Automation is changing how we do business in nearly every industry, and industrial controls are at the heart of every automated system. Equipment failure leading to unexpected downtime is one of the worst-case scenarios. When something goes wrong, partnering with the right industrial control repair provider is critical.

Quad Plus industrial machine repair technicians are standing by 24 hours a day, every day, with the tools, knowledge, and experience to diagnose and repair industrial controls, drives, circuit breakers, and more. If you’re searching for a trusted partner to solve your industrial repair problems, here is everything you need to know to make the best decision for your operation.

What Are Industrial Control Systems?

An industrial control system is one or more control components that monitor and control physical processes in machine applications. Industrial controls can link machines together, allow workers to interface with machinery digitally and physically, and integrate with software to achieve manufacturing goals, improve transportation, speed up packaging and shipping, revolutionize healthcare, and more.

Some examples of industrial control system components include:

• HMI: Human Machine Interface
• IED: Intelligent Electronic Devices
• PLC: Programmable Logic Controllers
• SCADA: Supervisory Control and Data Acquisition
• Control Valves: Devices used to control processes

Key Factors When Choosing Industrial Control Repair Providers

The right provider will have a major impact on your operation’s success and the long-term life of your equipment. When evaluating potential providers, here are a few key factors to keep in mind.

• Experience. The right provider will have years of experience in your industry, preferably with your specific application. Their technicians should also have extensive experience with a variety of industrial control systems.
• Range of Services. By choosing a service provider who offers a wide range of services, you can reduce the number of providers you must work with for different tasks. Other services to consider are acceptance testing, maintenance, circuit breaker repair, and retrofits.
• Reliable Support. The best provider is only helpful if available when you need it! Not all industrial control repair needs are emergencies, but when your entire production line comes to a halt on a Friday evening, the last thing you need is to wait until Monday morning to reach your provider. Find a provider who provides around-the-clock emergency service and support.
• Strong Communication. You shouldn’t have to chase down quotes for service or updates on repairs in progress. The right industrial control repair provider will keep you up-to-date on all projects and ensure you receive all documents and reports on time. Customer reviews are a great place to discover whether a provider has a good reputation for customer communication.

The Importance of Response Time in Industrial Control Repairs

The driving force behind automation technology is to make things faster. When equipment failures lead to unexpected downtime, delays in industrial control repairs can mean significant financial losses. Rapid response times from repair providers can mean the difference between an inconvenience and a catastrophe.

Your operations’ speed and efficiency are also crucial to your customers. Lengthy disruptions can damage your reputation or cause clients to choose another company. Maintaining your competitive edge means avoiding downtime whenever possible and minimizing the impact whenever it strikes.

What to Look for in a Provider’s Repair Tools and Technology

Advanced technology should be critical to your industrial control repair provider. Look for a provider with advanced diagnostic tools such as automated test benches, simulation software, and in-circuit emulators. Diagnostic tools should include signal generators and analyzers, data capture systems, logic analyzers, and the ability to deliver component-level repairs.

It is also important to find providers with technicians trained by OEMs for their specific systems. They should have manufacturer-specific tools when necessary and access to the latest software the manufacturer provides.

Common Pitfalls to Avoid When Choosing an Industrial Control Repair Partner

Training and experience are critical when choosing an industrial control repair provider. Avoid any companies without a proven track record in servicing controls across a variety of brands and manufacturers and in different applications. Other pitfalls to avoid include:

• Limited Capabilities. The right company to partner with will have a range of repair capabilities that include components such as HMIs, PLCs, drives, sensors, and more. Your repair provider should have experience servicing components from different manufacturers and knowledge of both legacy devices and new technology, including mixed environments.
• No Access to Parts. Sourcing common parts may be easy for most providers, but many operations rely on legacy equipment that the manufacturer no longer supports. Your partner should have an inventory of common and hard-to-find parts and the ability to quickly source parts when necessary.
• No Emergency Service. Emergency repair services should be available 24 hours a day, every day, all year long. Look for a provider with onsite service and remote support for the best coverage.
• No Warranty or Support. If a service provider will not stand behind their work, why should you? Only partner with an industrial control repair provider who offers a warranty on their work and provides technical support following a repair or installation.

Ensuring Compliance with Industry Standards in Control Repairs

Safety and manufacturing standards exist to keep people safe when working in hazardous environments and to protect expensive equipment from damage. Your industrial control repair partner should know all applicable standards when completing work on any equipment.

Two main standards apply when working with industrial controls. The National Electrical Manufacturers Association (NEMA) provides standards and general information for ratings, testing, performance, and the manufacturing of industrial and control systems. Industrial control repair technicians must also follow OSHA standards for the Control of Hazardous Energy (Lockout/Tagout) and use proper PPE to protect themselves from dangerous working conditions.

Industrial Control Repair Partner You Can Trust

The experts at Quad Plus have decades of experience in every industry, including manufacturer training from Siemens and ABB. We have exclusive access to OEM documentation to tackle your issues and provide repairs using the manufacturer’s schematics.

We provide onsite support dispatched to your location to provide quick solutions and reduce downtime. Once configured, our remote support specialists can gather information from your system, review the information, and make recommendations.

Our expert repair team is available 24 hours a day, every day, to solve your problems quickly, efficiently, and safely. Plus, you will enjoy a one-year warranty on all repairs and equipment services performed by a Quad Plus expert.

When you’re ready to partner with an industrial control repair expert who is as invested in your operation’s outcome as you are, it’s time to call Quad Plus.

Contact a Repair Expert Now!

Large-scale and complex projects have many moving parts, with most having several smaller projects that must all come together to deliver a finished product. Once the construction phase of a project is complete, the final phase is commissioning.

Commissioning is a detailed process designed to confirm that the design, installation, and operation of systems, buildings, or machinery align with the customer’s operational requirements. The installation and functionality of all systems and components are verified to ensure efficient, well-integrated operation and to solve any problems that are uncovered to improve overall operation and reliability.

Comprehensive, thorough commissioning reduces operational costs, improves energy efficiency, reduces waste, ensures the safety of people and equipment, and prevents costly production delays due to errors, defects, and other complications.

Ensuring Quality Assurance Throughout Commissioning

In industrial and manufacturing settings, the commissioning process ensures that complex projects such as building construction or large machine installations are completed successfully and that project specifications are met. Once commissioning is complete, machinery and equipment are energized, and new buildings are placed into service, ready to achieve expectations and production requirements.

Commissioning is also essential to an operation’s energy efficiency and sustainability. The process can uncover inefficiencies and opportunities to improve energy consumption and reduce emissions. Improvements can include integrating renewable energy sources or enhancing the performance of a building’s envelope. Continuous monitoring and adjusting can sustain the progress of these goals over time.

Building codes, standards, and regulations are all important to protecting the safety of people and expensive equipment. The commissioning process ensures compliance with all applicable laws and standards, including those that cover fire protection, emergency power and lighting, and air quality. This provides safe operation and reduces legal and liability risks associated with building and worker safety.

Understanding the Commissioning Process and Its Key Phases

Although commissioning activities happen once construction and installation are complete, they begin during the project’s pre-design phase and continue throughout the process. For most projects, the commissioning activities are the final goal, so project schedules and milestones are typically defined by the completion schedule of commissioning activities.

