During a recent infrared inspection, a significant hot spot on a client’s medium voltage transformer termination was identified. Elevated temperatures on medium voltage connections are often caused by deteriorating contact surfaces, loose connections, contamination, or internal component failure.

During the scheduled maintenance outage, we prepared the circuit for inspection and offline testing. As our technicians attempted to remove the loadbreak elbow from the loadbreak insert, they immediately noticed the connection was unusually difficult to separate.

At that moment, the decision was made to stop.

Rather than forcing the connection apart and risking damage to the cable or transformer termination, our technicians chose the safer approach and reassessed the situation. In medium voltage systems, taking the extra time to evaluate an abnormal condition can be the difference between a controlled repair and a major outage.

Had the connection been forcefully removed, the client may not have been able to return to service that same day. Because our technicians recognized the abnormal condition early, we were able to create a repair plan, return with the correct materials, and complete the repair safely with minimal downtime.

The safest solution was to cut off the existing loadbreak elbow and replace both the elbow and loadbreak insert. Fortunately, there was enough cable length remaining to complete a new termination without requiring additional cable replacement or splicing.

After the repair was completed, we brought the removed loadbreak insert back to our shop for further inspection. Once disassembled, the cause of the overheating became clear. The internal connection surfaces showed severe thermal damage and burning, and the elbow’s conductive pin appeared to have partially melted and fused inside the loadbreak insert — creating excessive resistance and heat buildup.

Had this issue gone undetected, it could have resulted in:

• Equipment damage
• Unplanned outages
• Emergency repair costs
• Extended downtime

This project serves as a reminder that in electrical maintenance, being safe rather than sorry is always the right decision.

The post Be Safe Rather Than Sorry – Medium Voltage Transformer Hot Spot appeared first on All-Test.

In the dynamic landscape of industrial operations, precision and efficiency are paramount. As plant managers, ensuring that every component of our facility operates at optimal levels is not just a priority, but a necessity. One often overlooked yet critical aspect of maintaining peak performance is electrical calibration. In this article, we’ll delve into the significance of electrical calibration and how it can elevate your plant’s operational prowess.

Understanding Electrical Calibration

What is Electrical Calibration?

Electrical calibration is the process of adjusting and verifying the accuracy of electrical instruments and equipment. This meticulous procedure ensures that measurements taken by these devices are precise and reliable. From voltage meters to temperature controllers, electrical calibration encompasses a broad spectrum of instruments crucial to the smooth functioning of industrial machinery.

The Importance of Electrical Calibration

Electrical Calibration Enhances Accuracy

In the realm of industrial operations, even the slightest deviation in measurement accuracy can lead to significant repercussions. Whether it’s monitoring voltage levels or controlling temperature parameters, precision is non-negotiable. Electrical calibration guarantees that your instruments provide accurate readings, minimizing the margin for error and bolstering the reliability of your processes.

Optimized Performance

A well-calibrated electrical system operates at its peak efficiency. By fine-tuning instruments to match specified standards, you’re maximizing the performance potential of your equipment. This optimized performance not only improves productivity but also extends the lifespan of your machinery, mitigating the risk of unexpected breakdowns and costly downtime.

Compliance and Safety

Regulatory compliance and safety standards are integral aspects of industrial operations. Electrical calibration ensures that your instruments adhere to these standards, providing you with the peace of mind that your facility operates within legal boundaries. Moreover, calibrated equipment reduces the risk of safety hazards, safeguarding both your workforce and your assets.

Cost-Efficiency

Investing in electrical calibration may seem like an additional expense, but in reality, it’s a strategic investment in long-term cost-efficiency. By preemptively identifying and rectifying potential inaccuracies, you’re averting costly issues down the line. The expenses incurred due to operational disruptions or faulty measurements far outweigh the relatively minor costs of regular calibration.

The Process of Electrical Calibration

Assessment and Analysis Cost-Efficiency

The first step in electrical calibration involves a comprehensive assessment of your instruments. Experienced technicians meticulously examine each device, identifying any deviations from standard specifications. Through advanced analytical techniques, they pinpoint areas that require adjustment or fine-tuning.

