Introduction
The National Electrical Code (NEC) lays out the legal requirements for safe electrical installations across the United States. As our reliance on electricity grows, the NEC must evolve to address new developments in electrical technology and changes in how we use energy. That's why the 2021 edition of the NEC includes an important update to Section 110.26 regarding electrical panel service and circuit capacity in industrial facilities.
In this article, I'll provide an in-depth look at these NEC changes and explain why they make a complete reassessment of your facility's electrical system critically important. Gaining a full understanding of the new NEC 110.26 requirements will allow you to proactively address any deficiencies and ensure your electrical infrastructure is fully compliant and positioned for current and future demands.
Overview of Key Changes to NEC Section 110.26
Section 110.26 of the National Electrical Code covers the requirements for electrical panel and service capacity in commercial and industrial buildings. The 2021 NEC update includes two major changes:
1. New Load Calculation Requirements
The updated 110.26 now requires electrical load calculations for industrial facilities to be based on actual maximum electrical load instead of estimates.
Previously, load calculations could be estimated based on square footage. However, the new language explicitly requires determining the actual realistic maximum electrical load expected on the service and feeder system.
This change recognizes that many industrial facilities now have more significant and concentrated electrical loads from large motors, drives, heating equipment, and other machinery.
2. Mandatory Push Button Tests
The updated 110.26 also introduces a new requirement for mandatory push button tests to verify the overall system capacity under maximum load.
These field evaluations must be conducted during peak load conditions to validate that the system can actually handle the true realistic maximum load.
Why These Changes Are Significant
These two key updates to NEC Section 110.26 have major implications for industrial facilities. Here are some of the key reasons the new requirements make reassessing your electrical system critically important:
Outdated Electrical Panels
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Many older industrial facilities still have outdated electrical panels and services that were sized based only on the building footprint or general estimates.
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The new NEC 110.26 requirements reveal these inadequate electrical systems by requiring precise load calculations and real-world capacity testing.
Increased Electrical Demand
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Modern manufacturing equipment, machinery, and processes often have a much higher electrical load density compared to older facilities.
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Even facilities upgraded over the years can now exceed total service and circuit capacity due to increased use of automation, motors, heating, and computing technology.
Improved Safety
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Exceeding panel or circuit capacity can lead to overloaded circuits, tripped breakers, overheated wires, and increased fire risk.
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Reassessing and upgrading overloaded electrical systems is essential to maintain workplace and equipment safety.
Compliance Assurance
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The updated NEC 110.26 requirements make vague estimates or rules of thumb no longer acceptable.
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Thorough load calculations and testing are now legally mandatory. Proactive reassessment ensures full compliance.
Performing a Complete Electrical System Reassessment
Given the significance of the NEC Section 110.26 changes, a full reassessment of your facility's electrical service capacity is likely needed. Here is an overview of the recommended best practices:
1. Load Calculation
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Inventory all electrical equipment and usage throughout the facility.
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Calculate expected demand in amps for each circuit under maximum real-world load.
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Aggregate the total anticipated maximum facility electrical load.
2. Service Capacity Evaluation
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With the maximum electrical load calculated, compare it against the capacity of the existing main service panel and circuits.
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Evaluate any areas exceeding 80% of rated capacity during peak demand.
3. Push Button Testing
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Schedule testing during typical peak production runs with all major equipment operating.
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Push buttons to simulate peak demand on each circuit and take current measurements.
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Verify service and circuits remain within 80% of rated capacity under peak demand.
4. Remediation and Upgrades
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For any overloaded panels or circuits identified, plan upgrades to increase capacity.
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Budget for new higher capacity panels, wiring, and circuits as needed.
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Implement upgrades to achieve full NEC 110.26 compliance.
Leveraging Electrical Engineering Experts
Given the specialized electrical engineering knowledge required, partnering with electrical experts is highly recommended when undertaking the complete electrical system reassessment needed to meet the new Section 110.26 NEC standards.
Some key benefits of leveraging electrical engineering expertise include:
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Efficient Load Calculations - Electrical engineers have the specialized skills and tools to rapidly and accurately calculate electrical loads.
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Testing Experience - Electrical engineers have the right instruments and expertise to conduct push button testing.
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Upgrade Recommendations - Engineers can provide detailed recommendations for cost-effective capacity upgrades.
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Project Management - Electrical engineers can oversee the entire reassessment project and upgrades.
By partnering with qualified electrical engineering experts, industrial facility owners and managers can ensure their electrical systems are fully reevaluated to comply with the latest NEC 110.26 capacity requirements in a timely and cost-effective manner.
Conclusion
The recent changes to NEC Section 110.26 represent a major shift in requirements for electrical service and circuit capacity in industrial facilities. Mandatory load calculations and push button testing reveal any inadequacies in existing systems designed based on estimates or general rules of thumb.
To maintain safety, compliance, and readiness for current and future production needs, a complete reassessment of your facility's electrical infrastructure is now essential. By leveraging the expertise of electrical engineering professionals, this critical reassessment process can be completed efficiently and cost-effectively.
Proactive reevaluation and upgrades pave the way for optimized electrical safety and performance. Don't wait for an incident, outage, or violation to necessitate action. Partner with electrical experts now to ensure your equipment and workforce are supported by a fully modernized and NEC 110.26 compliant electrical system.