It’s also vital for the commissioning team to follow a project’s progress and check parameters and requirements at all major milestones and other points throughout the process. That way, problems can be found while they are easier to correct and before hindering progress on future steps.

Key Stages of the Commissioning Process

Major industrial and commercial construction and installation projects follow a common commissioning process. Larger projects may require more details, documentation, and preparation for each stage, but smaller or single installations will still follow a more simplified version of the same process.

1. Pre-Design 
2. Design 
3. Pre-Construction
4. Construction
5. Commissioning
6. Occupancy and Operations
7. Ongoing Commissioning

Pre-Commissioning: Planning and Preparation

The pre-design and design phases of a project occur before commissioning activities begin. During these phases, project managers assemble the commissioning team to follow the project’s progress and final activities before handing a finished product to the customer.

Key members of the commissioning team usually include leaders from the various construction disciplines involved, including electrical, mechanical, and automation. Subject matter experts and vendor representatives are also on the team, along with members of the client’s operation team who will take over once the commissioning process is complete.

The commissioning team is typically responsible for these activities during the Pre-Design Stage of a project:

• Project Requirements. The project’s primary goals and all owner requirements and expectations are defined.
• Commissioning Budget. The commissioning process of a project is critical and has associated costs that will impact the project’s overall profitability, including labor, material, and resources needed.
• Develop the Commissioning Plan. Define the commissioning process, acceptance requirements, and project schedules, and develop all reporting and documentation formats. This plan is likely to grow and change as the planning phase continues.

Once the project moves into the design phase, the commissioning team will monitor the project requirements to ensure they are met in the design. Design reviews will be conducted once drawings, specs, and data sheets are available to uncover issues early and before any materials or equipment purchase.

Once construction and installation begin, the commissioning team continues to monitor the project requirements to ensure that all quality standards are met and that construction and installation activities comply with the design documents.

Commissioning: Critical Testing and Validation Procedures

Once all construction and installation activities are complete, the commissioning team must complete all tasks necessary to set up and operate systems and equipment. Functional testing and inspections will be performed and documented, and integrated systems will be tested to ensure seamless operations.

Mechanical systems typically undergo a pre-commissioning process, including activities such as flushing pipes and pressure and leak testing. Rotating parts are checked, and motors and pumps are often run to verify initial operation and that there are no problems with cooling systems or vibration.

Electrical systems are energized and wiring verified. The electrical commissioning process includes detailed inspections of automation systems and control devices to ensure settings are correct and protective devices are functioning. Any problems or defects must be corrected before the commissioning process can continue.

Once all pre-commissioning checks are done, systems and equipment are energized and brought online. Mechanical systems are tested both with and without process materials. Electrical systems are verified, HMI screens are checked, and communications systems are tested.

Performance & Operational Verification

Finally, once all mechanical and electrical systems are verified, full system operation and verification, including any auxiliary systems, can be completed. Industrial and manufacturing processes are slowly started and monitored, and fault scenarios are tested. Any adjustments to machine operation are made until all production parameters are met.

Some systems and contracts include a trial period, during which an industrial or manufacturing plant must operate uninterrupted for a specified period of time before the commissioning process and verification are considered complete. If operations must be stopped to make corrections or adjustments, the trial period starts over.

During this phase, the customer’s operations team also receives training to make the hand-off process smooth. Operators need to understand how systems work and how to operate them properly.

Post-Commissioning: Hand-off & Ongoing Activities

Once all systems and installations have been tested and validated and the final product handed over to the customer, the main commissioning process is complete. The final stages of the process include ongoing training that may be necessary, along with any remaining tests that may not have been possible earlier in the process.

For example, some systems require seasonal testing to ensure proper operation under various conditions. Other systems, such as cooling and air conditioning, can only be tested once environmental temperatures reach a certain point.

Mission Critical Facility Commissioning

The complex technology integral to mission-critical operations makes the commissioning of these systems more complicated. Stricter industry standards and regulations must often be adhered to for these operations, and failure tolerances are exceedingly low.

Data centers store and exchange digital information and are critical for operating various critical services, such as cloud applications and online ordering systems. The infrastructure required for data center operation must be exceptionally reliable.

Electrical components such as power distribution units, cooling systems, and equipment such as servers and networking devices must operate seamlessly. Commissioning activities will include validating the continuity of the power and cooling systems, testing redundancy systems, and verifying disaster recovery plans.

Semiconductor manufacturing facilities are highly regulated and use incredibly advanced technology to ensure high product yield, quality, and consistency. Strict control of the manufacturing environment for semiconductors is necessary, which requires systems to manage temperature, humidity, and contamination. The commissioning process includes thorough inspections of these systems, along with validation for HVAC systems, gas and material delivery systems, chemical handling processes, and cleanrooms.

Pharmaceutical production facilities are a matter of public health. They are mission-critical and must adhere to some of the most stringent regulations. Critical systems to be included in the commissioning process include HVAC, production equipment, and sterilization equipment. Regulatory standards require specific validation processes for installation, operation, and performance.

Factory Acceptance Testing (FAT)

This step of the process is performed on equipment before installation. These tests are typically performed by the manufacturer at their facility before delivery to a customer’s location, but they can also be performed by a third party.

The purpose of factory acceptance testing is to ensure that equipment and systems meet the specifications and standards of the manufacturing process. Any problems with machines, equipment, and individual components can be identified and corrected before installation or integration with other systems.

This process saves time and money, as uncovering problems after the equipment is delivered and installed can significantly disrupt a project’s timeline and budget. Machines and equipment will still be subject to inspections and testing upon receipt, after installation, and a final acceptance testing and verification performed during the commissioning process.

Addressing Common Challenges in Commissioning

Changing local and national building codes is a common challenge that complicates the commissioning process. These rules and regulations are continuously updated to improve safety and working conditions for people and make industrial and manufacturing processes more energy efficient. Verification and validation processes must include these stipulations and the customer’s expectations for a project. Customer expectations must be managed to ensure they align with current regulations.

Increasingly complex new technologies also present unique challenges in the commissioning process, especially when integrating new technology into legacy systems. Old and new technologies must work together correctly to achieve a successful outcome. Including experts with sufficient experience with new and legacy technology is critical to ensure efficient problem-solving when joining them together.

Commissioning Best Practices

The most important consideration during the commissioning process is planning. Engaging the commissioning team early in the process helps ensure proper planning and execution throughout. Factory acceptance testing (FAT) is another critical consideration to avoid costly problems that should be solved before the delivery or installation of equipment and components.

Missed milestones in complex projects can complicate the process and compromise or delay successful completion. Mechanical completion milestones should be defined, and expectations should be set at the start of the project, especially when construction or installation activities overlap with commissioning tasks.

Schedule management will play a significant role in project completion and when coordinating commissioning tasks. When the possibility of a critical milestone being missed arises, early communication and problem-solving must be engaged to get the project back on track or to adjust subsequent timelines to avoid bottlenecks or the cascading effects of one missed deadline derailing the next steps.

Why Choose Quad Plus for Commissioning?