Precision Calibration

Once the assessment is complete, the calibration process begins. This involves precise adjustments to align the instruments with established reference standards. Technicians utilize advanced calibration equipment and methodologies to ensure utmost accuracy. Every parameter is meticulously calibrated, leaving no room for error.

Verification and Certification

Following calibration, verification tests are conducted to validate the accuracy of the adjusted instruments. This phase ensures that the devices meet the required performance criteria. Upon successful verification, the instruments are certified, providing tangible proof of their accuracy and compliance with industry standards.

Documentation and Maintenance

Proper documentation of calibration activities is essential for regulatory compliance and quality assurance. Detailed records outlining the calibration procedures, results, and certification are maintained for future reference. Additionally, regular maintenance schedules are established to uphold the calibrated status of the instruments over time.

In the intricate web of industrial operations, precision reigns supreme. As plant managers, prioritizing the calibration of electrical instruments is not just a matter of efficiency—it’s a strategic imperative. From enhancing accuracy and optimizing performance to ensuring compliance and safety, the benefits of electrical calibration are manifold.

By investing in regular calibration procedures, you’re not only safeguarding the integrity of your processes but also fortifying the foundation of your facility’s success. So, embrace the power of precision, and watch as your plant ascends to new heights of operational excellence.

Remember, in the realm of industrial operations, precision is not just a luxury—it’s a necessity. And electrical calibration is the key to unlocking its full potential.

The post Maximizing Efficiency and Precision: The Benefits of Electrical Calibration for Plant Managers appeared first on All-Test.

Cost-Effective Solutions

In the field of electrical services, ensuring the optimal performance of equipment is crucial. Electrical transformers play a pivotal role in power distribution, and when they malfunction, they disrupt operations and lead to significant downtime. One strategic approach that has gained traction in recent years is outsourcing the repair of electrical transformers. In this article, we will delve into the benefits of outsourcing these repairs, exploring how it contributes to efficiency and reliability in electrical systems.

Economies of Scale

Outsourcing transformer repairs often allows companies to tap into the economies of scale offered by specialized repair facilities. These facilities handle a multitude of transformer repairs, enabling them to purchase materials in bulk and reduce overall costs. This cost-effectiveness translates into more affordable repair services for businesses seeking to optimize their budgetary allocations.

Reduced Capital Expenditure

Investing in specialized equipment and skilled personnel for in-house transformer repairs can be a substantial capital expenditure. Outsourcing eliminates the need for such investments, as repair facilities come equipped with state-of-the-art tools and experienced technicians. This frees up capital for other critical aspects of business operations.

Expertise and Specialization

Skilled Technicians

Outsourced repair facilities often have a team of highly skilled technicians who specialize in transformer diagnostics and repairs. These professionals undergo rigorous training and stay abreast of the latest technological advancements in the field. Leveraging their expertise ensures that transformers are repaired with precision and in accordance with industry standards.

Advanced Diagnostic Technologies

Professional repair facilities invest in advanced diagnostic technologies and training that may not be readily available to every in-house maintenance team. These technologies allow for comprehensive assessments of transformer health, enabling technicians to identify issues accurately and address them proactively. Outsourcing thus ensures a thorough and precise diagnosis of transformer problems.

Minimized Downtime

Quick Turnaround

Timely repairs are crucial to minimizing downtime in any electrical system. Outsourcing transformer repairs often results in quicker turnaround times, as specialized facilities prioritize efficiency. This swift resolution minimizes disruptions to operations and prevents prolonged periods of downtime that can be detrimental to businesses.

Access to Spare Parts

Professional repair facilities maintain an inventory of commonly used transformer spare parts. This immediate access to necessary components further accelerates the repair process. Unlike in-house teams that may need to order parts and wait for delivery, outsourcing ensures a more streamlined and expedited repair timeline.

Compliance with Standards and Regulations

Adherence to Industry Standards

Electrical systems are subject to various industry standards and regulations to ensure safety and reliability. Professional repair facilities are well-versed in these standards and adhere to them meticulously. Outsourcing transformer repairs helps companies maintain compliance, mitigating the risk of regulatory issues.

Quality Assurance

Outsourced repair services often come with quality assurance guarantees. This assurance is derived from the expertise of specialized technicians, adherence to industry standards, and rigorous testing protocols. Companies can rest assured that their transformers are repaired to the highest quality, reducing the likelihood of recurring issues.

