Case Study: Intrusive LV Switchgear Maintenance

Critical Defect Identified During Planned Maintenance

Overview

During a programme of intrusive low voltage (LV) switchgear maintenance, PTM Combined Services identified incorrectly installed cable terminations within the main switchboard. Our inspection revealed that the cable lugs had not been correctly crimped and had instead been tapped onto the conductors, creating a potentially serious safety and reliability risk.

The Challenge

Faults such as incorrectly terminated power cables are often hidden behind switchgear covers and cannot be identified during routine visual inspections. Poor terminations can lead to increased electrical resistance, overheating, arcing and, ultimately, equipment failure or fire.

The objective was to carry out a thorough intrusive inspection to assess the condition of the LV switchgear and identify any hidden defects before they resulted in an unplanned outage.

Our Solution

Following safe isolation of the switchboard, our engineers carried out a detailed internal inspection of the equipment.

During the inspection we discovered:

  • Incorrectly installed cable lugs
  • Lugs that had been tapped onto conductors rather than correctly hydraulically crimped
  • Potential overheating and reliability concerns
  • A non-compliant termination that required immediate attention

The defect was documented, reported to the client and recommendations were issued for immediate remedial works, including the installation of correctly sized compression lugs using the appropriate hydraulic crimping tools.

Results

The intrusive inspection identified a hidden defect before it could develop into a serious electrical failure. By discovering the issue during planned maintenance, PTM Combined Services helped the client avoid the risk of equipment damage, costly downtime and potential safety hazards.

This project highlights the importance of regular intrusive maintenance on critical LV electrical infrastructure and demonstrates our commitment to identifying problems before they become failures.

Services Delivered

  • Intrusive LV Switchgear Maintenance
  • Electrical Asset Condition Assessments
  • LV Switchboard Inspection
  • Cable Termination Inspection
  • Fault Identification & Reporting
  • Planned Preventative Maintenance (PPM)
  • Remedial Recommendations
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