Understand Why Equipment Failed and Prevent Future Failures
Over 85% of equipment failures have identifiable root causes beyond "equipment age" or "bad luck." Manufacturing defects, improper application, inadequate maintenance, power quality issues, or operating conditions outside design parameters cause most failures.
Professional failure analysis determines actual causes enabling targeted prevention measures. Without analysis, facilities replace equipment repeatedly at enormous cost—never addressing underlying problems causing premature failures.
Equipment failure analysis involves systematic investigation of failed electrical equipment to determine failure mechanisms, root causes, and contributing factors. Services include:
Physical Examination
Detailed inspection of failed equipment
Testing & Analysis
Laboratory testing and forensic analysis
Operating History Review
Analysis of loads, environment, and maintenance
Root Cause Determination
Identify underlying causes and prevention strategies
Analyses cover: transformers, circuit breakers, motors, generators, cables, switchgear, protective relays, capacitors, bushings, surge arresters—all major electrical equipment types. Investigation methodologies follow industry standards and forensic engineering practices.
Replacing failed equipment identically without determining why it failed guarantees recurrence. Transformers fail from cooling system problems, chronic overload, or power quality—replacing with identical unit operating under same conditions produces identical failure. Motors fail from voltage imbalance, bearing problems, or contamination. Analysis identifies causes enabling corrective actions: improved maintenance, load management, environmental controls, or different equipment specifications preventing repeat failures.
Real Example:
Hospital replaced padmount transformer three times in 10 years—highly unusual for equipment rated 40+ years. Each replacement: $85K equipment plus $30K installation plus downtime costs. After third failure, detailed analysis performed. Investigation revealed transformers consistently overloaded—facility electrical demand grew 60% since original installation but transformer capacity unchanged. Load monitoring showed peak loads at 135% of transformer rating. Root cause: inadequate capacity, not equipment defects. Solution: upgraded to properly sized transformer ($110K) plus load management system ($25K). No failures in 8 years since. Cost without analysis: $345K (three replacements). Cost with analysis and proper solution: $155K (analysis $20K + solution $135K). Savings: $190K plus eliminated future failures.
Equipment failures within warranty periods require professional analysis supporting claims. Manufacturers deny claims citing improper application, inadequate maintenance, or external causes. Independent failure analysis provides objective evidence of manufacturing defects, design problems, or material failures supporting warranty claims worth tens to hundreds of thousands of dollars.
Individual equipment failure often indicates broader system issues. Analysis revealing power quality problems, environmental issues, or maintenance deficiencies enables correction preventing failures across multiple equipment types. Single investigation identifying systemic cause prevents dozens of future failures.
Major equipment failures involving injuries, property damage, or business interruption often lead to litigation or insurance claims. Professional failure analysis provides required documentation of failure cause, contributing factors, and whether failures resulted from defects, negligence, or unforeseeable circumstances.
Equipment fails prematurely when operating conditions exceed design specifications. Transformers in high-ambient-temperature locations, motors in contaminated environments, or equipment exposed to power quality issues all experience accelerated aging. Analysis identifies environmental factors enabling mitigation: improved ventilation, environmental enclosures, power conditioning, or equipment rated for actual conditions.
Equipment occasionally fails from manufacturing defects: improper assembly, substandard materials, or quality control failures. Without professional analysis, manufacturers attribute failures to external causes denying warranty coverage. Failure analysis provides evidence of defects supporting claims. Transformer failure from manufacturing defect: $500K-$15M replacement cost; warranty coverage: $0 cost with proper documentation.
Inadequate maintenance causes many failures: contamination not cleaned, connections not torqued, oil not processed, cooling systems not maintained. Analysis identifying maintenance deficiencies enables program improvements preventing failures across equipment population. Single analysis improving maintenance program prevents hundreds of future failures worth millions.
Without understanding how equipment failed—thermal damage, electrical breakdown, mechanical wear, chemical degradation—facilities can't implement effective prevention. Analysis reveals specific failure mechanisms enabling targeted solutions. Cable failed from water treeing: implement moisture prevention. Motor failed from bearing wear: improve lubrication program. Transformer failed from cooling system blockage: implement inspection procedures.
Facilities experiencing multiple failures of similar equipment suspect systemic issues but lack data identifying problems. Analysis of failed units reveals common failure modes indicating improper sizing, environmental issues, or application outside equipment design parameters. Root cause identification enables equipment changes, application corrections, or specification modifications preventing ongoing failure cycles.
Best Practice: Secure failed equipment immediately. Evidence degrades quickly. Initiate analysis within days of failure while evidence and witness recollections are fresh.
Typical Duration: Initial assessment: 3-5 days. Complete analysis: 4-8 weeks depending on complexity and laboratory testing requirements. Expedited analysis available for critical situations or warranty deadlines.
$500K-$20M+
Cost of recurring equipment failures not prevented
$15K-$100K
Typical equipment failure analysis cost
30-500x
ROI from preventing recurring failures
Guidelines for objective evaluation of data in failure analysis investigations.
Comprehensive reference for failure analysis methodologies, techniques, and case studies.
Equipment-specific standards (C57 transformers, C37 breakers, etc.) include failure investigation recommendations.
Systematic approach applicable to electrical equipment failure investigations.
Professional failure analysis identifies root causes and enables permanent prevention.
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