Case Study: Preventing Catastrophic Failure at a Manufacturing Substation

FACILITY BACKGROUND

• Location: Main Substation at a large woodworking facility
• Total Insurable Value (TIV): $525 million 
• Equipment: High-Voltage 115-kV Switch/Bushing
  
  

The Challenge 

The substation was a critical component of the facility’s operations, responsible for regulating and distributing electrical power. Environmental conditions, including a coastal location with salt-laden air, compounded the risks to the electrical system. A routine infrared thermography inspection identified an alarming anomaly: 

• Fault Type: B-phase load side lug connection 
• Temperature Rise: +85.5°C above normal 
• Severity: Critical (4-star rating) 

Impact Assessment 

If undetected, this fault could have led to: 

• Equipment failure, triggering a complete substation outage. 

• Estimated property damage exceeding $1 million. 

• Business interruption potentially lasting between one to four months.

Solution 

Infrared thermography, a non-destructive testing technique, was used to detect abnormal heat signatures in the substation equipment. After identifying the fault, immediate corrective actions were implemented: 

• Proper cleaning maintenance. 
• Utilization of specialized insulation, larger conductors etc. 

Results 

• Fault mitigated without any unplanned downtime. 
• Significant cost savings by avoiding catastrophic equipment failure. 
• Demonstrated the value of predictive maintenance to insurers and stakeholders. 
  
  

Key Takeaways 

1. Proactive Risk Management: Routine infrared thermography inspections are essential for identifying and addressing critical anomalies. 
   
2. Environmental Awareness: Facilities in challenging environments, such as coastal areas, face unique risks that require tailored maintenance strategies. 
   
3. ROI of Infrared Thermography: A relatively small investment in infrared thermography services resulted in cost avoidance exceeding $1 million. 
   

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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