to the Association through the Correlating Committee ofthe National Electrical Code Committee."T h e committee was formed and an organizational meeting washeld December 12, 1968 in Boston. Twenty-nine members orrepresentatives attended. This Recommended Practice on Elec.trical Equipment Maintenance represents the cumulative effort ofthe entire Committee.

70B-455ELECTRICAL E Q U I P M E N T M A I N T E N A N C ETABLE OF CONTENTSP a g e No.Chapter 1 General110. P u r p c e e. . . . . . . . . . . . . . . . . . . . . . .70B- 6120. Scope . . . . . . . . . . . . . . . . . . . . . . . .70B- 6130. Definitions70B-6. . . . . . . . . . . . . . . .C h a p t e r 2 W h y a n Electrical P r e v e n t i v eProgram Pays Dividends: .Maintenance(EPM)210. W h y E P M ? . . . . . . . . . . . . . . . . . . . . . .70B- 7220. V a l u e a n d Benefits o f a Properly A d m i n i s t e r e d E P M P r o g r a m70B-- 7230. C a s e Histories: T h e y G a m b l e d a n d Lost . . . . . . . . .70B- 9C h a p t e r 3 W h a t is a n E f f e c t i v e Electrical P r e v e n t i v e M a i n t e n a n c eProgram?310. G e n e r a l. . . . . . . . . . . . . . . . . . . . . . .320. P l a n n i n g a n E P M P r o g r a m. . . . . . . . . . . . . .330. M a i n Parts of a n E P M P r o g r a m. . . . . . . . . . . .340. E P M S u p p o r t Procedures . . . . . . . . . . . . . . . .Chapter4PlanningandDevelopingMaintenance P r o g r a m410. I n t r o d u c t i o nElectrical70B-1270B-1270B-14Preventive. . . . . . . . . . . . . . . . . . . . .420. S u r v e y of Electlical Installation4210. Definitionan70B-12. . . . . . . . . . . .70B-1570B-16. . . . . . . . . . . . . . . . . . . . . .70B-164220. D a t a Collection . . . . . . . . . . . . . . . . . . . .70B-174230. D i a g r a m s a n d D a t a. . . . . . . . . . . . . . . . . .70B-17. . . . . . . . . . . . . . . . . . .70B-194250. E m e r g e n c y Procedures . . . . . . . . . . . . . . . . .70B-204260. T e s t a n d M a i n t e n a n c e E q u i p m e n t. . . . . . . . . . .70B-21430. Identification of Critical E q u i p m e n t . . . . . . . . . . .70B-224240. S y s t e m D i a g r a m s

56CONTENTS708"-- 5TABLE OF CONTENTSP a g e No.440. E s t a b l i s h m e n t of a Systematic P r o g r a m4410. P u r p o s e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4420. A t m o s p h e r e or E n v i r o n m e n t4430. L o a d Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . .4450. I n s p e c t i o n F r e q u e n c y. . . . . . . . . . . . . .450. M e t h o d s a n d Procedures4520. F o r m s70B-25. . . . . . . . . . . . . .4440. H i s t o r y of E q u i p m e n t70B--2570B--2570] -26. . . . . . . . . . . . . . . . . . . . . . .701 2770B-2770B-29. . . . . . . . . . . . . . . . . . . . . . .70B-29. . . . . . . . . . . . . . . . . . . . . .70B--30453. P l a n n i n g455. Analysis of Safety Procedures . . . . . . . . . . . . . .70B-52456. R e c o r d s70B-32. . . . . . . . . . . . . . . . . . . . . . .457. E m e r g e n c y Procedures . . . . . . . . . . . . . . . . .Chapter 570B-33Bibliography510. I n t r o d u c t i o n. . . . . . . . . . . . . . . . . . . . .Appendices . . . . . . . . . . . . . . . . . . . . . . . . .70B-3470B-38A. S y m b o l sAolS o m e Typical'Electrical S y m b o l s . . . . . . . . . . .70B-38A-2S o m e T y p i c a l Electrical S y m b o l s . . . . . . . . . . .70B-39A-3S o m e T y p i c a l Electrical S y m b o l s . . . . . . . . . . .70B-40B. D i a g r a m sB-1T y p i c a l U s e of Symbols in a Single Line Power Distribution D i a g r a m . . . . . . . . . . . . . . . . . . .70B--4113-2 T y p i c a l W i r i n g D i a g r a m13-3. . . . . . . . . . . . . .Typical Schematic Diagram. . . . . . . . . . . .70B-4270B--43C. F o r m sC-ITypical Work Order Request Form. . . . . . . . .70B--44D. I n s p e c t i o n sD-ISuggestions for a W a l k - t h r o u g h Inspection C h e c k List . . 70B--46

70B-6ELECTRICAL EQUIPMENT MAINTENANCE57CHAPTER 1 - - GENERAL.110.Purpose.1110. The purpose of this recommended practice is to reducehazard to life and property that can result from failure or malfunction of industrial-type electrical systems and equipment. The firstthree chapters of these recommendations for an effective Electrical Preventive Maintenance (EPM) program have been preparedwith the intent of providing a better understanding of benefits,both direct and intangible, that can be derived from a well-administered EPM program. This practice explains the function,requirements, and economic considerations that can be used toestablish such a program.120.Scope.1210. This recommended practice is confined to preventivemaintenance for industrial-type electrical systems and equipment,and is not intended to duplicate or supersede instructions that electrical manufacturers normally provide. Systems and equipmentcovered are those operating at 15 kV and below and are typicalof those installed in industrial plants, institutional and commercialbuildings, and large multifamily residential complexes. Consumerappliances and equipment intended primarily for use in the homeare not included.130. Definitions.1310. Electrical Preventive Maintenance (EPM) is the practice of conducting routine inspections, tests, and the servicing ofelectrical equipment so that impending troubles can be detectedand reduced, or eliminated.1320. Electrical equipment is a general term applied to material,fittings, devices, fixtures, and apparatus that are part of, or areused in connection with, an electrical installation. This includesthe electrical power generating system, substations, distributionsystems, utilization equipment, and associated control, protective,and monitoring devices.

