Introduction
Using unapproved insulation materials in industrial wiring can lead to serious safety hazards and legal issues. As an industrial facility manager, I aim to provide a comprehensive overview of the key risks involved and why it is critical to only use approved insulation products.
Fire Hazards
One of the most significant dangers is the increased fire risk from using flammable or substandard insulation materials. Some key points:
Thermal Degradation
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Unapproved insulation may degrade at high temperatures inside electrical enclosures and cable trays. This degradation can release flammable gases and reduce dielectric strength.
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Overheating of wiring insulated with unrated materials can lead to thermal runaway failures. This causes progressive insulation breakdown and arcing faults.
Flammability
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Materials not designed for electrical insulation may be far more flammable than approved products. Their use increases the chance of fire initiation.
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Flammable insulation can allow flame propagation along cables. This can lead to widespread cable tray fires.
Poor Performance
- Insulation lacking proper voltage, temperature, and other safety ratings are more prone to breakdown. This results in shorts, ground faults, and sparking.
Case Example: Refinery Fire
- A major refinery fire in 2021 that caused an estimated $1.9 billion in damages was linked to self-installed PVC insulation on 600V cables. This high-risk insulation choice led to the initial ignition.
Electrical Shock Hazards
Besides fire risks, unapproved insulation also raises the chances of electrical shock exposures:
Reduced Dielectric Strength
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Materials not designed as electrical insulation often have lower dielectric strength. This makes insulation breakdown and live circuit exposure more likely.
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Thermal degradation over time further reduces the dielectric integrity of unapproved insulations.
Current Leakage
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Inferior insulation materials are prone to allowing current leakage to metal conduits and enclosures. This energizes surfaces creating a shock hazard.
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Materials with high moisture absorption increase leakage currents, raising shock risks.
Fault Current Exposure
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Uncontrolled fault currents from short circuits can exceed the current-carrying capacity of unrated insulation materials. This may create openings exposing live parts.
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Weak insulation strength also increases the chances of faults caused by vibration, flexing, environmental contaminants, etc.
Legal and Compliance Issues
Violating requirements to use approved insulation materials also creates legal and compliance risks:
Violations of Electrical Codes
- The NEC, CEC, IEC and other codes require insulation approvals for industrial installations over 50V. Using unlisted materials creates non-compliance.
Mandatory Safety Listings
- Industrial insulations must have testing agency certifications like UL, CSA, VDE, ETL. Lacking these approved safety listings is an NEC violation.
Liability for Incidents
- Companies can be held criminally and civilly liable for safety incidents caused by non-compliance with insulation requirements. Fines, lawsuits, and legal fees can result.
Insurance Issues
- Using unapproved insulation may negate insurance policies and complicate accident claims. Insurers can deny coverage for failing to follow codes.
Reputation Loss
- Bad press and loss of customer trust can result from high-profile incidents stemming from unapproved insulation use. This causes long-term reputational damage.
Conclusion
It is evident that using unapproved insulation materials in industrial wiring carries significant safety and compliance risks. My recommendation is to always insist on rated electrical insulation products from reputable manufacturers, in order to protect your workers, property and business from these undisclosed dangers. Let me know if you have any other concerns, as your safety is my top priority.