the 15 “hottest” electrical problems you’ll find lurking in facilities

8/20/2019 The 15 “Hottest” Electrical Problems You’Ll Find Lurking in Facilities

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The 15 “Hottest” Electrical Problems You’ll Find Lurking in Facilities

The 15 “Hottest” Electrical Problems You’ll Find Lurking in Facilities

Oct 8, 2015

B !" #mith$ Hart%ord #team Boiler &ns'ection ( &nsurance )o* +Electrical Construction and Maintenance

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,$---. Breaker

This "#$$$A breaker has an obious oer tem%erature condition on the &'%hase terminal( A high resistance or loose bolted connection is causing this

%roblem( Earl) detection and correction o! this %roblem *ill %reent a ma+or %lant'*ide %o*er outage( The adanced *arning !rom the thermogra%hic

image *ill also %reent a signi!icant un%lanned business interru%tion(

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Bad Fuse )li'

This !use cli%# on the load'side o! the &'%hase# has lost its tension( The loose s%ring tension creates a high'resistance +oint that %roduces e,cessie heat

-as seen b) the in!rared camera.( Fuse cli%s can be accidentall) bent during “rough” !use changes( Fuse cli% mounting scre*s can be accidentall) tor/ued

and loosened i! !uses are t*isted during remoal or insertion( Heating at this !use cli% can also cause man) nuisance blo*n !uses due to the internal !use

element heating !rom this local bad connection(

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Bushing

This trans!ormer bushing is sho*ing a concentration o! heat at the bushing itsel! and at the internal bushing0trans!ormer connection( You can see that the

bolted cable lugs are much cooler than the bushing( sing thermogra%h) to detect this condition allo*s !or a %lanned maintenance shutdo*n to !urther

inestigate and re%air the %roblems( A trans!ormer loss is t)%icall) accom%anied b) a long %lant outage !or re%airs and %arts %rocurement(

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Fuse )lam's

The A'%hase and the &'%hase# line'side !use clam%s# are sho*ing e,cessie heat( These !use clam%s are the bolt'do*n st)le( 2ost terminals and

electrical connections hae !actor)'designated and re/uired tor/ue alues listed on e/ui%ment stickers( 3t is im%ortant to %ro%erl) seat the !use blades and

the bolted *edges be!ore tightening the !asteners *ith the tor/ue *rench( 3! )ou are not !ollo*ing the !actor) tor/ue s%eci!ications# )ou ma) hae man)

connections in )our !acilit) that look like this( 4erheating o! the !use mounting %arts can cause annealing o! the metals and loss o! strength(

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Hot Breaker

This single'%ole# "6 lighting circuit breaker has an oerheating %roblem caused b) a loose terminal scre*( This breaker *as oerheated to the e,tent

that it had to be re%laced( The e,cess heat %roduced at the loose breaker terminal also caused the THH7# 8$9& conductor insulation to oerheat seeral

inches a*a) !rom the terminal( The tem%erature'damaged conductor lengths should be cut back and re'terminated *hen %ossible or re%laced *hen too

short(

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Loose 2ire

The :'%hase# load'side *ire on this control %anel contactor *as not installed %ro%erl)( A!ter the %anel *as de'energi;ed and locked and tagged out# the

%lant electrician onl) touched the *ire( 3t *as so loose that it actuall) !ell right out o! the *ire clam%( 3t is ironic that this contactor and *ire su%%lied %o*er

to one o! the machine “sa!et)” deices( The *ire *as cut back and %ro%erl) re'terminated to allo* !or continued %lant %roduction(

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4ld Fuse Holder

This is an old'st)le !use %ullout *ith t*o cartridge !uses installed( 4ne o! the !use cli%s is %roducing *a) too much heat( The in!rared camera can onl)

detect the sur!ace tem%erature o! the %ullout deice( The !use and the !use cli% are both on the underside o! the insulated housing( The !use cli% and !use

barrel tem%eratures are actuall) much hotter than the measured %ullout sur!ace tem%eratures(


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4ld #6itch

This is a ='%hase kni!e s*itch mounted on an o%en't)%e s*itchboard( There is no enclosure coering the energi;ed %arts( These s*itches are still in use in

