FACILITY BACKGROUND
- Location: Main Switchgear, Industrial Manufacturing Plant
- Total Insurable Value (TIV): $1 billion
- Equipment: 480-Volt, 1,600-Amp Switchgear
The Challenge
The switchgear, a vital component of the plant’s electrical distribution system, exhibited a critical fault during a routine infrared thermography inspection:
- Fault Type: B-phase line side bus bar to bushing connection.
- Temperature Rise: +582°C above baseline.
- Maximum Temperature: 688°C.
- Severity: Critical (4-star rating).
The fault may have been caused by loose connections or improper assembly during installation, compounded by dissimilar metals in the connectors.
Impact Assessment
If left unresolved, this fault could have resulted in:
• Extensive damage to the primary switchgear, or total loss.
• Property damage exceeding $1 million.
• Business interruption lasted over 120 days.
Solution
The infrared thermography survey identified the abnormal heat signature, prompting immediate action:
- Emergency shutdown then de-energizing the switchgear to allow safe access.
- Replacing faulty components and ensuring all connections were tightened to the correct torque specifications.
Results
- Immediate correction of the fault, avoiding equipment failure.
- Reinforced the facility’s commitment to safety and proactive maintenance.
- Minimized risk exposure and ensured operational continuity.
Key Takeaways
- Precision Matters: Proper installation and maintenance, including torque specifications, are critical to the longevity of electrical systems.
- Early Detection Saves Millions: Identifying faults before failure prevents significant financial and operational losses.
- Predictive Maintenance in Action: Infrared thermography services continue to prove its value as a cornerstone of electrical risk management.
Interested in learning more about how infrared thermography services can help your business uncover dangerous areas of abnormal temperature in electrical systems? We invite you to contact us to speak to a specialist.
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