Focus on Core Competencies

Strategic Resource Allocation

Outsourcing transformer repairs allows companies to focus on their core competencies. Rather than diverting internal resources towards maintenance activities, businesses can concentrate on enhancing their primary services or products. This strategic resource allocation can lead to increased competitiveness in the market.

Continuous Improvement

With the burden of transformer repairs lifted, internal teams can dedicate more time to continuous improvement initiatives. This could involve enhancing overall system efficiency, implementing new technologies, or developing innovative solutions. Outsourcing serves as a catalyst for continuous improvement within the organization.

To sum up, outsourcing the repair of electrical transformers offers a plethora of benefits, ranging from cost-effectiveness and expertise to minimized downtime and regulatory compliance. By leveraging the capabilities of specialized repair facilities, businesses can ensure the longevity and optimal performance of their electrical transformers. As the electrical industry continues to evolve, embracing strategic approaches like outsourcing becomes essential for staying ahead in a competitive landscape.

The post Outsourcing Electrical Transformer Repairs: A Strategic Approach for Efficiency and Reliability appeared first on All-Test.

In the complex world of electrical systems, transformers play a pivotal role in ensuring a steady and efficient power supply. However, like any machinery, transformers are susceptible to wear and tear, potentially leading to costly repairs. As a seasoned professional electrician, I’ve witnessed firsthand the transformative impact of routine transformer testing. In this article, we’ll delve into the various ways transformer testing can not only enhance the reliability of your electrical infrastructure but also save you significant expenses in the long run.

Understanding the Transformer’s Crucial Role

Before we explore the benefits of transformer testing, let’s establish the critical role transformers play in the seamless functioning of electrical systems. Transformers are responsible for altering the voltage levels of electricity, making it feasible for efficient power transmission and distribution. From substations to industrial facilities, transformers are omnipresent, silently powering our everyday lives.

The Silent Culprit: Common Transformer Issues

Transformers, though robust, are not immune to issues. Over time, factors such as overloading, overheating, and insulation degradation can lead to malfunctions. Left unchecked, these problems can escalate, resulting in extensive downtime and costly repairs. Identifying and addressing these issues proactively is where transformer testing comes into play.

Early Detection through Routine Testing

Preventive Medicine for Transformers
Imagine being able to detect potential transformer problems before they escalate into full-blown crises. This is precisely what routine transformer testing offers—a preventive approach to electrical maintenance. By conducting regular tests, electricians can identify issues such as insulation breakdown, winding faults, and oil contamination early on, allowing for timely and cost-effective interventions.

Cost-Effective Repairs vs. Costly Replacements

From Repairs to Replacements: The Financial Implications
Repairing a transformer in its early stages of malfunction is not only quicker but significantly more economical than replacing an entire unit. Transformer testing empowers electricians to pinpoint the root cause of a problem, facilitating targeted repairs that address the issue without unnecessary expenditures. In essence, it’s about nipping potential problems in the bud before they spiral into major financial setbacks.

Downtime Costs: A Financial Wake-Up Call

The Hidden Price of Downtime
In the world of business and industry, downtime is money lost. When a transformer fails unexpectedly, it can bring operations to a standstill, leading to not only transformer repair costs but also substantial financial losses due to halted production. Transformer testing helps mitigate this risk by identifying potential failures in advance, allowing for scheduled maintenance that minimizes downtime and its associated financial repercussions.

Enhancing Longevity and Efficiency

Prolonging Transformer Lifespan
A well-maintained transformer is a long-lasting transformer. Regular testing not only prevents major issues but also ensures that the transformer operates at optimal efficiency. This not only extends its lifespan but also contributes to energy savings, making transformer testing a sustainable practice that aligns with both financial and environmental goals.

Compliance and Safety Standards

Meeting the Standards: Regulatory Compliance and Safety
In today’s regulatory landscape, adherence to safety and compliance standards is non-negotiable. Transformer testing is not just a best practice; it’s often a requirement to meet industry standards and regulations. By staying ahead of these requirements, businesses not only avoid fines and legal complications but also create a safer working environment for their personnel.