58WHY EPM PAYS DIVIDENDS70B-7CHAPTER 2 - WHY AN EPM PROGRAMPAYS DIVIDENDS210. W h y EPM?2110. Electrical equipment deterioration is normal, but equip.ment failure is not inevitable. As soon as new equipment is installed,a process of normal deterioration begins. Unchecked, the deterioration process can cause malfunction or an electrical failure. Deterio.ration can be accelerated by factors such a's a hostile environment,overload, or severe duty cycle. An effective EPM program identifiesand recognizes these factors and provides measures for coping withthem.2120. I n addition to normal deterioration, there are other po.tential causes of equipment failure that may be detected and cor.rected through EPM. Among these are load changes or additions,circuit alterations, improperly set or improperly selected protec.tire devices, and changing voltage conditions.2130. Without an EPIV[ program, management assumes a muchgreater risk of a serious electrical failure and its consequences.220. Value and Benefits of a Properly Administered EPMProgram.2210. A well-administered program will reduce accidents, savelives, and minimize cosdy breakdowns and unplanned shutdownsof production equipment. Impending troubles can be identified- - and solutions applied - - before they become major problems requiring more expensive, time-consuming solutions.2220. Benefits of an effective EPM program fall in two generalcategories. Direct, measurable, economic benefits are derived byreduced cost of repairs and reduced equipment downtime. Lessmeasurable but very real benefits result from improved safety. Tounderstand fully how personnel and equipment safety are servedby. an EPM program, the mechanics of the program - - inspection,testing and repair procedures - - should be understood. Such anunderstanding explains other intangible benefits such as improvedemployee morale, better workmanship and increased productivity,less absenteeism, reduced interruption of production, and improved insurance considerations. Improved morale will come withemployee awareness of a conscious management effort to promotesafety by reducing likelihood of electrical injuries or fatalities, electrical explosions, and fires. Reduced personal injuries and property loss claims can [ielp keep insurance premiums at favorablerates.

Table ILosses Associated with Electrical FailuresIncludes Electrical and Fire Damage*1967 & 1968Class o/EquipmentGeneratorsMotorsTransformersCircuit BreakersCablesControllersSwitchgearSwitch Bds.Switches Air & OilTOTALNo. o/LossesAll CausesIncl. UnknownDollar LossAll CausesIncl. UnknownNumberCauseUnknown514208727733744234 1001,041,64017,25020109381121141791766 6,548,590240DollarLossDue CauseUnknown Number o[Losses ofKnown Causesdue to DefectioeMaintenanceDollar Loss ofKnown Causesdue to 0,000152,500254,000181,50011,000252563814451823113 1,0006,250 1,978,300433 3,595,850.*Statistics compiled by only one of the major insurance groups (Factory Mutual) which specialize in industrial fire and machineryinsurance.I;

60WHY EPM PAYS DIVIDENDS70B-92230. While benefits resulting from improved safety are difficultto measure; direct, measurable, economic benefits can be docu.mented by equipment repair cost and equipment downtime recordsafter an EPM program has been placed in operation.2231. Dependability can be engineered and built into equipment, but effective maintenance is required to keep it that way.Experience shows that equipment lasts longer and performs betterwhen covered by an EPM program. In many cases, the investmentin EPM is small compared to the cost of equipment repair and production losses associated with an unexpected equipment shutdown.2232. Careful planning is the key to economic success of an EPMprogram. With proper planning, maintenance costs will be heldto a practical minimum, while production is maintained at a practical maximum.2240. Electrical preventive maintenance requires the support oftop management, because it is top management who must providefunds to initiate and maintain the program. Maintenance of industrial electrical equipment is essentially a matter of businesseconomics. Maintenance costs can be placed in either of two basiccategories: (1) preventive maintenance; or (2) breakdown repairs.Money spent for preventive maintenance will be reflected as lessmoney required for breakdown repairs. An effective EPM programholds the sum of these two expenditures to a minimum. Figure 1is a typical curve illustrating this principle.2250. Electrical preventive maintenance is a form, of protectionagainst accidents, lost production and loss of profit. EPM enablesmanagement to place a dollar value on the cost of such protection.An effective EPM program satisfies an important part of manage.ment's responsibility for keeping costs down and production up.2260. Insurance statistics document the high cost of inadequateelectrical maintenance (see Table I). This table represents resultsof a study performed by only one of the major insurance groups(Factory Mutual) which specializes in industrial fire and machineryinsurance. The table indicates that in a two-year period (1967-68),one-half of the losses associated with electrical equipment failuresmight have been prevented by an effective EPM program.250. Case H/storles: They Gambled and Lost.2310. A total plant shutdown resulted from the failure of atransformer in an industrial plant. Cause of the failure was contamination of the transformer insulating oil. The contamination

61ELECTRICAL EQUIPMENT MAINTENANCE70B. -

industrial electrical systems and equipment without duplicating or superseding instructions which manufacturers normally provide. Reports to the Association through the Correlating Committee of the National Electrical Code Committee." The committee was formed and an organizational meeting was

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