7e* York &it) and other large cities that date back to the earl) da)s o! electrical installations( The A'%hase kni!e s*itch blade is oerheating at the hinged

+oint and at the blade'to'line'side connection( 3! these s*itch %arts are annealed !rom oerheating# the) ma) all need to be re%laced( 3t ma) be er) di!!icult

to !ind re%lacement %arts !or e/ui%ment this old( 2an) o! these s*itches *ere designed *ith cu%%ed :elleille *ashers to hold tension on the kni!e blade

+oints( 4erheating can cause the :elleille *ashers to lose their “s%ring” and !latten out(

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Po6er Feed %rom Plant

This is the connection %oint bet*een a rene*able resource %o*er %lant and the local utilit) grid( A medium'oltage cable termination is sho*ing e,cessie

heat com%ared to the other t*o %hases( >ince this connection is high ato% a utilit) %ole# it *ould be hard to smell or see an) smoke i! it deelo%ed( 3t is also

!ar a*a) !rom the areas *here an)one normall) %er!orms *ork( 3! )ou are not including this t)%e o! e/ui%ment in )our electrical maintenance %rogram# )ou

are risking a com%lete and une,%ected outage( ?eie* the sco%e o! )our o*n electrical maintenance %rogram( 3t should include ins%ection and serice to

all e/ui%ment and %ossible %oints o! electrical !ailure# including the medium'oltage distribution s)stems(

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Po6er Plant

This %o*er %lant has multi%le %roblems *ith oerheating terminations on the net*ork( A single thermogra%hic image can see all o! the hot s%ots in one

ie*ing and at a sa!e distance a*a) !rom the medium' or high'oltage e/ui%ment( The criticalit) o! an) s)stem is based on the conse/uences o! a

!ailure( 3n a manu!acturing %lant !ailure and outage# onl) one customer is t)%icall) a!!ected( 4n the other hand# *hen a utilit) electrical connection !ails#

entire geogra%hic areas can be a!!ected b) the resulting outage( se this analog) to decide *here to a%%l) thermogra%h) to )our o*n !acilit)’s internal

net*ork o! e/ui%ment and %o*er distribution( @hat are )our most critical s)stem com%onents that could take )our *hole !acilit) do*n

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"ene6able Link Fuse

This is a ='%hase !used s*itch using three rene*able'link !uses( The re%laceable !use link inside has t*o bolted connections to hold the link to the !use

blade ends( Each o! these bolts is !ield'tightened *hen the !use link is re%laced( This adds t*o more !ailure %oints and t*o more %otential higher'resistance

connections( This t)%e o! !use is a code &lass'H !use( The) are usuall) rated !or onl) 1$#$$$A interru%ting ca%acit) -A3&.( 4er the )ears# utilit) net*ork

u%grades hae t)%icall) increased the aailable short circuit current to alues that e,ceed 1$#$$$A( 3t is *ise to re%lace these older rene*able link !uses

*ith modern current'limiting !uses such as code &lass'B or &lass'? !uses -as a%%ro%riate.(

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#olar Panel

This is a thermogra%hic image o! a solar module( 2an) indiidual solar cells make u% one solar module( The solar cells are the s/uares *ithin the grid o!

dots on the module( You can see the cells that are giing o!! a much higher heat signature( The hotter cells are not su%%l)ing energ) to the grid s)stem

because the) are locall) dissi%ating their energ) as heat( As ne* rene*able energ) technolog) adances# ne* uses are !ound !or the thermogra%hic

camera( 6ie*ing the thermogra%hic image needs to be combined *ith the *isdom o! a seasoned thermogra%her to %ro%erl) inter%ret and diagnose

conditions(

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#6itchgear

This ='%hase# !used s*itch in a lumber mill s*itchboard is sho*ing oer tem%erature %roblems on the :'%hase# line'side connection o! the !use( Poor

connections can cause enough heat to destro) the internal %arts o! the electrical e/ui%ment( 3! not corrected in time# the metals can melt and cause an

arcing'!ault *ithin the enclosed e/ui%ment( Arcing ground !aults and %hase'to'%hase !aulting can com%letel) destro) multi%le s*itchboard

sections( Thermogra%h) is a great tool to see heat %roduced b) electrical e/ui%ment *here is unsa!e to use )our sense o! touch to “!eel” the heat

directl)( >%ecial sa!et) %recautions are de!ined in 7FPA $E !or %ersonnel *ho %er!orm thermogra%hic testing(