Investing in Peace of Mind

Transforming Worry into Confidence
In the fast-paced world of electrical systems, uncertainties can keep facility managers and business owners up at night. Investing in routine transformer testing is, in essence, an investment in peace of mind. Knowing that your transformers are regularly evaluated and maintained provides a level of confidence that transcends the financial benefits, offering assurance in the reliability of your electrical infrastructure.

A Proactive Approach to Electrical Preventative Maintenance

In the realm of electrical systems, the saying “an ounce of prevention is worth a pound of cure” holds true, especially when it comes to transformers. Routine testing not only acts as a shield against unexpected failures but also as a savvy financial strategy. By opting for preventive measures, businesses can safeguard their bottom line, enhance operational efficiency, and ensure the longevity of their crucial electrical assets. So, the next time you consider the cost of transformer testing, remember that it’s not just an expense; it’s a strategic investment in the future resilience of your electrical infrastructure.

The post How Transformer Testing Can Save You Thousands in Repairs! appeared first on All-Test.

Medium and high voltage systems use similar transformers that are rated at those higher voltages.

Single Phase Control Power Units

These control power transformers are usually single phase in nature and are fused. Fusing may be at both or only one of the levels.

These transformers provide a range of current in the 1–50-amp levels. They are rated in VA. POTENTIAL transformers, on the other hand may be 3 phase in nature, and a topic for another blog. For now, let us stick with single phase control power units.

Common sizes are 100, 500, 750, 1000 VA; and higher.

Control power transformers are (usually) powered AHEAD of the main breaker be very careful when investigating and working these devices.

Location of these devices? Good luck! Some OEM’s build convenient draw out cabinets to safely shut down control power systems: open a certain door/cabinet and access to fusing and the transformer may be safe and easy. Still, test it first.

Some are still powered after opening their cabinets. Still, some OEM’s hide their control power system. Some mount them in dangerous locations.

Some may have fusing with or without a disconnect switch ahead of the fusing. Some are in accessible locations. Other OEM’s work very hard to make accessibility difficult, depending upon their design philosophy.

In ALL cases, refer to the OEM’s documentation for safety instructions regarding these important and necessary systems.

If in doubt, STAY OUT of control power systems.

The post Control Power Transformers in Switchgear II appeared first on All-Test.

Manufacturers understand this and design systems to handle this phenomenon. They add an extra component, rated for the high heat which occurs during flashover.

Tungsten Arc Blades

Tungsten is a common material used as it handles the arcing heat well. It is imperative that this additional tungsten blade operates as intended.

Generally, this “arc blade” is the first part of the electrical connection to make contact during the closing of electrical disconnect switches, and the last part of the electrical connection to break contact during the opening.

Different voltage levels require different technologies, but the idea is generally the same: drag the electric arc between 2 conductors, increasing the distance between them and voltage will eventually lose the energy it needs to sustain itself.

Arc Blade System Inspection

It’s important these blade systems are inspected to make certain they are in working order. When an arc blade hangs up, the resulting mechanism may report the switch is open when in fact part of it still conducts electric power!

How often does this happen? Thankfully, not often. But as we all know in electrical safety, it only needs to happen once to kill a person.

There is NO substitute for a physical inspection, after the appropriate LOTO of the electrical & mechanical systems in use.

All the fancy advanced test apparatus which populates our industry these days are NOT a substitute for an experienced set of eyes to verify proper operation.

See the video for my case in point: this switch mechanism showed OPEN switch status, while the arc blade STILL was hung up and able to conduct 13,200 volts! Fortunately, this was discovered during a PM shutdown, was corrected and no one died.

Switch Mechanism With Arc Blade Hung Up.

The post Electrical Disconnect Switches & Circuit Breakers appeared first on All-Test.

In the realm of facility management, ensuring the safety and efficiency of large machinery and electrical systems is paramount. The cost of electrical failures, both in terms of downtime and repairs, can be astronomical. This is where the proactive strategy of regular infrared imaging scans comes into play. As an experienced electrician specializing in electrical image scanning, I am here to guide you through the importance of this preventive measure and how it can help facility owners like you save both time and money.

