Keeping Farm & Ranch Operations Safe: The Role of Electrical Preventive Maintenance

Electrical equipment is the backbone of industrial and agricultural operations, but it’s also a major hazard. Every year, U.S. fire departments respond to over 36,000 fires at industrial and manufacturing properties, with electrical failures responsible for 20% of them. In high-risk areas like manufacturing zones and processing facilities, faulty wiring, overloaded circuits, and neglected maintenance often spell disaster. The stakes are even higher in agricultural settings, where the NFPA reports that 29% of animal housing fires result from malfunctioning electrical systems, leading to devastating losses and costly downtime. 

⚠️ Extreme fire hazard on a Poultry Confinement farm

Why Should Every Facility Have an Electrical Preventive Maintenance Program?

An electrical preventive maintenance (EPM) program is a proactive approach to maintaining electrical systems and equipment, aiming to identify and address potential issues before they cause failures or safety hazards. This involves regular inspections, testing, and maintenance tasks to ensure optimal performance, extend equipment lifespan, and minimize downtime. Without it, the risks skyrocket. The Institute of Electrical and Electronics Engineers (IEEE) reports that electrical equipment is three times more likely to fail without preventive maintenance. Yet, many facilities gamble on reactive repairs, which can be a dangerous and costly choice.

An effective EPM program flips the script. It identifies risks like loose connections, dust buildup, and overheating before they escalate. Most electrical failures aren’t freak accidents; they’re preventable. Defective insulation, overloaded circuits, and foreign objects are often the culprits behind dangerous short circuits.

Fluctuating electrical loads cause thermal expansion and contraction, loosening connections over time. Add in dust accumulation in electrical panels, and resistance builds – a recipe for overheating. In fact, loose connections alone account for over 30% of electrical failures. Another 17% are caused by live electrical components exposed to moisture. For industrial and agricultural facilities, dust and moisture are constant threats.

The EPM mantra is simple: Keep it cool, clean, dry, and tight. Preventive maintenance isn’t just a safety measure; it’s a financial win, saving facilities from costly repairs and unplanned downtime. 

Who to Hire

An effective EPM program starts with the right people. Hire licensed electricians with experience in your specific systems for inspections, testing, and repairs, and ensure all work meets NEC and NFPA codes. Specialized equipment like electrical distribution systems often requires additional certifications, while high-voltage systems and protective relay devices demand service from certified professionals with advanced training.

Skimping on qualifications is a costly mistake. Investing in experienced personnel means safer operations, fewer breakdowns, and a longer lifespan for your electrical systems.

Scheduling

Establishing your EPM schedule may take some careful planning, but understanding the three primary scheduling types can simplify the process:

• Calendar-Based: Regularly scheduled inspections and maintenance, typically every 2 to 3 years as recommended by manufacturers.

• Predictive: Maintenance based on signs of potential breakdowns, using data and diagnostics to predict failures.

• Prescriptive: Reactive maintenance is performed after a breakdown occurs.

Aim to rely on calendar-based scheduling as much as possible, using predictive maintenance when necessary. Some equipment will need more frequent inspections, especially if it’s:

• Critical Equipment: Systems whose failure would cause significant downtime or safety hazards.

• Exposed Equipment: Machinery in harsh environments prone to dust, moisture, or corrosion.

• Manufacturer-Specified: Equipment with stricter maintenance guidelines.

• Inadequate Enclosures: Electrical components not properly enclosed for their environment are prone to premature failure.

  
  

When building your customized EPM checklist, identify critical systems, follow manufacturer recommendations, and adjust the schedule based on inspection data to ensure effective preventive maintenance.

Inspecting, Testing, and Servicing

Planned downtime is essential for inspecting and maintaining electrical systems. It’s the best opportunity to assess overall system health and perform intensive testing.

Thermographic Inspections:

Before a scheduled outage, schedule a thermographic inspection. Using infrared technology, this non-invasive test pinpoints hidden issues like loose or dirty connections, load imbalances, or faulty installations. To obtain accurate results, certified thermographers should perform the inspection under peak-load conditions.

A yearly thermographic scan is a smart move. It catches potential hazards before they lead to costly failures. 

Operational Checks:

During the outage, ensure circuit breakers and disconnect switches are opened and closed to verify functionality. Test and calibrate protective relays and circuit breaker trip devices regularly to ensure proper operation.

Additional Tests and Procedures:

Specialized contractors can conduct other tests to assess equipment health, including:

• Relay and Circuit Breaker Tests: Confirm protective devices operate correctly.

• Oil Tests: Evaluate the condition of insulating oil in electrical systems.

• Dissolved Gas Analysis: Detect internal transformer issues through gas breakdown analysis.

• SF6 Gas Leak Testing: Ensure no gas leakage in SF6-insulated equipment.

  
  

Additional EPM Checklist

Include these tasks in your EPM plan:

• Check and test transformers

• Inspect AFCI and GFCI breakers

• Test voltage regulators

• Clean and inspect motor controls

• Verify electrical panel condition

• Ensure proper metering operation

• Test switches and gears

• Check wiring distribution and terminations

• Evaluate grounding and overcurrent protection

• Inspect light fixtures (e.g., recessed, security, motion-sensored, fluorescent)

• Replace ballasts and lamps as needed

• Assess special systems like generators, alarms, UPS, surge protection, and telecommunications.

  
  

Download a printable EPM Checklist below.

EPM Checklist

Thorough, routine inspections and proactive servicing will significantly reduce the likelihood of electrical failures, keeping your facility safer and more efficient.

Record-Keeping

Accurate record-keeping is a key part of a successful EPM program. Detailed records provide insights into system performance, help detect patterns of deterioration, and ensure timely inspections and repairs.

Maintain a clear, digital record that includes:

• An inventory of all electrical equipment

• Records of wear, damage, and past repairs

• Scheduled and unscheduled maintenance logs

• Spare parts inventory

• Outage and abnormality reports

• Equipment schematics, warranties, and manuals

• Performance data and associated KPIs

  
  

Effective record-keeping reduces downtime by streamlining troubleshooting and repair processes. It also provides historical data to refine your EPM program, improving overall system reliability and safety.

Sources

• National Fire Protection Association. (2023). Fire statistics for industrial and manufacturing properties. Retrieved from NFPA research (via USFA/NFIRS data).

• Animal Welfare Institute. (2025). Barn Fires: A Deadly Threat to Farm Animals. AWI.

• National Fire Protection Association. (2023). NFPA 70B: Standard for Electrical Equipment Maintenance.

• National Fire Protection Association. (2018-2023). NFPA 150: Fire and Life Safety in Animal Housing Facilities Code / NFPA 70E: Standard for Electrical Safety in the Workplace.

• U.S. Fire Administration. (2021). Nonresidential building fires: 2017–2019 data. FEMA.

• OSHA/IEEE/NFPA collaborative coverage (2024–2025) on arc flash and workplace electrical safety.