The Quad Plus team aims to exceed your expectations and experiences with other system integration companies. Our engineers stay with your project from planning and design through commissioning. The engineer who designed your system will be on-site to ensure your requirements are met when it’s time to start up your equipment. Our commissioning process incorporates:

• System Testing & Power Up. Includes visual inspection, hardware evaluation, communication, and software configuration. We ensure your operational needs are met and uncover any problems so we can immediately correct them.
• I/O Checkout. This process ensures PLC and control systems are appropriately adjusted to meet your production standards. We verify electrical devices, verify communications, and compare drawings to what is physically present to ensure that all individual devices are connected and working correctly.
• Drive Optimization. Tuning algorithms are selected to achieve optimal drive efficiency. Electrical characteristics and associated load are also considered with the goal of optimal calibration for maximum efficiency.
• Machine Sequencing. Dry run (webless run, ghost rolling) performance tests are performed to sequence and simulate your system. Operations and programs are verified before any strip, web, or other material is run through the machine. Only after this calibration is a full wet run performed to identify any necessary fine adjustments.
• Production Trials and Hand-Off. Your plant operators and our startup engineers work together to run product lines and monitor processes to uncover and solve problems. Only after a successful trial is equipment considered ready for hand-off. Documentation that includes system settings and test results is often provided, and user training and demonstrations are provided.

Plus, we offer much more than commissioning. We have experience with all aspects of the system integration lifecycle, from multi-discipline engineering and power services to repair, service, and industrial safety. Our team has decades of experience with your equipment.

Contact Quad Plus Now!

Industrial and manufacturing operations will come to a grinding halt without a dependable power source. Still, natural disasters and other emergencies make it impossible to eliminate unexpected downtime resulting from power outages.

Instead, businesses must have plans to ensure safety standards are met, and production gets back on track as quickly as possible when the inevitable happens.  An emergency power services plan is the best way to protect your assets and your crew.

Understanding the Risks of Power Outages in Industrial Settings

When power outages occur in industrial and manufacturing settings, the first thing that happens is that production lines suddenly stop. The immediate result is often a loss of material currently in the machine and the inability to continue production. Every minute that machines sit idle costs the company money.

In some cases, worker safety can be put at risk during an outage, especially if emergency response service plans are not in place. Blackouts can make it dangerous to maneuver in hazardous environments, and the storage of hazardous materials can become compromised, for example. Power outages can also damage equipment, mainly if power surges occur when electricity is restored, or equipment is not properly shut down.

The Impact of Downtime on Financial and Operational Performance

When production lines come to a halt, the entire supply chain connected to those lines also stops. Power outages that affect a wide area will cause even more significant problems as delivery networks are disrupted and customers are affected.

Customers who rely on the continual supply of certain products, such as hospital medical supplies, may have to turn to other suppliers. Repeated or sustained outages can damage a company’s reputation with its customers as products become increasingly unreliable.

Another possible consequence is unsold inventory remaining in storage when delivery channels are disrupted or customers need help to make purchases and cannot access online materials or office personnel. Perishable items may have to be discarded, and the quality of sensitive items may drop if environmental requirements are not met.

Downtime due to power outages also makes it difficult for some workers to do their jobs at all, while others may have to work overtime to resolve problems. Balancing the bottom line will become more difficult the longer the outage lasts, especially when revenue streams are also disrupted.

The Critical Role of Emergency Power Services in Maintaining Operations

Emergency power services are vital for keeping critical systems online during a power outage and for allowing the safe shutdown of large machinery and equipment. One crucial system that emergency power should facilitate is communications and data storage systems. Emergency services personnel and repair services will rely on both systems to maintain operations and return all services online.

How do emergency power services benefit industrial operations?

Along with providing continuous power for critical systems, emergency power services allow industrial operations to transition to backup power supplies or power down equipment safely rather than abruptly.

Key Components of a Robust Emergency Power Plan

With so many potential consequences facing manufacturers during a power outage, the importance of an emergency power services plan becomes clear. Here are the key components of a robust strategy.

• Determine Your Requirements. Depending on the complexity of your operations and source of backup power, it may not be feasible to have your entire system on a redundant emergency power service source. In some cases, any interruption in production may be intolerable, and a powerful backup generator system may be necessary.
• Choose Backup Equipment. Generators and uninterrupted power supplies (UPS) can be chosen by prioritizing various features. These features can include auto start-stop capability, charging alternator, sight gauges, security features, fuel priming pumps, and EPA emissions certifications.When choosing a generator, emergency power service requirements will be determined by the size and type of equipment. Fuel types will depend on the availability and price of fuel, along with the generator’s environmental impact. The facility must also consider the space needed for an appropriately sized generator and the weight of the equipment.
• Secure a Fuel Supply. A reliable fuel supply is critical for emergency power generation, and you’ll want to secure your source and delivery options long before an emergency occurs to ensure demand from affected businesses and communities does not threaten your supply. Depending on the type of fuel your generators use, it may be beneficial to store fuel onsite so it is ready to use in an emergency.
• Perform Regular Testing. Executing an emergency plan under adverse conditions is far more likely to be successful if the participants are familiar with their role and have practiced their tasks. Staging drills for the entire crew will help reduce the impact of an outage when it occurs.

It’s also important to regularly test your emergency power service system, including backup generators, UPS systems, and associated equipment such as circuit breakers.

How often should emergency power systems be tested?

According to the National Fire Prevention Association’s (NFPA) standard 110, complete emergency power supply system testing should be performed once every three years, inspected weekly, and exercised monthly. Regular maintenance schedules for each component of an emergency power service system should also be followed.

Why is it important to have both a UPS system and a generator in an industrial facility?

UPS systems are not designed for long-term power supply. Instead, they are used to protect from short-term blackouts and power surges. Once the batteries from UPS systems become depleted, a backup generator supplies power. In other words, a UPS system is perfect for short outages and to bridge the power gap while generators from an emergency power service system are started up and synchronized.

Emergency Power Solutions, Including Generators and UPS Systems

A combination of UPS systems and backup generators is necessary for emergency power services in industrial and manufacturing settings. Here are different types of generators a facility can choose from.

• Natural Gas. Natural gas burns cleaner and produces less noise than other fuel sources. However, it can also be less efficient than other fossil fuels, and improper handling can pose serious safety risks.
• Diesel. Diesel is the most commonly used fuel in manufacturing and industrial operations. It is more stable and efficient than gasoline, allowing large quantities to be stored onsite.
• Portable. Perfect for remote locations or short-term use, large commercial portable generators can supply large amounts of power for extended periods.
• Standby. For larger operations that are usually connected to a power grid, a standby generator is ready to switch on if an outage occurs and can provide power for several days.

Three main types of UPS systems are divided by how power flows through the unit. A standby UPS protects against surges and provides a short duration of battery backup during an outage. AC power runs through a standby UPS under normal conditions. When a power outage is detected, it switches to battery.

A line-interactive UPS provides conditioned power, eliminates voltage fluctuations, and provides a backup battery power source. AC power runs through a voltage regulator during regular operation and switches to the battery when an outage is detected.

An online, double-conversion UPS converts AC power to DC and then back to higher-quality AC power with no distortions or voltage fluctuations, which are often expected from grid power. Intelligent systems also use a high-efficiency mode to suspend double conversion when the input power quality is high enough.