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Trans%ormer )onnection

These three single'%hase trans!ormers are connected to %roide a ='%hase serice to a manu!acturing !acilit)( You can see that t*o o! the secondar)

terminal connections are oerheating( 4ne bad connection is on each o! t*o trans!ormers( >ince this is the main serice su%%l) !or the !acilit)# a !ailure at

this %oint in the s)stem means a total une,%ected %lant shutdo*n( 3! the %roduction e/ui%ment is running at the time the termination !ails# the ='%hase

e/ui%ment *ill single'%hase and is likel) to cause additional %roduction e/ui%ment damage be)ond the !ailed termination(

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Trans%ormer Lo6 4il

This is a er) interesting image( This %admount trans!ormer has a li/uid leel gauge installed in the trans!ormer tank( The gauge is *orking %ro%erl)# telling

the o*ner that the oil leel is at the minimum leel( Coes the electrical maintenance %rogram call !or someone to ins%ect items like the trans!ormer li/uid

leel gauge 3s it checked monthl) Yearl) Eer Luckil)# in this case# an in/uisitie thermogra%her ie*ed this trans!ormer through the in!rared

camera( The oil cannot circulate i! the radiator su%%l)# and return %i%es are not both belo* the tank oil leel( For eer) 1$9& that this trans!ormer

continuousl) o%erates oer its tem%erature rating# its li!e is reduced b) one'hal!( Luckil)# this %otentiall) catastro%hic !ailure *as reduced to a lo*'cost

maintenance actiit)(

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"elated 8alleries 9 "EF"E#H 8.LLE"Y

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&an You 7ame That Animal0

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1$ Eas) @a)s to Troubleshoot *ith an 4scillosco%e

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D 2ore Electrical A%%s You @on’t @ant to 2iss ,

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1= Preentable :us*a) Failures You 7eer @ant to >ee 1

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http://ecmweb.com/computers-software/8-more-electrical-apps-you-won-t-want-misshttp://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-seehttp://ecmweb.com/computers-software/8-more-electrical-apps-you-won-t-want-misshttp://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-see


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Are you using thermography as part of your electrical preventive maintenance program? If not, you should “see” what you’re missing

!" #mith is director of thermography services for $artford #team %oiler Inspection and Insurance &o and a 'evel(III thermographer

)ith the help of %ill *iot and Norm +aver -oth $#% 'evel(II thermographers., they have com-ined more than /0 years of experience

in the thermography -usiness to show how 1/ electrical disasters were averted using thermography 2he success of a thermography

program critically depends on the s3ill level of the thermographer interpreting the image

After seeing these examples of impending disasters, you’ll -e wondering what “invisi-le” disasters are lur3ing in your facility4

5or more information on thermography chec3 out6http677wwwmunichrecom7$#%7thermography7indexhtml

!" can -e reached at "onald8#mith8!r9hs-com

Related Galleries

&an :ou Name 2hat Animal?

http://www.munichre.com/HSB/home/index.htmlhttp://www.munichre.com/HSB/home/index.htmlhttp://www.munichre.com/HSB/thermography/index.htmlmailto:[email protected]://ecmweb.com/ops-amp-maintenance/can-you-name-animalhttp://www.munichre.com/HSB/home/index.htmlhttp://www.munichre.com/HSB/thermography/index.htmlmailto:[email protected]://ecmweb.com/ops-amp-maintenance/can-you-name-animal


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1; Preventa-le %usway 5ailures :ou Never )ant to #ee

http://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-seehttp://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-see


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Protecting Yoursel! !rom Arc Flash Ha;ards

Oct 18, 2014:a;e


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=lectronics =ngineers I===. reports that >,000 wor3ers are admitted to -urn centers for extended in


