Unplanned electrical outages can cost millions of dollars for manufacturers, industrial process plants, commercial buildings and other organizations. A Lawrence Berkeley National Laboratory study estimated that the annual cost of power interruptions is about $80 billion - 72% allocated to commercial customers and 26% to industrial customers. And that’s just reflective of failures on the supply side. Power outages caused by internal failures are difficult to quantify and vary widely by industry. The NFPA 70B Recommended Practice for Electrical Equipment Maintenance, references a study conducted by Factory Mutual on losses associated with internal electrical failures. The study documented 766 losses totaling over $6.5 million. More than 56% of the failures were caused by inadequate maintenance and testing, accounting for an estimated $3.6 million in losses. Equipment failure can be caused by load changes, circuit alterations, improper or misadjusted settings of protective devices, improperly selected protective devices, and changing voltage conditions. The Institute of Electrical and Electronic Engineers (IEEE) Standard 493 shows research on the reliability of various types of electrical equipment and compiles the causes of failure.

Electrical system failures can be effectively reduced by focusing on improvements in the areas you can control – electrical equipment application, operations and maintenance procedures.

As electrical loads cycle between high and low demand, thermal expansion and contraction cause connections to loosen. Electrical panels accumulate dust and dirt that deposit on these connections. These loose and dirty connections provide a high resistance path that causes more than 30 percent of electrical failures. While equipment deterioration is normal, the failure it can cause unchecked, is avoidable. The fundamental path to electrical reliability lies in preventative maintenance and proper equipment application. According to the Institute of Electrical and Electronics Engineers (IEEE), electrical components are three times more likely to fail if preventive maintenance is not performed. Implementing an electrical preventive maintenance (EPM) program should be your first objective for improving power system availability.

An effectively administered EPM program will reduce costly outages, reduce accidents, and save lives. This program will identify impending issues and apply solutions to correct them, before they become major problems that require time consuming and expensive solutions.

Electrical preventive maintenance is cost-effective in several different ways. First, it is cheaper to repair equipment before it fails. When electrical equipment fails, particularly protective devices like circuit breakers or relays, there is usually damage to other system components. Often the equipment can’t be repaired and must be completely replaced. Identical equipment may be difficult to find and using an alternative may require other system modifications.

An EPM program will also improve equipment efficiency and reduce utility bills. A loose or dirty connection has increased resistance which results in higher power losses. By simply tightening and cleaning electrical connections, you can lower energy costs. When considered over a period of time, these energy losses can add up to quite a significant amount of money.

No single intervention strategy can eliminate electrical equipment failures. But downtime can be reduced through a multi-faceted approach that includes engineering controls and preventative maintenance performed by properly trained personnel. If only one major outage occurs, the associated costs of equipment damage and loss of production may far exceed what it would have cost to be proactive in the first place.

The effectiveness of an electrical preventative maintenance program relies completely on the capabilities of the personnel involved. All employees should be trained in proper maintenance and testing procedures for electrical equipment in their area of responsibility. This includes understanding the functionality of the equipment, both electrically and mechanically, and having a thorough knowledge of electrical safety practices and procedures. To be effective, training should allow for students to actually perform the maintenance, testing or power studies with real equipment. Learn more about Training

Power system studies improve electrical system reliability. A protective device coordination study will ensure adequate system protection and reduce the extent of the power system affected by an overcurrent trip. A short circuit study will prevent extensive equipment and system damage because of underrated equipment in the event of a fault. A load flow study will reduce power losses and unnecessary wear on electrical equipment that can lead to catastrophic failure. Engineering studies should be sealed by registered Professional Engineers that ensure the accuracy of results and provide realistic, non-commercial recommendations. Learn more about Power Studies

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