Training and Preparedness to Ensure Your Team Is Ready

Having the right equipment for emergency power services is only the beginning. Regular testing and maintenance of UPS systems, backup generators, and associated equipment is critical to ensure they are ready to work when a power outage occurs.

Plus, your entire team should be familiar with your emergency preparedness plan and practice the steps needed during a power outage.

The NETA-accredited technicians at Quad Plus can test your UPS batteries for charging station voltage, specific gravity, cell voltage, load bank, and cell/inter-cell impedance. We also test and maintain all aspects of your emergency power services system and can help your facility design a backup system that protects your workers, equipment, and bottom line.

Understanding Electrical Cable Testing Standards

Electrical cable testing standards ensure the safety and reliability of electrical installations by providing a uniform method for assessing the integrity of cables and checking for faults. Standards provide a common language for manufacturers, customers, and technicians to use and limits to ensure consistent expectations locally and globally.

IEEE Standards

The Institute of Electrical and Electronics Engineers (IEEE) is the world’s largest organization of technical professionals. Its goal is to advance the knowledge and development of technology to benefit everyone. Its members are both volunteer and elected, and its operation includes full- and part-time employees from nearly every country.

The following IEEE Electrical Cable Testing Standards apply to most situations:

• IEEE 400 Series. his series includes guidelines for field testing and evaluating the insulation of shielded power cable systems. It also includes DC testing for cable systems, very low frequency (VLF) testing, partial discharge, and damped AC testing.
• IEEE 2412. Establishes procedures for testing the integrity of fire resistive cable systems in passenger rail and road tunnels.

ANSI/NETA Standards

The International Electrical Testing Association (NETA), in collaboration with the American National Standards Institute (ANSI), has developed comprehensive standards to ensure that electrical power systems and equipment are installed correctly, function properly, and meet manufacturer standards and tolerances. They provide two main electrical cable testing standards.

• ANSI/NETA ATS. This standard applies to acceptance testing for electrical power systems and equipment to determine readiness for initial energization. It defines electrical test procedures, including applied potential, test duration, and power factor tests,  and it establishes standards for technician training, certification, and supervision.
• ANSI/NETA MTS. This standard covers maintenance testing specifications for electrical power equipment and systems, including field tests and inspections, to determine the condition and reliability of electrical systems and their suitability for continued service.

IEC Standards

The International Electrochemical Commission (IEC) publishes international standards for electrical, electronic, and related technologies such as power generation, solar energy, and home appliances. Here are their main international electrical cable testing standards:

• IEC 60228. Standards for wire sizes and resistance.
• IEC 60502. Standards for power cables with extruded insulation and guidance on operating at voltages of 1kV to 30 kV.
• IEC 60840. Testing procedures for high-voltage transmission cables and cables rated for 30kV and higher.
• IEC 62067. Testing procedures for very high-voltage (EHV) cables.
• IEC 63026. Specifies standards for offshore wind farm and subsea cable destiny.

OSHA Standards

The Occupational Safety and Health Administration (OSHA) provides safety standards for most workplaces in the United States to protect workers from hazards and create safer working environments. Here are a few specific sections of OSHA Standard 1910 that may apply when performing cable testing on various job sites.

• Subpart I. Covers PPE requirements for working in hazardous conditions, including working with electrical components.
• Subpart R. Includes regulations for special industries, such as textiles, sawmills, and logging operations.
• Subpart S. This section covers specific electrical safety standards for the workplace.

Changes to ANSI/NETA Standards in 2023

There were several changes and updates to ANSI/NETA MTS standards. A new section was added for electric vehicle charging systems, references have been updated, and new workplace safety practices were added, in addition to other changes.

Regarding electrical cable testing standards, the section for testing medium- and high-voltage cables received a major rewrite after years of being unable to reach a consensus throughout the industry. A subcommittee was created in 2020 to make recommendations to revise this section and provide clear information on cable testing.

One major change included dielectric insulation testing for medium- and high-voltage cables to recommend very low frequency (VLF) withstand test. Previous versions of this electrical cable testing standard allowed the tester to determine which testing method to use. Tan-Delta testing and offline/online partial discharge testing are considered accurate methods, but optional at this time, and an appendix has been added to help technicians better understand when to utilize these optional tests.

Now that specific tests to perform are included, the electrical cable testing standard was also amended to add the expected test values, while other test values were reviewed. Offline and online partial discharge test values remain unchanged, and Tan-Delta values were moved to new tables at the end of the section.

Finally, a consensus was reached regarding acceptable insulation resistance values for shielded medium- and high-voltage cables. Because the correct method to verify insulation resistance is a formula with constants that are not easy to attain, the insulation resistance test should not be used in cable testing to find a discrete number for acceptability,

Key Factors Driving Changes in Cable Testing Standards

Testing and safety standards are continually revised to keep pace with technological advancements and changing industry and consumer demands. These changes not only accommodate new technology and applications but also reveal opportunities to improve safety and testing procedures.

Recent changes to IEEE and ANSI/NETA standards are driven in part by growth in renewable power generation and increasing demand in urban areas for buried cables rather than overhead lines. New materials in cable insulation also called for updates, along with evaluation of modern production processes for power cables and accessories. Environmental and sustainability concerns are also driving changes as regulations push for more sustainable practices and safer materials in both the manufacturing process and electrical cable testing standards.

Environmental & Sustainability Challenges in U.S. Cable Testing

The primary challenge in terms of sustainability and environmental challenges in electrical cable testing standards comes from the need to balance rigorous testing with the ecological impact of testing procedures and equipment. For example, PVC and plastics are traditionally used for cable insulation, but these materials are not biodegradable and produce pollution when improperly disposed of. Standards are gradually moving toward the use of more sustainable materials, but testing and maintenance standards must move along the same path.

Energy consumption during testing is another concern. In particular, testing high-voltage cables using AC testing methods uses a particularly high amount of energy. Current electrical cable testing standards are now emphasizing lower-consumption methods such as VLF testing. Still, legacy equipment and outdated procedures can sometimes complicate the shift in this direction.

Some electrical cable testing methods, including those that use chemicals and dielectric fluids, create waste that is harmful to the environment unless strict disposal methods are used. Changes in electrical cable testing standards are now incorporating detailed guidelines for the handling and disposal of testing byproducts to prevent environmental contamination.

Underground and submarine cable testing poses environmental concerns for the natural habitats surrounding these cables. Regular testing and maintenance of these cables can cause harmful disruptions to habitats, and non-invasive testing methods can provide a potential solution for some of the disruptions.

How International Standards Compare to American Cable Testing Standards

The IEC is the primary organization concerned with international electrical cable testing standards. American standards are typically provided by the IEEE and ANSI/NETA. In most cases, the goals of cable testing are aligned across organizations, and differences are found mainly in methods and scope.

For example, IEC standards are primarily focused on high-voltage and extra-high-voltage cables which are present in European systems that rely heavily on underground high-voltage cables. North American distribution systems commonly rely on medium-voltage cables, and the IEEE and ANSI/NETA include detailed sections of electrical cable testing standards for these systems.

