PM testing of electrical equipment and systems

The Good, the Bad and the Ugly

The Good, the Bad and the Ugly


There are a lot of stories out there regarding T-shooting, repair, PM and testing of electrical equipment and the integrety of companies performing this work. Which brings me to this story.
I was hired by a large transfer switch (ATS) manufacturer to rewire one of their 1600A bypass isolation type (ZBTS160FC-7) ATSs that had recently burnt up at a hospital. The chief engineer reported that when they were performing their weekly generator test, they heard a loud BOOM when this ATS was transferring to emergency. The ATS was immediately isolated and LOTO (not a problem since it was a redundant chiller circuit.) This was one of the nastiest blowups that I have ever had to deal with. The main emergency solenoid as well as 80% of the wiring harnesses on the ATS power panel and in the bypass switch area were burnt and melted (by code, ATS wiring is not protected by fuses.) In performing the damage assesment inspection, I asked the chief where the platform was to roll out the ATS power panel (this model racks out horizontally.) He looked at me confused and said "we don't have a platform!" I looked at him and pointed to the inspection sticker on the door of the unit. The sticker was from another large ATS manufacturer (if not the largest, that we will call CO. X) and was dated the year before. I asked the chief how CO. X was performing the preventive maintenance PM) each year and he answered "they don't rack them out." I looked him in the eye and said " when I rack this out I will show you why it burnt up!" With the ATS racked out on a makeshift platform, I had the chief try to manually transfer the ATS with the handle (very hard to operate) and showed him the hard, dried grease in the mechanism gears at the back of the unit and said "this lack of cleaning and proper lubrication caused the unit to burn up." He looked at me with terror in his eyes and said "Oh my God, I have 6 more like this, can you give me a quote to PM them?"We repaired the unit, performed a complete PM and tested it to bring it up to proper operating condition.
We got the contract to PM and test the other 6 units successfully and, needless to say, left the site with a very happy customer.:grin:
Morals of the Story:
All switchgear companies are not created equal.
Just because it has a PM inspection sticker from a manufacturer doesn't mean the work was done correctly.

Tony

The Good, the Bad and the UglyThere are a lot of stories out there regarding T-shooting, repair, PM and testing of electrical equipment and the integrety of companies performing this work. Which brings me to this story.I was hired by a large transfer switch (ATS) manufacturer to rewire one of their 1600A bypass isolation type (ZBTS160FC-7) ATSs that had recently burnt up at a hospital. The chief engineer reported that when they were performing their weekly generator test, they heard a loudwhen this ATS was transferring to emergency. The ATS was immediately isolated and LOTO (not a problem since it was a redundant chiller circuit.) This was one of the nastiest blowups that I have ever had to deal with. The main emergency solenoid as well as 80% of the wiring harnesses on the ATS power panel and in the bypass switch area were burnt and melted (by code, ATS wiring is not protected by fuses.) In performing the damage assesment inspection, I asked the chief where the platform was to roll out the ATS power panel (this model racks out horizontally.) He looked at me confused and said "!" I looked at him and pointed to the inspection sticker on the door of the unit. The sticker was from another large ATS manufacturer (if not the largest, that we will call CO. X) and was dated the year before. I asked the chief how CO. X was performing the preventive maintenance PM) each year and he answeredI looked him in the eye and saidWith the ATS racked out on a makeshift platform, I had the chief try to manually transfer the ATS with the handle (very hard to operate) and showed him the hard, dried grease in the mechanism gears at the back of the unit and saidHe looked at me with terror in his eyes and saidWe repaired the unit, performed a complete PM and tested it to bring it up to proper operating condition.We got the contract to PM and test the other 6 units successfully and, needless to say, left the site with a very happy customer.:grin:Morals of the Story:All switchgear companies are not created equal.Just because it has a PM inspection sticker from a manufacturer doesn't mean the work was done correctly.Tony

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The Importance of Electrical Testing and Tagging Services on Construction Sites

Construction sites are bustling hubs of activity, where numerous workers rely on electricity to power tools, machinery, and lighting. This makes construction sites a high-risk area for electrical hazards that pose significant risks to both the workforce and the overall project. This is why the importance of electrical testing and tagging services plays a vital role in ensuring safety and compliance on construction sites. We will delve into its importance on construction sites and why it should be a priority before starting any sort of work in the field.