Understanding Electrical Failures

Types of Electrical Failures

Electrical systems, especially in facilities with large machinery, are susceptible to a range of issues. These include overheating, loose connections, and corrosion. Over time, these problems can escalate, leading to catastrophic failures that result in significant downtime and costly repairs.

The High Costs and Risks Associated with Failures

The repercussions of electrical failures extend far beyond the immediate financial burden. They can also jeopardize the safety of your facility and personnel. Fire hazards, damaged equipment, and potential harm to employees underscore the importance of proactive maintenance.

The Need for Proactive Maintenance

Prevention is undoubtedly better than a cure in the realm of electrical systems. Reactive approaches, such as fixing problems only when they become evident, are not only more expensive but also riskier. This is where regular infrared imaging scans prove their worth.

What Is Infrared Imaging Scanning?

How Infrared Imaging Scans Work

Infrared imaging scans, also known as thermography, are a non-invasive, non-destructive method for assessing the condition of electrical systems. They work by capturing thermal images that highlight temperature variations in equipment, revealing potential issues before they escalate.

Why They Are Effective for Electrical Systems

Electrical problems often manifest as temperature anomalies. By detecting these irregularities early, infrared imaging scans can pinpoint areas of concern, allowing you to take preventive action.

Non-Invasive Nature of Scans

Unlike traditional inspection methods that may require shutting down systems, infrared imaging scans are non-invasive. This means you can identify problems without disrupting operations, a crucial advantage for facilities with continuous production.

The Benefits of Regular Infrared Imaging Scans

Early Detection of Issues

One of the most significant advantages of infrared imaging scans is their ability to detect problems at an early stage. This early detection empowers you to address issues before they become critical, saving both time and money.

Preventing Catastrophic Failures

By identifying potential failures before they happen, you can prevent catastrophic events that could lead to extended downtime, costly repairs, and even safety hazards.

Extending the Lifespan of Equipment

Regular scans can help extend the lifespan of your machinery and electrical components. By addressing issues promptly, you reduce wear and tear, enhancing the longevity of your assets.

Cost Savings Over Time

While it’s true that investing in regular infrared imaging scans incurs an initial cost, this is far outweighed by the long-term savings. Preventing failures and reducing downtime can lead to substantial financial benefits.

The Process of Conducting an Infrared Imaging Scan

Hiring a Qualified Thermographer

To ensure accurate and reliable results, it’s essential to hire a qualified thermographer. These professionals are trained to conduct scans and interpret the data effectively.

Preparation and Safety Measures

Before the scan, your facility and equipment need to be properly prepared. Safety measures should be in place to protect personnel during the process.

Data Collection and Analysis

The thermographer will collect data by capturing thermal images of your electrical systems. It is important to note that a direct line of sight to wire connections is required. This data is then analyzed to identify temperature anomalies and potential issues.

Reporting and Recommendations

After the scan, you’ll receive a detailed report outlining any identified problems and recommendations for corrective actions. This report is invaluable for planning maintenance and repairs.

Cost Comparisons: Maintenance vs. Repairs

Weighing the costs of regular scans against the expenses associated with major repairs paints a clear picture of the financial benefits of preventive maintenance.

Safety Improvements and Risk Reduction

Beyond financial savings, the safety enhancements resulting from early issue detection are immeasurable. Protecting your employees and facility from harm is an ethical obligation and a legal requirement.

DIY vs. Professional Scans: What’s Best for You?

Pros and Cons of DIY Scans

While some may consider performing infrared scans in-house, there are notable drawbacks, including the need for specialized equipment and training. Weigh these factors against the benefits before deciding.

Why Professional Scans Are Recommended

Professional thermographers bring expertise and experience to the table. Their ability to conduct thorough scans and provide accurate recommendations is unmatched.

Choosing the Right Thermography Service

When selecting a thermography service provider, consider their qualifications, experience, and reputation. A well-established provider is more likely to deliver reliable results.

Scheduling Regular Infrared Imaging Scans

Frequency of Scans

Determining the optimal frequency for infrared imaging scans depends on factors such as equipment age, usage, and industry standards. Consult with your thermographer to establish a suitable schedule.

Integration into Maintenance Plans

Infrared imaging scans should complement your existing maintenance plans. By incorporating them into your routine, you ensure ongoing protection and cost savings.