In terms of testing methods, American electrical cable testing standards are likely to be more specific in maintenance requirements and include detailed instructions for inspection intervals, testing frequencies, and environmental factors that affect the health of a cable. Both international and American standards prescribe specific testing for new cables and installations.

The scope of American standards tends to cater to US regulations and provide specific guidance for industries such as utilities, construction, and public infrastructure. IEC standards are more broadly applicable across countries and industries and reflect European practices, but not always locally-specific regulations.

The Impact of New Electrical Cable Testing Standards on Industrial Operations

For industrial and manufacturing operations, new standards in cable testing are all good news. Better practices and regular inspections bring significant benefits, including:

• Preventive Maintenance. Rather than requiring emergency action due to an unexpected failure, regularly testing cables can identify potential issues and allow for scheduled maintenance and repair. Proactive testing can also offer insight into the overal working life left in a cable.
• Longer Working Life. Regular cable testing and inspection allow problems to be detected and solved before they become major issues that require the replacement of the cable. Delaying the need for replacement cables results in a more reliable system and reduced expenses.
• Cost Efficiency. Timely maintenance can defer the need for replacement equipment, and a reliable electrical system can also reduce unexpected downtime and the associated losses.
• Increased Safety & Compliance. Providing a safe workplace for employees is required in the United States, and failure to do so can result in serious consequences for industrial and manufacturing operations. One of the main purposes of industry and regulatory standards is to keep people safe. Complying with all electrical cable testing standards is the best way to protect your workers, your equipment, and your entire operation.

Compliance Challenges with Evolving Testing Standards

Complying with national and international electrical cable testing standards, such as those provided by the IEEE and NETA, is often legally required, depending on the industry and location. In the United States, compliance with all applicable OSHA standards is required for nearly all employers who are not regulated by another federal or state agency. Failing to comply with required standards could result in hefty fines, penalties, or even shutdowns.

Complying with electrical cable testing standards also helps reduce your liability for workplace incidents. Power cables can potentially cause serious harm to workers, and companies are far more likely to be held liable for damages if required standards and recommended steps are not followed.

In addition to legal and financial liabilities, other parties may have an interest in ensuring your operations adhere to all standards for cable testing and other industry regulations. For example, insurance policies can stipulate adherance, and insurers may cancel coverage or reject a claim due to non-compliance. Vendors and contractors can specify that cable testing and maintenance adhere to industry standards.

Best Practices for Adapting to New Testing Standards

First, be proactive to stay current with changing electrical cable testing standards. Organizations like the IEEE and ANSI/NETA regularly publish information relating to updates and changes in the industry. Attending industry events and staying connected with informed colleagues can also help keep you informed.

For testing providers, it may be prudent to conduct a gap analysis to compare their current testing processes with new standards and determine where their crew needs additional training. It’s also critical to determine whether tools need to be upgraded and whether processes and procedures need to be reexamined.

It can be helpful to partner with groups that offer training and certification for workers. For example, NETA offers a program for Certified Electrical Testing technicians with guidelines for education, training, experience, and on-the-job supervision that makes it easy to ensure that cable testers are up to date on the latest techniques and protocols.

Emerging Technologies in Electrical Cable Testing

New technology makes it easier to be proactive when it comes to cable management. Innovations in testing are delivering more precise measurements that allow for better predictions, longer cable life, and a reduction in unexpected cable failures.

Smart Technology

Smart technology, or devices that can communicate with each other and with other systems, has impacted nearly every industry. Smart devices allow more data to be captured using sophisticated technology, and this data can be easily compiled, shared, analyzed, and stored for future use.

Some smart devices can remain in place and collect data, allowing for remote monitoring and reducing the need for traveling field technicians. Along with being more cost effective, remote devices can reduce risks associated with hands-on testing of cables, including electric shock and arc flash.

When it’s time to analyze all this collected data, artificial intelligence and machine learning are already helping to detect patterns, trends, and anomalies and providing enhanced insight into the remaining life of a cable or component and when future maintenance should be performed.

Advanced Partial Discharge (PD) Detection

Online PD testing allows for the real-time monitoring of insulation health without requiring cables to be offline. It reduces downtime and provides insights into wear patterns over time for more accurate failure prediction. Ultra-high-frequency PD detection is extremely sensitive and is used to detect insulation faults at earlier stages, and is useful in critical applications and high-voltage systems where precise measurements are essential.

VLF and Damped AC Testing

Very Low Frequency (VLF) testing uses low-frequency alternating current to test the insulation of medium- and high-voltage cables. It provides a safer alternative to DC testing that is non-destructive and effective for long cable runs.

Damped AC (DAC) testing uses a damped AC signal that reduces stress on insulation without impeding diagnostics. Industries such as offshore wind use DAC testing for long-distance high-voltage cables.

Fiber Optic Sensing

Distributed Temperature Sensing (DTS) uses embedded fiber optic sensors along cables to measure temperature variations and identify hotspots that might point to an insulation failure. Distributed Acoustic Sensing (DAS) uses sensors to detect vibrations along the length of a cable to identify faults resulting from mechanical strain or disturbances. DAS technology is especially useful for monitoring buried cables in challenging climates and environments.

The Importance of Choosing the Right Cable Testing Partner

Cable testing is critical to ensure the safety and reliability of your operations. New cables must demonstrate that they are fit for purpose before being energized, and aging cables must be monitored and tested for deterioration and remaining lifespan.

It is imperative to partner with a NETA-certified organization that has a roster of NETA-certified technicians with the knowledge and experience to perform acceptance and maintenance testing of your power cables and electrical systems.

Quad Plus is an all-inclusive power systems service provider for nearly every industry. Our team of NETA-certified technicians is ready to perform acceptance and maintenance testing according to all electrical cable testing standards. To learn more or to get started, contact Quad Plus today.

Control systems integration is more than just connecting various systems to work together. It’s about coordinating and synchronizing your operation’s systems to optimize performance, reduce costs, and improve productivity.

New technology offers a seemingly endless supply of opportunities to improve and upgrade manufacturing systems. Still, these opportunities can only be taken advantage of when integrated into your existing environment, including legacy systems.

What is Control Systems Integration?

In manufacturing and industrial operations, control systems integration means bringing together multiple digital automation systems into a consolidated, unified system. It eliminates islands of automation and operational silos that were common when digitizing and automating machinery was first embraced.

Initially, individual operations or machines were integrated with digital automation technology, and each operated as a stand-alone device. Data was collected and processed from each system, but operation-wide data processing meant manually collating the data from each process, which was often slow and open to errors.

Integrating these control systems creates an intelligent network of processes and machines and the real-time data collection and processing to go along with it. Manufacturing plants and industrial operations become easier to manage, maintain, upgrade, and scale up with control systems integration.

The Top 10 Benefits of Seamless Integration in Your Factory

Control systems integration delivers significant advantages to manufacturing and industrial processes. When your operation’s machinery, software, and crew are all working together seamlessly, you’ll enjoy these benefits:

1. Increased Productivity. When workflows are streamlined and repetitive tasks are automated, workers can spend their time on more important aspects of their jobs.

2. Reduced Costs. Reducing manual and redundant processes cuts the cost of operations, including labor, maintenance, and materials.

