Infrared Windows
and NFPA 70
Martin Robinson
CEO
IRISS, Inc.
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NFPA 70E
Tasks & Hazard/Risk taken from Table 130.7(C)(9)
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NFPA 70E
Table 130.7(C)(11)2
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NFPA 70E
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IR Window Program
Cost Analyses
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Electrical Panel Removal
Man-hours
• 3 Man Live Electrical Thermography Team consists of:
– 2 x Electrical Engineers:
– 2 x Electricians for panel removal
– 1 x Infrared Themographer (Contracted)
Time For Live Inspection 1 hour 6 minutes
(excludes PPE Suit‐up Time)
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Cost Analysis of Energized IR
Survey Removing Panels
Operation
Man Hours
Total Man Hours
Rate ($/hr)
Thermographer 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)
Cover Removal
0.5
1.0
$125
Total
$125.00
Infrared Inspection
0.1
0.1
$150
$15.00
Cover Replacement
0.5
1.0
$125
$125.00
Thermographer 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 =
$650.00
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Cost Analysis of Energized IR Survey
Using IR Windows
Operation
Man Hours
Total Man Hours
Rate ($/hr)
Thermographer PPE Suit-up
0
0
$150
Electrician PPE Suit-up
0
0
$125
Manpower Costs Per PPE Suit-up As Per NFPA 70E =
Operation
Total
$0
$0
$00.0
Man Hours
Total Man Hours
Rate ($/hr)
0
0
$125
$0
Infrared Inspection
0.15
0.5
$150
$22.50
Cover Replacement
0
0
$125
$0
Thermographer Waiting Time
0
0
$150
$0
Electrician Waiting Time
0
0
$125
Cover Removal
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
$0
$22.50
190.00
$212.50
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5 Year Cost Benefit
Analysis
$ Savings
Per
Inspection
Total %
Saving
$212.50
$437.50
67%
$235.00
$1,065.00
82%
$1,950.00
$257.50
$1,692.50
87%
$2,600.00
$280.00
$2,320.00
89%
$3,250.00
$302.50
$2,947.50
91%
Cumulative Cost
Without IR Windows
Cumulative Cost
Using IR Windows
Year 1
$650.00
Year 2
$1,300.00
Year 3
Year 4
Year 5
Period
• Example shows a saving of nearly $3,000.00 over a 5 year
period (91%) for 1 cable compartment in a Medium Voltage
Electrical Panel
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Cost Analysis For Paper Mill Scenario:
Paper Mill “X” currently have 150 pieces of primary switchgear that they inspect annually (due to intrusive nature of the inspection).
These inspections are currently completed “ENERGISED” in line with the requirements of NFPA70E & 70B. (full PPE and Strict guidelines on how inspections are completed)
Inspection is completed by 2 Plant Electricians ( required for panel removal) and 1 Contract Thermographer.
Inspections currently take approximately 150 hrs (3 weeks)
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Cost Analysis of Energized IR Survey Removing Panels
Operation
Man Hours
Total Man Hours
Rate ($/hr)
Thermographer PPE Suit-up
0.5
0.5
$150
Total
$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)
Cover Removal
0.5
150.0
$125
$18,750.00
Total
Infrared Inspection
0.1
15.0
$150
$2,250.00
Cover Replacement
0.5
150.0
$125
$18,750.00
Thermographer 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 =
$74,400.00
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Cost Analysis of Energized IR Survey Using IR Windows
Operation
Man Hours
Total Man Hours
Rate ($/hr)
Thermographer PPE Suit-up
0
0
$150
Total
$0
Electrician PPE Suit-up
0
0
$125
$0
Manpower Costs Per PPE Suit-up As Per NFPA 70E =
Operation
Man Hours
Cover Removal
Total Man Hours
Rate ($/hr)
$0
Total
0
0
$125
$0
Infrared Inspection
15.0
15.0
$150
$2,250.00
Cover Replacement
0
0
$125
$0
Thermographer 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 150 IRISS VPFR 75 (3 inch diameter) Infrared Inspection Window =
$28,500.00
Year 1 Manpower Costs Per Inspection of 1 Electrical Panel =
$30,750.00
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5 Year Labor Savings:
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
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Increased Inspection
Frequency:
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%
• Example shows that using IR windows you can increase your
inspection frequency by a factor of 4 and the 5 year program
cost is less than the original Annual “Energized” inspection
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method
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Infrared Inspection
Case Study
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Case Study 1: 8.3 kV Load
Interrupter Switch
Feyen‐Zylstra, LLC Electrical contractors, a TEGG services contractor secured an Electrical Preventative Maintenance contract (EPM) with the Bradford White Corporation. The maintenance agreement included a value added product and service comprising of the installation of 40 4inch IRISS infrared windows during a scheduled maintenance shutdown.
A crew of 11 technicians completed the installation of the IR windows on the 1st July as well as performing cleaning and housekeeping tasks on the High Voltage equipment. A sample of the newly installed IR window is shown:
During the second week of service (11th July) the Feyen‐
Zylstra technicians identified a fault using the newly installed IR windows on the B Phase of 14.4 KV 200 Amp fuse. At this time the fuse displayed max temp of 65 °C.
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Case Study 1: 8.3 kV Load
Interrupter Switch
Due to the nature of the fault it was decided to monitor the component closely. Another IR inspection was completed on the 31st July, the results were results were alarming as the problem temperature had risen to 508 °C, an increase indicating a significant and accelerated deterioration of the assembly
Image taken through the Plexiglas window shows at this stage the fault was in fact luminescent
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Case Study 1: 8.3 kV Load
Interrupter Switch
Once the Fault had been identified an immediate shutdown was planned. This entailed putting in place a temporary generator system to allow for production to continue whilst the repair was completed
As soon as the temporary generator system was in operation the switchgear was made safe and the repairs were allowed to be completed with minimal disruption to plant operations and 34
production
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Case Study 1: 8.3 kV Load
Interrupter Switch
As soon as the switchgear was opened it became apparent that the original suspicions and analysis was right on the mark.
The fuse itself was visually discoloured from the heat damage
The fuse clamp assembly was burnt and the plastic tightening knob was melted off its mount and was found lying in the bottom of the enclosure. 35
Case Study 1: 8.3 kV Load
Interrupter Switch
Before the Repair the temperature was in excess of 500 °C
After the Repair the temperature is approximately 50 °C
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Case Study 1: 8.3 kV Load
Interrupter Switch
Cost Savings
The decision to include IR Windows in the maintenance agreement proved to be priceless. Had they not been installed this fault would have probably gone undetected, especially as the maintenance had just been completed on the switchgear!!!
Identifying the fault allowed the maintenance teams to plan the maintenance shutdown, order parts, manpower etc… with no loss in production time. The cost to the plant in loss of production revenue would have run into several million dollars!
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Questions????
Visit www.iriss.com and download your free copy of:
“10 Things you Need to Know About Infrared Windows”
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