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In addition, the latest version of N5PA C0=6 #tandard for =lectrical #afety in the )or3place has made changes to safety, maintenance, and

training reuirements &hanges were made to the ways in which electrical ris3s are evaluated to help prevent exposure to electrical arc flash

haards and to support compliance with B#$A reuirements

RELATED

$ow to "educe =lectrical $aards in the )or3place

Danaging Arc 5lash in :our 5acility

)hile employers are o-ligated -y law to follow B#$A regulations for creating a safe wor3 environment, electrical wor3ers need to play an

active role in ensuring their own safety on the 01> stipulating that the meeting -etween the employer

and contractors must -e documented Focumenting the meeting helps to ensure and validate that you have the information you need to stay

safe on the


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In the past, N5PA C0= was am-iguous a-out if it was sufficient to use ta-les supplied -y the standard for the arc flash -oundary distance

flash protection -oundary. or if the distance would have to -e calculated $owever, several provisions in the latest version of N5PA C0=

ma3e it more difficult to defend the easier method of using the ta-les, especially for locations where the voltage is greater than /0*

2he newest revision to >G &5" 1G10>HG reuires owners7employers to estimate incident energy and even recommend the methods to use in

certain circumstances, such as adhering to I=== #tandard 1/J for euipment operating up to 1/,000* and using special analysis software for

higher voltages %y calculating the -oundary and providing you with the information, your employer ensures you understand when and at

what distances PP= and safe wor3 practices are needed to protect against arc flash haards

Tip !: "e sure you are #ualified for the $o, and get training if you need it.

N5PA C0= >01/ defines a ualified person as one who has demonstrated s3ills related to the construction and operation of the electrical

euipment and installations and has received safety training to identify and avoid the haards involved Per revisions to N5PA C0= in >01>,

only ualified persons can perform testing and maintenance within the limited approach -oundary

=mployers need to ma3e sure that employees and contractors who wor3 around not


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2he latest editions of N5PA C0= spell out the types of euipment that need to -e la-eled, specifically switch-oards, switchgear, panel-oards,

industrial control panels, meter soc3et enclosures, and motor control panels that are li3ely to reuire examination, ad01/ has -een slightly modified regarding what information needs to

-e included on field la-els, stating that the la-els should include6

K Nominal system voltage

K Arc flash -oundary

K At least one of the following6

L Incident energy and wor3ing distance or arc flash PP= category -ut not -oth.

L Dinimum arc rating of clothing

L #ite(specific level of PP=

If this information is not clearly availa-le, contractors should inform the owner of the electrical euipment N5PA C0= clearly indicates that

electrical euipment owners are responsi-le for documentation, installation, and maintenance of the field(mar3ed la-els

Tip (: )ress the part. Use new arc flash **+ tales to choose arcrated clothing and other **+.

N5PA C0= >01/ introduces a new format for selecting the appropriate arc(rated clothing and PP= for -oth A& and F& systems In the past,

the ta-le method was somewhat cum-ersome, and the new format is designed to simplify the process

#pecifically, new tas3(-ased ta-les have -een added for determining when arc flash PP= is necessary 5or each tas3, the ta-le indicates if there

is an arc flash haard yes or no. 2he new ta-le addresses ris3 -ut not severity of the exposure 5or example, when you are operating a power

circuit -rea3er after it has tripped and no true reason for the trip was discovered or corrected, PP= is reuired $owever, it will ta3e further

engineering analysis -y you or your employer to determine what type of PP= is reuired


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Tip -: a'e it safe. /erify an electrically safe wor' condition.

)or3ers need to test and verify that a system is de(energied, including the loc3out7tagout procedure Furing this wor3, euipment is

considered to -e energied and wor3ers must -e informed of the level of PP= necessary for the 01/ stipulates that wor3ers need to use an adeuately rated test instrument to test each phase conductor or circuit

part to verify it is de(energied %efore and after each test, wor3ers need to verify that the test instrument is operating satisfactorily through verification on a 3nown voltage source

2est euipment manufacturers are la-eling their euipment with the energy category for each device, and only &ategory III or I* instruments

should -e used on industrial electrical systems )hile there might -e many availa-le “live” sources for verifying operation of a low(voltage

instrument, higher voltage test points may not -e availa-le 2he manufacturers of high(voltage measuring and detection devices also offer a

separate porta-le test source to verify operation

Tip 0: Get perission. Know when an energied electrical wor' perit is re#uired.

