Breaker Injection Testing Campaign Delivers Enhanced Safety and Compliance
Interstates recently conducted a comprehensive breaker injection testing campaign for a major U.S.-based client. The campaign emphasized compliance with updated NFPA 70B standards and overall operational reliability. Covering more than 200 breakers across 35 sites, it showcased the importance of proactive maintenance in industrial facilities.
This large-scale project aimed to ensure that each circuit breaker functioned correctly, helping prevent potential equipment damage and ensuring safe, compliant operations. Ryan McKnight, Assistant Project Manager at Interstates, says, “Breaker injection testing allows us to verify each breaker, safeguarding electrical systems.” To accommodate the client’s operational schedule, Interstates coordinated precise testing across multiple locations to minimize disruptions while conducting thorough assessments.
NFPA 70B Compliance and Operational Safety
NFPA 70B, updated in 2023, has elevated breaker injection testing from a best practice to a regulatory requirement, making clear its important role in preventing hazardous conditions. Although the client had a strong testing program even before the NFPA update, aligning with these standards further demonstrated their commitment to safety.
Adam Dittbenner, Instrumentation Manager at Interstates, explains the standard’s value: “Compliance with NFPA 70B not only confirms breaker functionality but also identifies deficiencies early, reducing the risk of unplanned outages or personnel injury.” Through Interstates’ testing procedures, the breakers were evaluated to ensure they tripped at the correct amperage and within designated time frames, resulting in a safeguard against electrical issues and failures.
Detailed Testing and Additional Services
Breaker injection testing requires specialized equipment and skilled technicians. Interstates used the Megger DDA-6000, a high-capacity testing device, to inject current into each breaker. This process involves powering down the facility, removing the breaker, and connecting it to testing equipment to assess the trip settings. Dittbenner says, “Each breaker undergoes resistance and insulation testing to confirm it will perform under fault conditions.” The data collected provided valuable insights, helping the client make informed decisions on maintenance and replacements.
To maximize downtime efficiency, Interstates offered the client additional preventive maintenance services, including infrared scanning and equipment cleaning. Infrared scanning is a noninvasive technique that helps detect issues like loose connections or overloads, allowing technicians to address these problems before restarting the system. Equipment cleaning was also provided to meet NFPA 70B requirements, reducing dust-related risks.
“These additional services provide a comprehensive assessment of the client’s electrical infrastructure,” explains McKnight. “They help ensure that all components work safely and reliably, extending equipment life and minimizing disruptions.”
Collaborative Efforts Minimize Disruption
Close coordination with the client was critical to the project’s success. Interstates’ team met with client representatives several weeks in advance to outline schedules, shutdown procedures, and testing protocols for the breaker injection testing campaign. Technicians also arrived on-site a day early to set up and address any questions from the client’s team, fostering transparency and preparation. McKnight says, “Maintaining consistent communication throughout testing keeps the project on track and allows us to address any issues immediately, ensuring a smooth execution.”
The Broader Impact on Operations
In addition to meeting compliance standards, breaker injection testing delivers significant operational benefits. Properly functioning breakers safeguard equipment, reduce unplanned outages, and extend the lifespan of a facility’s electrical systems. Bundling services, such as infrared scanning and cleaning with breaker testing, also offers cost savings through reduced travel and service disruptions.
This campaign reflects Interstates’ broader commitment to safety and reliability. Through expert testing and proactive maintenance strategies, Interstates helps clients optimize their operations and meet the latest industry standards. “We protect equipment and empower clients to operate with confidence, knowing their systems are robust and compliant,” Dittbenner says.
Interstates’ breaker injection testing campaign demonstrates the critical role of proactive maintenance in enhancing plant safety and performance. If you want to ensure compliance and reliability at your facility, our experts are ready to provide you with a proven pathway to safe, efficient operations.