3. Improved Data Accuracy. Integrated systems seamlessly share data across platforms to minimize errors caused by manual data entry.

4. Better Collaboration. Better data collection means better access to information across departments, making it easier for them to work together to solve problems.

5. Quicker Decision Making. With fast access to accurate data from various systems across your organization, identifying issues and making decisions becomes faster and easier.

6. Streamlined Operations. Synchronized operations help eliminate production bottlenecks and reduce the need for operators to switch between multiple systems.

7. Upgraded Quality Control. Integrated monitoring and data collection systems allow quality issues to be identified and corrected early for better outcomes and less waste.

8. Increased Customer Satisfaction. Every customer benefits from fewer quality control issues and faster production times.

9. Easier Scalability. When it’s time to adapt to changing production demands, you’ll have all the data you need to predict future demands and integrate new technologies.

10. Improved Safety. Automated safety features help reduce human error, and eliminiating repetitive processes reduces the possibility of injury from repetitive movements.

Why Integrating Control Systems is a Game-Changer for Manufacturers

Control systems integration is a game-changer for manufacturers because it allows for a holistic view of production processes, which can lead to superior optimization of the entire operation. Rather than relying on collating information from multiple systems, often in different formats and with different data points collected, information can be collected about the entire system.

Integrated control systems also allow for the latest technologies to be leveraged to provide real-time data collection, monitoring, and analysis to deliver precise control over your critical processes and predict when maintenance will be necessary on your equipment.

How Better Integration Improves Real-Time Monitoring and Data Sharing

Data integration gives manufacturers a strategic advantage over the competition as it drives efficiency and agility. By automatically collecting and managing data from sources across your operation, data can be used more quickly and effectively.

To reap these benefits of real-time monitoring and data sharing, manufacturers must collect data from enough sources, including machinery, supply chains, workers, and even customers. However, collection is only the beginning as independent systems collect different data points and use different formats that must be collated.

With control systems integration, this data can be collected together across all platforms so it can be seen in its entirety, and different data points can be easily compared to each other, as well as historical information and future projections.

Cutting Downtime and Boosting Productivity with Integrated Systems

Manufacturing machines and automated systems have relied on manual calibration to work effectively. Algorithms had to be manually calculated or created with computer software and then manually synchronized across systems. Any disruptions or changes to production could create cascading problems down the line.

Control systems integration ensures that components and processes work harmoniously and allow for small changes to be made and automatically accommodated down the line. What this means is more consistent performance from your operations. Projections are easier to calculate and meet, breakdowns can be predicted, and maintenance scheduled rather than encountered.

Control systems integration can significantly reduce unexpected downtime and allow maintenance downtime to be planned during off-peak hours. Production runs can be tighter, and inefficiencies can be minimized. The result is more time up and running at peak efficiency.

Making Your Operations Safer with Integrated Control Systems

Control systems integration in manufacturing boost operational safety in several ways. First, by automating processes, the likelihood of human errors leading to accidents and injuries is significantly reduced. Second, by optimizing conditions, workers can avoid unsafe environments as much as possible.

Integrated control systems also detect faults and other hazards more quickly, allowing for fast emergency response through automated systems or worker response. Control systems integration also allows for automated and engineered safety features, such as muting zones, rather than relying on manual lockout tagout (LOTO) procedures.

Planning for the Future: Scaling Up with Seamless Integration

Whether you’re expanding your operations, scaling up your output potential, or implementing new technology into your existing structures, seamless control systems integration makes scaling up less complicated and more successful for manufacturers.

Scaling up your operations means optimizing your company’s people, processes, and technology and accurate historical data is critical for effective planning and decision-making. High-quality data collected from integrated systems helps to identify trends, forecast future demand, and make operational decisions to accommodate those demands.

High quality data also helps to accurately forecast the working life of major equipment and machines so upgrades, retrofits, and new installations can be perfectly timed to make the most of these expensive investments.

Finding the Right Partner to Bring Your Systems Together

Whether you’re seeking to design a new installation for your large-scale industrial processes or retrofit legacy equipment with new technology, you need a partner that provides fully integrated solutions throughout the process, including design, development, implementation, and commissioning.

The control system integrators at Quad Plus specialize in this process and understand your operation’s specific needs. You’ll have expert assistance choosing the best hardware and software components and programming and configuring everything for seamless operation.

Our control systems integration specialists are ready to tackle every processing application, including stacking and de-stacking, web tension control, alignment and orientation detection and correction, air handling, and recipe-based batching and coatings application.

The Quad Plus control systems integration team also has more combined experience in every industry and every environment. That means our experts have hands-on knowledge of legacy systems and obsolete components, so we know what must be updated and what can be integrated with new technology to save you money.

We also deliver onsite support during the startup process of your integrated system. The engineers who designed your systems will complete the commissioning process and provide ongoing support to ensure your system stays up and running.

Contact a Quad Plus System Integrator Now!

Finding a Partner Who Specializes in Your Industry

Optimizing processes means having a deep understanding of how machines and technology are used in various industries and applications. These are a few of the industries that Quad Plus control systems integration team specializes in:

• Rubber & Plastics. Our system integrators have decades of experience in rubber and plastic sheet roofing, tires, and every sector of the industry, no matter what stage of system integration you are in
• Oil & Gas. Our expertise includes both domestic and international standards for the design and construction of new equipment and the retrofit of obsolete systems. We support all aspects of the industry, including drilling, well completion, and land-based and offshore applications.

• Metals. From tension control and line optimization to slitting, blanking lines, and tube mills, you need system integrators who know your equipment and your production goals.
• Marine. Shipboard equipment requirements are continually changing to meet increasingly demanding standards of efficiency, safety, and environmental impact. We support the latest technology in marine propulsion, material transfer, electrical winches, and hoists.
• Converting. Our engineering and service team has expertise in every market and technology, including tension and motion control technology, line optimization and speed increases, and every step of the converting process from coating and laminating to extrusion, slitting, and winding.

NETA, or the International Electrical Testing Association, serves the electrical power services industry by developing and publishing accepted standards for electrical testing. NETA is accredited by ANSI (American National Standards Institute) and provides certifications for technicians and companies who demonstrate the proper competencies.

Choosing NETA-certified companies for your electrical testing and maintenance means that you have the highest-trained technicians in the industry. To receive their accreditation, the technicians are required to pass multiple rigorous tests. You can expect the highest levels of accuracy and unbiased reporting from technicians servicing your equipment.

What Is a NETA Certified Company?

A NETA Accredited Company is an independent electrical power system testing provider. To become certified, companies must demonstrate that they are not associated with competing service or manufacturing interests. These third-party auditors must deliver unbiased testing results that are never influenced by external factors involving budgets, installation, or product manufacturing.

NETA-certified companies recognize that safety is always the priority, and upholding the highest industry standards is part of ensuring all other operational goals are met. In addition to standards published by ANSI, companies must also adhere to standards and recommendations from OSHA, ASTM, NFPA, IEEE, CSA, the National Safety Council, and any local agencies.

With a roster of NETA Certified Technicians, NETA-certified companies provide ongoing education and support for all personnel performing electrical power system testing and maintenance.