N5PA C0= >01/ states that an energied electrical wor3 permit is reuired to -e within the restricted approach -oundary "A%. or when

interacting with an increased ris3 of exposure to an arc flash 2his permit is a critical tool in helping wor3ers determine the ris3s involved in

performing a specific 01>, N5PA C0= added a reuirement for the use of ground fault circuit interrupters +5&Is. where reuired -y local, state, and federal

codes or standards 2he >01/ version of the standards adds to the reuirement -y stipulating that +5&I protection needs to -e provided for


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operating or using tools related to maintenance and construction activity with 1>/*71/A, >0A, or ;0A circuits At voltages greater than this,

either +5&I protection or assured euipment grounding conductor program must -e provided As3 to review the written description of this

program that is reuired -y B#$A to -e at the


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Kreger is a licensed power engineer, NETA Level III certified technician, member of the National Fire Protection Association (electrical

section, and master instr!ctor for the training gro!p of Emerson"s Electrical #eliabilit$ %ervices, &ol!mb!s, 'hio )e can be reached

at david*reger+Emersoncom

?odent


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Location o% the &ncident

sing large electric %rime moers to com%ress natural gas through underground %i%eline# >%ectra Energ) has man) stations in its s)stem( This %articular

station is e/ui%%ed *ith t*o 5k6# =#"5$'h% %rime moers !ed !rom 5k6# "#$$$A s*itchgear *ith closed transition reduced oltage starters !used at $$A(

The %hoto aboe sho*s the scene o! the arc !lash incident although this is obiousl) the !ront ie* o! the medium'oltage starter( Arc !lash anal)sis had

been com%leted !or this station# and the incident energ) aailable at this s*itchgear cubicle *as ("8 cal0cm"(

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.rc Flash .%termath

The author receied a %hone call earl) one morning !rom an electrical technician asking !or hel%( An arc !lash eent had occurred in 2&&'$5$ on circuit &'

1$$# *hich is the %rimar) !eed !or one o! the com%an)’s 5k6# =#"5$'h% %rime moers# and tri%%ed breaker 5">: in 2&&'$"5 in the substation( 7oteG 5">:

is the main breaker that !eeds 2&&'$5$( @hile hel%ing the technician troubleshoot oer the %hone# the %air concluded that the incident *as isolated to the

&'1$$ circuit breaker( The author instructed the tech to lock and tag out the motor disconnect and reset the 5">: main breaker to re'energi;e 2&&'$5$

%rior to his arrial on'site the ne,t da)( &arroll also brought along a certi!ied testing re%resentatie he’d called !or assistance( The on'site isual ins%ection

began the ne,t morning# starting *ith the &'1$$ breaker and starter cubicle( The t*o %hotos aboe sho* the condition o! the disconnect and !use cabinet

as the) !ound it(



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. )loser Look

Pushing !or*ard *ith the inestigation# the grou% o! troubleshooters %rom%tl) disassembled the contactor and started testing the !uses# control %o*er

trans!ormer# control *iring# %rotectie rela)# and 5k6 cables( 3t *as obious that the %ressure !rom the arc blast bent the bottom o! the door ho*eer# the

to% also sho*ed signs o! bending( The cables running !rom the load side o! the reduced oltage starter to the running contactor also had to be re%laced(

3n addition# the contactor *as be)ond re%air# as *ere all three acuum bottles# *hich had been destro)ed( Plus# the internal co%%er bus had been melted



