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ELECTRICAL CONSTRUCTION & MAINTENANCE
The Basics of Electrical Overheating
Electrical Construction and Maintenance
Chris Korinek, P-E., Synergy Technologies LLC
Mon, 2009-06-01 12:00
Practical tips for identifying and reducing the most common causes of electrical fires
Asan electrician, you've probably seen or at least heard about electrical fires. Fortunately, they are not an
everyday occurrence. However, the statistics surrounding them are sobering. According to data from the
National Fire Protection Association (NFPA), Quincy, Mass., in 2006, an estimated 20,900 reported U.S.
nonconfined home structure fires (involving electrical distribution or lighting equipment) resulted in 500
civilian deaths, 1,100 civilian injuries, and $862 million in direct property damage. What are the influencing
factors behind these numbers?
In my experience as a forensic engincer, there are three main independent modes of electrical overheating that
lead to electrical fires: excessive current, poor connections, and insulation breakdown. There is a rare fourth
mode — inductive heating — which will not be discussed in this article.
Excessive current is rare, because cireuit breakers and fuses (if sized correctly) typically protect against this
occurrence.
Poor connections can be very efficient at overheating, because they can generate a high wattage over a small
area for a long period of time. This is evidenced in the research from William J. Meese and Robert W.
Beausoliel in the “Exploratory Study of Glowing Electrical Connections,” published by the National Bureau of
Standards, and NFPA 921, the “Guide for Fire and Explosion Investigations” from NFPA. If the watt density is
high enough, the connection will glow. An oxide actually forms at the (loose) contact area, and the resistance of
the oxide causes the I°R power dissipation.Photo 1 shows a glowing connection at a common receptacle with a current of 12A with a 12 AWG conductor. If
we're lucky, proper enclosing of these connections will keep an occurrence like this from igniting nearby
combustibles, such as wood and cellulose insulation. Even though a poor connection is hazardous, there is
currently no way to detect a poor connection as soon as it begins. A GFCI or AFCT may sense a poor connection
after some electrical insulation becomes conductive and leakage current occurs (5 mA or 30 mA, respectively).
The red circles in Photo 2 show evidence of oxide buildup and small areas of melting due to the series arcing on.
the wire and the underside of the screw.
One of the more misunderstood modes of overheating is insulation breakdown. On one hand, we know how
frayed cords can cause overheating when the insulation is defeated, and strands of the hot wire touch strands of
the neutral or ground wire (see Stand Your Ground). This causes a parallel short circuit and arc — and sparks
may be ejected can ignite nearby fine combustibles, such as paper. However, there are other ways for an
overheating occurrence to ignite into flaming combustion, one of which is called are tracking, according to Sec.
8.9.4.5. of NFPA 921, the “Guide for Fire and Explosion Investigations.”With wet are tracking, a conductive liquid makes contact with an electrical circuit. Leakage current across an
insulator can begin and grow to arc tracking, which can glow and be hot enough to ignite combustibles. Some
examples of this are salt water on aquarium electrical devices or the rinse aid in a dishwasher leaking onto
internal wiring, If this liquid bridges between energized and nonenergized conductors, current can flow through
the liquid and heat plastic insulation supporting the conductors.
Over time, this current can degrade the plastic, turning a hydrocarbon into elemental carbon, which is semi-
conductive. This carbon itself can then conduct increasing amounts of leakage current, which can then glow and
ignite combustible gases coming off the plastic material. Dry arc tracking can oceur without a liquid and may
begin by the thermal degradation in the vicinity of a poor connection, such as that seen in Photo 1. Photo 3
illustrates lab-induced dry arc tracking and wet arc tracking situations on a plug face and microswitch,
respectively.
Photo 4 depicts a close-up of the inside of the microswitch in which the wet arc tracking occurred between the
contacts in the area shown by the red oval. In this case, the degraded carbon in the plastic conducted current
across its surface to cause the overheating.
What are some of the things that can be done to improve electrical safety other than following the NEC and
additional common requirements?+ Install GFCIs indoors, if possible, so they don't get wet. GECIs can overheat and become a fire hazard or
fail to operate and become a shock hazard if they are wet.
ink critically about hazardous or marginal applications and locations (saw mills, dusty areas, pool
pump rooms), and consider upgrading from an indoor to a hazardous-rated enclosure.
+ Avoid the poor wiring practices, as noted in Potential Problem Areas on page C26.
Korinek, P.E., is a forensic engineer and president of Synergy Technologies LLC in Cedarburg, Wis. He can be
reached at Chris@Synergytech.net,
Sidebar: Potential Problem Areas
‘Some commonly known defective wiring practices that can lead to electrical fires include:
+ Loose connections.
+ Aluminum and copper conductors spliced together with an incorrect connector. Aluminum oxide causes
overheating.
+ Some insulation piercing connectors when applied incorrectly can make poor connections due to
insufficient contact area or pressure.
Some fairly unknown or rare issues include:
+ NM cable, if placed against sharp edges of steel truss nailing plates, can have its insulation cut. This can
cause overheating as current flows from the “hot” conductor to the steel through the sharp edge, and
finally to the neutral or ground conductor (most likely due to a poor connection). If the cable is not
secured sufficiently — and stress is placed on the cable — this can also cause the insulation to be cut. Itis
believed that wires lightly contacting the sharp edge can allow heating without tripping a circuit breaker.
+ Appliances with water involved (such as dishwashers and aquariums) can be fire and shock hazards.
Precautions can be taken, however, such as installing GFCIs or AFCIs with sufficient grounding systems to
lessen shock and fire hazards. The photo below shows the aftermath of an aquarium light that started a
fire due to a poor connection at one of the fluorescent light pins.
+ Low-voltage applications (such as high-current landscape lighting) with field connections that are exposed
to combustibles, such as wood siding, can be dangerous. A glowing connection drawing 15A or more can.
generate significant heat and may ignite these combustibles. Ihave heard professionals say, “It's only 12V;
it should be safe.” Of course, this is safe for a shock concern, but it's definitely dangerous froma fire
standpoint, as overheating due to a poor connection is a function of current and is generally independent
of voltage.
Sidebar: Stand Your GroundHistorically, grounding has been present primarily for shock protection when actually it has increased the risk of
fire. A poor connection in a ground conductor network (possibly with conduit or armored cable) carrying
current can certainly be a fire hazard, especially when the grounding conductor has been neglected under the
rationalization that “it is only a ground” and thereby not important. A GFCI and AFCI can protect against both
shock and fire hazards when a ground is present.
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