Reasons Testing and Tagging is Important in Construction Work

Ensuring Worker Safety

The safety of workers should always be the top priority on construction sites. Electrical hazards can lead to severe injuries or even fatalities if not properly addressed. Regular electrical testing and tagging help identify faulty equipment, damaged cords, or defective wiring, mitigating the risk of electric shocks, fires, or explosions. By conducting thorough inspections, potential hazards can be identified and rectified promptly, preventing accidents and creating a safer working environment for all.

Compliance with Legal Requirements

Adhering to legal requirements is crucial for any construction company. In New Zealand, electrical safety regulations, such as the Electricity (Safety) Regulations 2010, outline the obligations and responsibilities regarding electrical installations and equipment. These regulations mandate that electrical appliances and tools are regularly tested and tagged by competent professionals. By implementing proper electrical test and tag practices, construction companies can demonstrate their commitment to compliance, avoiding penalties, fines, and legal repercussions.

Protecting Equipment and Assets

Construction sites are home to expensive machinery, tools, and equipment. Electrical faults can not only cause damage to these assets but also lead to financial losses for the company. By regularly testing and tagging electrical equipment, potential faults can be detected early on, allowing for repairs or replacements to be made promptly. This preventive approach safeguards expensive equipment, minimizes repair costs, and extends the lifespan of electrical assets, ensuring efficient and uninterrupted operations on construction sites.

Minimizing Downtime and Disruptions

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Electrical breakdowns or malfunctions can bring construction projects to a standstill, causing costly delays and disruptions. Regular testing and tagging help identify potential issues before they escalate into full-blown problems. By proactively addressing electrical faults, construction companies can minimize downtime, maintain productivity, and keep projects on track. Additionally, identifying and replacing faulty equipment during scheduled testing can prevent unexpected breakdowns during critical stages of the construction process.

Enhancing Reputation and Trust

In the highly competitive construction industry, reputation is key. Clients and stakeholders expect construction companies to prioritize safety and adhere to industry best practices. By implementing a robust testing and tagging program for electrical equipment, construction companies can demonstrate their commitment to safety, compliance, and professionalism. This not only enhances the company’s reputation but also instills trust among clients and stakeholders, leading to increased customer satisfaction and better business opportunities.

Trusted Testing and Tagging Experts

When it comes to electrical testing and tagging services in New Zealand, Jim’s Test & Tag is your trusted and reliable partner. Our team of trained professionals offer comprehensive testing, tagging, and inspection services tailored to the unique needs of construction sites.

By partnering with us, you can ensure your electrical systems are thoroughly inspected, and potential hazards are identified and addressed promptly. Ultimately, investing in testing and tagging electrical equipment or appliances is an investment in the safety, efficiency, and success of construction projects.

We provide the following testing and tagging services to help keep your business safe:

• Reminder Service – We will let you know before your equipment and appliances are due again for retesting so you don’t lose track.
• Data Management Service – We will keep an accurate record of your testing results for you.
• Repairing of Faulty Items – We can repair faulty items for you or coordinate with our partners to ensure that your appliances are well taken care of.
• Safe Work Method Statements (SWMS) – Every time we visit your site, we will conduct a risk assessment of your environment and report any hazards to you.

We provide a comprehensive range of services including as workplace safety inspections, electrical testing and tagging, RCD testing, and microwave testing, all in one place. You won’t need to look for different providers to keep your business safe.

This is why Jim’s Test & Tag is the most trusted name electrical testing and tagging services by the construction industry and other businesses all throughout New Zealand. Call us at 0800 454 654 to learn more about our services, or request a free quote via our online form

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