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and damaged# and the insulators had been damaged( The le!t %hoto sho*s damage to the back o! the contactor# *hile the right %hoto illustrates *here the

melted co%%er started dri%%ing !rom the bus bars and damaged acuum bottles(

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The ?nluck @ouse

Curing the inestigation# the cul%rit *as /uickl) !ound a %oor little charred mouse that *as still attached to a section o! the ertical co%%er bus( :ecause

no %hase barriers se%arated the hori;ontal co%%er bus on the to% o! the contactor# eer)one inoled agreed that the rodent %robabl) caused this incident

mostl) likel) *hen the critter made his *a) across t*o o! the hori;ontal bus bars and initiated an arc bet*een %hases(

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)ubicle 6ith )om'leted "e'airs

3n %re%aration o! re%air and remediation e!!orts# the author called the manu!acturer to get a %arts list and ordered the necessar) items to re%lace the

damaged com%onents( These included a ne* contactor# !use cli%s# co%%er bus -to connect the !uses and contactor.# ne* cable -!rom the starting contactor

to reduced oltage contactor.# ne* *iring harnesses# disconnect o%erating mechanism# and all ne* hard*are( The door -damaged !rom the %ressure o!

the arc blast. *as sent out !or re%air *hile the technician cleaned and re%ainted the cubicle( This %hoto sho*s the cubicle a!ter all re%airs *ere made(

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Adertisement

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Ae6 )ontactor 6ith Phase Barriers &nstalled

A!ter com%leting re%airs# the author noticed that the ne* contactor had slots on the to% running !rom the !ront to the rear( This %rom%ted him to immediatel)

call the manu!acturer to see i! %hase barriers could be installed bet*een the hori;ontal bus that connects the !use cli%s to the line side o! the contactor(

:ecause this *as not a stock o%tion !rom the !actor)# he had to ask !or that o%tion *hen the e/ui%ment *as designed and ordered( The le!t %hoto sho*s

the ne* contactor *ith the ne* %hase barriers installed# and the right %hoto sho*s the entire 2&&'$5$ cubicle *ith re%airs com%leted( 7oteG The author

e,%lored the %ossibilit) o! tr)ing to seal the 2&& to %reent rodents !rom entering( Ho*eer# because most o! the bottom o! the 2&& is o%en to cable

troughs# that solution %roed too di!!icult(

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Pre;enting Future )ritter )atastro'hes

Follo*ing this incident# the author *as called to another regional station *here similar e/ui%ment *as installed( This time# technicians %er!orming annual

maintenance to the 2&& !ound a dead mouse on to% o! a motor contactor *ithout the installed %hase barriers -%hoto aboe.( 4nce again# &arroll

contacted the manu!acturer immediatel) to order a set o! %hase barriers !or this e/ui%ment and considered himsel! luck) that the little gu) *ho had

*orked his *a) into this e/ui%ment did so *ithout causing serious damage like his earlier counter%art(

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"elated 8alleries 9 "EF"E#H 8.LLE"Y

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8 Things Eer) Electrical Pro!essional 7eeds to Bno* About Arc Flash

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True or FalseG Test Your >a!et) >ense /

o

1= Preentable :us*a) Failures You 7eer @ant to >ee 1

http://ecmweb.com/ops-maintenance/rodent-goes-roguehttp://ecmweb.com/arc-flash/9-things-every-electrical-professional-needs-know-about-arc-flashhttp://ecmweb.com/galleries/true-or-false-test-your-safety-sensehttp://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-seehttp://ecmweb.com/ops-maintenance/rodent-goes-roguehttp://ecmweb.com/arc-flash/9-things-every-electrical-professional-needs-know-about-arc-flashhttp://ecmweb.com/galleries/true-or-false-test-your-safety-sensehttp://ecmweb.com/ops-maintenance/13-preventable-busway-failures-you-never-want-see


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The 15 “Hottest” Electrical Problems You’ll Find Lurking in Facilities 1

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An electrical technical specialist for #pectra =nergy, #cott &arroll wor3s with >> electrical technicians, covers /C natural gas compressor

stations, and focuses on installation, maintenance, testing, and pro/,000 in materials and la-or

@ a hefty price to pay when the phase -arriers could have -een installed during manufacturing for approximately OC/ each Note6 )hile

conducting research on this su-

the 15 “hottest” electrical problems you’ll find lurking in facilities

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