A critical component of any electrical system, switchgear serves as a backbone for the distribution of electricity — from circuit breakers to fuses, switches and relays. Regular preventative maintenance includes evaluations for upgrades based on technological advancement, compliance with new regulations, improved reliability and efficiency as well as adherence to environmental standards.

In addition to regular testing, more intensive servicing at key intervals is required to ensure continuous, safe, and reliable operation. We upgrade circuit breakers to comply with modern specifications and can help with emergency or shutdown protocols by supplying loan/lease or exchange options for the most popular industrial breakers. In addition to testing, servicing options includes remanufacturing for life extension, reconditioning, solid-state trip device refit, contact replacement/resurfacing, new and obsolete parts replacement, and custom conversions for special applications.

Each piece of equipment is checked and tested:

• electrical and mechanical surfaces are cleaned
• cable and bus connections are verified, with re-torquing performed if necessary
• bolts and screw assemblies are confirmed, torqued according to specifications
• all moving parts are inspected for wear, followed by re-lubrication of components such as hinges, blades, and springs
• checking and adjusting as needed of interlocks, lights and status indicators to ensure correct operation

Load monitoring is generally conducted for 1 week for each piece of equipment: Peaks and Averages of Voltage, Current, KVA, KW, KVAR, Power Factor, and Harmonics are monitored.

Breaker testing is crucial for an effective predictive maintenance program, as breakers are relied upon to trip at fault levels for which they are designed. Any deviation from these levels can result in catastrophic failure (failure to open on a fault) or nuisance tripping, causing downtime in production.

The majority of electrical failures typically occur at contact points within an electrical system. Bolted connection tests play a crucial role in identifying significant issues before they escalate into catastrophic failures.

These tests involve measuring the resistance between bolted bus-to-bus connections, lug-to-bus connections, breaker-to-bus connections, and line and load breaker contacts.

Bolted connection tests are designed to ensure the absence of deteriorated connections at any metal-to-metal joint, such as bus-to-bus connections, wire-to-bus connections, internal breaker contact points, and wire connections to bus connections (breaker, panel lug). Test results for both the initial condition (as found) and the post-test condition (as left) will be meticulously recorded.

It’s important to note that equipment shutdown is necessary for these tests. In instances where connection points exhibit signs of deterioration, re-torquing to specifications and retesting will be performed. If no improvement is observed after the second test, a scheduled shutdown will be planned to address the issue by either cleaning contact points or replacing parts to prevent potential failure.

Every piece of equipment will have an IR scan performed. Panels will be cleaned out, and every bolted connection and wire connection torqued to spec. Minor infrared anomalies will be fixed at time of inspection. Major infrared anomalies will be immediately reported and an action plan made for repairs.

Tested utilizing a megohmmeter at a voltage range of 500-1000VDC. This method is employed to assess the integrity of cables, breakers, switchgear, and motor winding insulating components. The test involves applying a voltage higher than the operating voltage to a device or cable between two locations, while measuring resistive current. Low resistive values detected during the test indicate deterioration between these two points (such as cable to cable or breaker contact to breaker contact). If not addressed, this deterioration may lead to a short circuit between the points.

The Hi-Pot test is a nondestructive evaluation aimed at assessing the adequacy of electrical insulation against normally occurring overvoltage transients. It involves applying a high-voltage test to all devices for a specific duration, ensuring that the insulation is not marginally effective. This high-voltage test is systematically administered to all devices to verify the insulation’s robustness.

Hi-Pot tests play a crucial role in identifying various issues, including nicked or crushed insulation, stray wire strands or braided shielding, the presence of conductive or corrosive contaminants around conductors, terminal spacing problems, and tolerance errors in cables. Additionally, these tests help uncover inadequate creepage and clearance distances that may have been introduced during the manufacturing process.

Transformers are critical components in electrical power systems, requiring regular testing to ensure their reliability, safety, and performance. Various testing techniques are employed to diagnose issues, assess condition, and maintain the health of transformers. Here are just a few of the key transformer tests we can perform:

• insulation resistance testing (Megger Test)
• power factor (dissipation factor) Testing
• turns ratio testing
• sweep frequency response analysis
• dielectric breakdown voltage testing
• partial discharge testing
• frequency response analysis

Our comprehensive on-site services include:

• inspection, testing, and reconditioning of motors and generators
• motor and generator rewinding
• field balancing 
• bearing inspection to prevent failures
• advanced vibration data collection and analysis
• current signature analysis for motor health
• off-line motor surge, step voltage, and high potential testing
• on-line motor circuit and dynamic analysis
• borescope inspection for internal component checks
• oil analysis to monitor lubrication health
• ultrasonic analysis for detecting faults
• inspection and reconditioning of pumps and blowers
• preventive maintenance for AC/DC machines, fans, and blowers
• machine removal and installation
• start-up commissioning for new equipment
• laser alignment services