What Are the 4 Levels of NETA Certification for Technicians?

NETA Certified Technicians must be employed by a NETA Accredited Company. Certification is achieved by completing examinations and meeting the requirements for education, training, and years of experience.

There are four levels of certification a technician can move through:

• Level 1: Trainee Technician. This entry-level position requires a high school diploma or GED to get started. Typical duties include assisting higher-level technicians, taking measurements, setting up test equipment, and cleaning.

• Level 2: Certified Assistant Technician. Candidates for Level 2 must have two years of experience or at least two years of technical education plus one year of related experience. They must also complete 40 hours of safety training and 160 hours of electrical training before completing the Level 2 exam.

• Level 3: Certified Technician. Candidates for Level 3 must have five years of experience and complete 24 hours of safety training and 240 hours of electrical training in addition to the hours required for Level 2 before completing the exam. Once certified, a Level 3 Technician can supervise Level 1 and 2 techs.
• Level 4: Certified Senior Technician. With a total of 104 hours of safety training, 600 hours of electrical training, and ten years of experience, a technician can complete the exam to achieve this elite level of certification.

NETA Certification and Industry Compliance Standards

NETA certification ensures that equipment is safe to operate and that technicians have the training and experience necessary to perform testing and maintenance. NETA-certified testing companies can perform:

• NETA Accredited Acceptance Testing. Acceptance testing is performed before commissioning and is required for all installations. The purpose is to ensure that systems are installed according to the engineering design, and technicians will look for equipment defects, installation errors, and potential damage from shipping.
• NETA Accredited Maintenance Testing. NETA-certified power system testing mandates maintenance testing of existing infrastructure every three years. Standards for maintenance testing determine the correct field tests and inspections to assess distribution equipment, emergency energy sources, and other power systems and components. The purpose is to ensure safe operation and to maximize the life expectancy of critical equipment.

Key Benefits of NETA Certification for Electrical Testing

The primary benefit of NETA Accredited Companies and NETA Certified Technicians is the peace of mind of knowing that the people performing tests and maintenance on critical equipment can conduct the work safely. You’ll also rest easy knowing that each technician has the knowledge and experience to evaluate test data, make sound recommendations, and perform expert repairs and maintenance.

NETA-certified companies are not only dedicated to achieving accreditation, but they are also committed to the ongoing training and education of their crew. NETA certification comes with access to ongoing development opportunities and a community of like-minded professionals to ensure that all current standards and recommendations are recognized.

Why You Should Choose NETA-Certified Companies for Electrical Maintenance

The standards NETA-certified companies follow are designed to ensure that electrical equipment will operate safely and without creating hazards for workers and other equipment. New equipment must undergo a series of tests before initial operation, but years of operation will take a toll. Regular inspections will ensure that all safety measures are as functional as they were on day one.

Regular inspections also identify opportunities for preventive maintenance. Addressing worn, broken, or outdated components will help prevent unexpected downtime and disruptions to production due to emergency maintenance needs. Regular preventive maintenance also helps ensure a long working life for expensive critical manufacturing and industrial electrical equipment.

Long-Term Benefits of NETA Electrical Testing and Maintenance

When it comes to critical power systems in your industrial and manufacturing operations, you need more than just a one-time visit for inspections, testing, and maintenance. You need a partner who is as committed to the company’s goals as you are.

Quad Plus is a full-service power systems service provider with decades of experience in every industry. Our team of NETA-certified technicians adheres to the highest standards for safety, integrity, and efficiency.

We’re ready to perform NETA Accredited Acceptance Testing, NETA Accredited Maintenance Testing, and complete assessments of your electrical systems. We’ll work with your schedule to develop a preventive maintenance program to minimize downtime and ensure a long working life for your equipment.

Contact a NETA Certified Technician Now!

Unexpected downtime is one of the most costly frustrations for the industrial sector. In addition to lost production time, repairing the cause of the downtime can become expensive quickly. Overloads and power surges are a common source of unexpected shutdowns, maintaining electrical switchgear is an important element towards prevention.

What is Electrical Switchgear, and How Does it Function?

Switchgear has two main functions. The first is to control the flow of energy to equipment and devices, turning power on or off as needed. Switchgear can redirect power to different system parts or locations or stop the flow of power entirely in an emergency or during maintenance to prevent damage and injury.

The second function of switchgear is to regulate how much electricity is being used and where it is directed. Switchgear prevents circuits from being overloaded with too much power and ensures that sufficient power is being directed to the right equipment at the right time.

The Components of Electrical Switchgear

Switchgear comprises a series of circuit protection devices that work together to isolate and protect electrical equipment and machinery. Each component of the power distribution system performs a vital function. The key components of industrial electrical switchgear include:

Switches. These devices move to start or stop the flow of current in a circuit. Isolator switches ensure that no current can move through the circuit. Disconnecting switches are similar to isolator switches but are used in situations that require infrequent operation. Load break switches can break current while under load and are used for switching energized circuits.
Fuses. Fuses protect circuits when too much current is flowing. An internal strand of conductive material melts or breaks under too much current to stop the circuit.
Relays. Relays detect faults in electrical systems and guide circuit breakers so defective components are isolated. Relays are used in a coordinated fashion to ensure that only the nearest breaker is tripped when a fault occurs.
Circuit Breakers. These provide a similar function to fuses but can detect more fault types and can be reset once tripped.
Lightning Arrestors. Sometimes called surge arrestors, these devices provide a low-resistance path to discharge surges caused by lightning strikes.
Busbars. Typically made of copper or aluminum, busbars are designed to withstand high currents and temperatures.

What Are the Different Types of Switchgear?

The main categories of switchgear are high-voltage (HV), medium-voltage (MV), and low-voltage (LV). High-voltage switchgear is typically limited to utility substations and large power distribution facilities and can handle voltages above 38kV. Smaller systems, including most homes, use low-voltage switchgear rated up to 1kV.

In most industrial and commercial settings, medium-voltage switchgear rated between 1kV and 38kV is critical for the dependability of the power distribution system. It can prevent damage to equipment from short circuits and overcurrents, isolate malfunctioning machinery and devices, and regulate power distribution.

Switchgear can also be categorized by the type of insulation used:

Air-insulated switchgear uses ambient air, providing affordable and simple options in environments not constrained by small spaces.
Gas-insulated switchgear uses SF6 (sulfur hexafluoride) and is useful in areas with high voltage requirements and tight space constraints.
Hybrid switchgear utilizes both air and SF6 gas to provide versatile devices suitable for many applications.
Fluid insulation, including oil, is preferred for systems that are prone to overheating and when high dielectric strength is required.
Solid insulation, like resins, provides high resistance and is not prone to chemical or thermal deterioration.
Why is Switchgear Important for Industrial Safety?

Switchgear is designed to withstand large power surges and unexpected overloads. To prevent widespread damage, surges are diverted, and affected areas are isolated. Switchgear acts like a shield to protect expensive electrical equipment and manufacturing machinery, reducing the need for repairs and extending the working life of equipment.

Arc-resistant switchgear provides another layer of safety to workers and equipment. An arc flash happens when current travels through air and releases a large amount of energy in the form of heat and light. An arc flash can lead to dangerous fires or explosions that can rupture panels, melt some metals, and harm nearby workers.