Cost Considerations and ROI

While there is an initial cost associated with regular scans, it’s crucial to consider the return on investment (ROI). The prevention of a single major failure can justify the expense.

In conclusion, regular infrared imaging scans are a powerful tool for facility owners housing large machinery. They offer the ability to detect and address electrical issues before they become costly and potentially dangerous failures. By investing in proactive maintenance, you not only safeguard your facility and personnel but also enjoy significant long-term cost savings. Don’t wait until disaster strikes; take action today to ensure the reliability and safety of your electrical systems.

The post Don’t Let Electrical Failures Ruin Your Day! Discover the Magic of Infrared Imaging Scans appeared first on All-Test.

Sometimes during transformer infrared inspection or during a GA oil analysis problems are found.

Elbow Problem

Bushing Well Insert Problem

If you don’t fix transformer issues found during your infrared inspection you might find yourself doing this!

Transformer problem areas can include the following internal parts:

• HV Cable
• Loadbreak Insert
• Bushing Well
• Oil in the Transformer Front
• Current Limiting Fuses

All transformer repairs require at least 8 hours of outage.

Draining the Transformer Oil

Changing out Internal Parts

Some transformer fixes require draining the DGA oil so the transformer’s internal parts like current limiting fuses or expulsion fuses can be changed out.

Current Limiting Fuses

Expulsion Fuses

All-Test can help you with infrared inspections and transformer maintenance & repair.

The post What Does A Transformer Repair Entail? appeared first on All-Test.

A frequently used voltage level for industrial facilities is 480 volts.  At this voltage, hundreds or thousands of amps are needed to supply industrial electrical systems. These rely on switches and circuit breakers. 

In this article, bolted pressure switches are discussed. 

Several bolted pressure switch designs were developed through the years as a safer means to turn power on and off.  

These designs work well when maintained and IF they are correctly installed.

Bolted pressure switches contain two major items: operators and blades.  Operators use large springs to the provide mechanical force needed to turn a switch on and off. Blades are designed to carry power, or interrupt it (turn on and off the power)

Near the leading edge of the blades, an “arc tip” may be found.  It’s purpose is to carry the high heat involved when a contact opens and closes.  Arc tips, generally made of tungsten, handle the extremely high and short lived heat when a switch opens and closes. The tungsten carries electrical current for a short time before the copper ( or aluminum) main blade fully close or open. 

The switchblades are opened and closed at approximately the same moment in time.  Equipment operating at 1000 volts or less the “same time” duration is less important. 

However, at medium voltage levels ( 1000-100,000) volts, this “same time” synchronization becomes more important; that’s another topic for another time. 

Bolted pressure switches may or may not have fuses. Never assume the fuses are safe to remove if the switch is open- in my 40 years  in electrical cabinets, I’ve seen plenty wired incorrectly!!

Bolted pressure switches require  maintenance. Without maintenance, they frequently fail, get hung up, open only one or two phases, overheat, burn, explode, catch fire and WILL put an entire facility in the dark.

Bolted pressure switches are not blister packed at Walmart, so it’s important they are maintained. There are hundreds of choices but very few can be retrofitted. 

Maintaining a bolted pressure switch needs done according to the original equipment manufacturers instructions.  In absence of those instruction’s, don’t guess.  

REMEMBER: Just because you haven’t seen problems doesn’t mean there are no problems!  These system’s do not announce failure. When called to operate, malfunction will put your facility without electrical power quicker than you can say “why didn’t I maintain this?”

WE routinely service bolted pressure switches.  Call or email us when we can help. 

Neil Volk

Electrical Engineer 

The post Bolted Pressure Switches appeared first on All-Test.

Hi, I’m Neil, owner and operator of All-Test Company. We help people keep their switchgear up and running via testing, repair, preventative maintenance, calibration and product sales. I have learned quite a bit about switchgear in my 39 years of hands-on field experience working at Square D Company and owning and operating my own business for 27 years. I’d like to share a few things in the hopes to save you time, frustration and, most importantly, keep you safe. Thanks for reading! Do not hesitate to reach out if I can assist you further.

The post Hi I’m Neil… appeared first on All-Test.