Outdated electrical panels and wiring can be hazardous. Although routine maintenance and inspections should be conducted on all electrical systems, aging infrastructure must often be updated or replaced. Completing work of this nature can pose additional risk factors not encountered in standard electrical jobs. Safety protocols and best practices should be put in place to protect people and property.

Potential hazards

First, let’s look at the hazards created by outdated electrical panels and wiring. Older panels, wiring and components are often not capable of handling the electrical load necessary to power modern appliances and technology. As a result, there is a higher risk of overheating and electrical fires. Deteriorating and aging wires also can become exposed over time, elevating the risk of fire and electrical shock. 

Additionally, as electrical codes are regularly updated, older systems are no longer in compliance. Modern electrical systems may require different gauges, color-coded wiring or grounding requirements. If an incident occurs with noncompliant electrical components, there could be legal ramifications, not to mention the potential loss of life or property.

So, what are some indicators that a system is outdated? It’s probably time for an update if:

• A breaker or breakers continually trip
• There are fuses but not breakers
• The electric panel is warm or has a burning smell
• Lights flicker when powering on appliances
• There are not enough outlets to power electronics

As a rule of thumb, if the electrical system is more than 25 years old, consider a replacement.

Where to start

Tackling an update or replacement of an outdated electrical system requires a thorough assessment and careful planning. Electrical contractors should start by examining the existing panels and wiring to determine where updates are needed. It is critical to reference the National Electrical Code (NEC) and local building codes to make sure every component is in compliance with the latest safety regulations. Once necessary improvements have been identified, a detailed plan for the scope of the project can be created. 

Prior to starting any work, it is imperative to ensure that the power supply to the electrical panel is disconnected. All the appropriate lockout/tagout (LOTO) procedures referenced in NFPA 70E, Standard for Electrical Safety in the Workplace, should be followed to prevent accidental re-energization. 

And it should go without saying, but this type of work should only be performed by electricians and qualified electrical workers.

Replacing equipment

Several sources, including the Electrical Safety Foundation, NEC, NECA, NFPA, and OSHA, offer resources on identifying and updating electrical systems. When replacing an outdated panel, the new one should meet all safety and compliance requirements and be capable of handling the maximum electrical load requirements necessary. Ensure that installation is done in accordance with all manufacturer instructions and specifications and that proper grounding and bonding protocols are taken. 

If wiring needs to be replaced, it should be done with new and properly insulated wires. The NEC and local regulations will dictate the appropriate wire sizes for the job. Reference NFPA 70E for proper wiring techniques to ensure that all connections are safe and secure.

Once all panels or wiring are installed, the system should be inspected and tested for safety and functionality. A final walk-through inspection will ensure that the entire system is safe and compliant.

Electricians and electrical workers should take additional safety precautions when updating panels and wiring. They should use the appropriate insulated tools for the job and the correct personal protective equipment, such as rubber gloves, protective eyewear and arc-resistant clothing, to help minimize the risk of injury or incident. Insulated tools will reduce the risk of shock and electrocution.

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