Arc flashing can happen inside switchgear assemblies or their enclosures. Resistant switchgear is designed to withstand high temperatures and pressure and deflect it away from workers and equipment.

Safety Standards and Compliance for Effective Switchgear Operation

Because electrical switchgear plays an important role in maintaining a safe and productive environment, adhering to all industry standards and guidelines is critical, especially when servicing and maintaining the equipment. Improper electrical safety in the workplace can cause electrical shock or burns to workers, fires and explosions from equipment, mechanical hazards, and dangerous heat buildups.

All operation and maintenance personnel should be appropriately trained in handling switchgear and responding to adverse conditions. All crew members working with or around electrical switchgear equipment should be trained on lockout/tagout procedures and the correct use of personal protective equipment (PPE) such as insulated gloves, leather boots, safety glasses, and flame-resistant clothing.

Every industrial organization is also responsible for ensuring that distribution systems are located in proper enclosures that can control moisture levels and temperature and restrict entry to only trained, authorized personnel.

How Often Should Switchgear Be Inspected or Maintained?

We recommend working with your power service partner to identify how often your switchgear should be inspected or tested. NETA (International Electrical Testing Association) provides a periodic maintenance schedule for each of your electrical assets. A visual inspection of the switchgear and the environment should be performed to check for corrosion and fluid leaks and ensure the proper environmental conditions for the equipment. Internal components of electrical switchgear should be inspected, cleaned, and lubricated.

More frequent testing would be warranted when equipment problems or deterioration are suspected or in environments with high reliability requirements. This comprehensive Periodic Maintenance Schedule provides specific information on testing and maintaining electrical components.

Benefits of Regular Switchgear Maintenance

The best time to discover a problem with industrial electrical switchgear is before major problems occur. Regular preventive maintenance helps ensure that critical safety equipment is properly functioning when it’s time to be used.

When potential problems are identified and addressed before they become major issues, downtime and costly repairs are minimized while the equipment’s working life is extended. Safety and reliability are critical features of every electrical system, and regular maintenance ensures consistent power flow with fewer adverse incidents.

The Importance of Proper Switchgear Enclosures

One primary function of switchgear enclosures is to protect against outside conditions and contaminants. Enclosures can be designed for indoor use or with added protection for outdoor locations. Added safety features can also be included, such as an arc-resistant design classification that will contain any arc explosion within the enclosure to prevent harm to workers and equipment.

How Modern Switchgear Enhances Efficiency & Safety

Modern electrical switchgear components have many features to enhance the operational safety and efficiency of power systems while also making them safer for maintenance personnel. For example, segregated compartments for items such as busbars, switches, and instruments can minimize the risk of arc flashing. The isolation of potential faults helps to contain issues and prevent escalation.

The increasing adoption of digital switchgear is reshaping power management and distribution. By collecting power consumption and performance data in real-time, a high degree of usage optimization allows operations to be more energy efficient.

Digital switchgear also provides smart load management by prioritizing power distribution using real-time demand, and advanced protection features can isolate faults and overloads quickly to prevent damage. Plus, remote operation of digital switchgear is not only safer for operators, but it also enhances responsiveness to changing needs.

Condition-Based Maintenance

Digital switchgear also allows industrial organizations to incorporate condition-based maintenance in addition to regular inspections and preventive maintenance performed on a schedule. Using data collected by the switchgear, potential issues can be predicted before they become apparent either visually or using electrical power testing equipment. This allows organizations to be more reliable and to address problems with greater efficiency by focusing efforts during planned maintenance periods.

Electrical Safety Rules & Regulations

Manufacturing standards ensure that all electrical switchgear equipment meets strict requirements for safe operation. OSHA provides standards for employees working with or around dangerous electrical equipment. The NFPA and ANSI/IEEE standards all contribute to the safe manufacture and operation of electrical switchgear in North America, and IEC standards ensure the same worldwide.

The Future of Safety and Reliability with Switchgear

As with most industrial electrical components, integration with smart technology and IoT devices is already being used in some installations, with even more on the horizon. Innovations that allow for better monitoring of devices and predictive maintenance are already hitting the market, and increasing adaptability to changing demands is delivering greater efficiency for manufacturers and more.

At Quad Plus, our goal is to help you achieve a long working life for your major industrial and manufacturing equipment. That means performing regular preventive maintenance and retrofitting old or outdated equipment with new technology to enjoy its benefits without investing in all new machinery and equipment.

To learn more about improving your operation’s efficiency and safety with switchgear services, smart retrofits, and expert maintenance, call Quad Plus today.

Field service engineers (FSE) are problem solvers who work in various industries. They travel to customer work sites to install, repair, and service equipment and technology. In tech, FSEs might work on telecommunications systems. A medical field service engineer might specialize in servicing diagnostic equipment.

In manufacturing and industrial operations, FSEs travel to production sites to solve problems with customer equipment. They are responsible for installing and maintaining various industrial systems and equipment, along with keeping records and supervising technicians.

So, What Does a Field Service Engineer Do?

The primary job of a field service engineer is to service and maintain equipment and software.  Daily tasks will depend heavily on the industry in which they specialize and the needs of their customers.

Here’s a look at some general tasks common across most industries and specialties.

• Installation. Supervising the installation of entire systems and upgrading old machinery with new components.
• Problem-Solving. Analyzing error codes, system faults, and adverse outcomes to find solutions.
• Repair & Maintenance. Preventive maintenance, routine service, performing repairs, replacing faulty parts and equipment, and supervising technicians who perform maintenance tasks.
• Documentation. Maintaining service records, test results, warranty information, and presenting customers with updates and information.
• Future Planning. Developing new systems and processes to improve profits, energy efficiency, and other customer goals.

What is the Difference Between a Field Service Engineer and an Engineer?

Site engineers are responsible for the overall operations at a job site. They ensure that plans are followed and design specifications are adhered to. They also monitor work quality, manage resources and schedules, and ensure safety protocols are followed.

FSEs provide hands-on technical support. They often work closely with one aspect or area of a project and apply their knowledge and expertise to this area.

What is the Difference Between a Field Service Technician and a Field Service Engineer?

Most engineers will have at least a bachelor’s degree, often in engineering or a technical field. Technicians usually have an associate’s degree or a certification from a technical school. For both options, an extensive technical background and hands-on experience are often considered for candidates without these educational requirements.

Engineers are assigned more responsibility than technicians as they are expected to have a broader knowledge base and experience. Both perform tasks such as repairs and maintenance and communicate with customers. Field service engineers are also responsible for creating technical reports, teaching and training technicians, and performing emergency services.

What Skills Make a Great Field Service Engineer?

To start, field service engineers should be able to work well independently. The job involves traveling alone to customer sites and often completing work unaccompanied by a crew. When additional technicians are on the job, it is frequently the role of the FSE to supervise their work.

Excellent communication skills are also critical. Writing reports is a big part of the job, and communicating to business owners about specific issues, repairs made, and future recommendations are done frequently.

Because the central role of field service engineers is troubleshooting, critical thinking and problem-solving skills are a must. Customers rely on them to find the cause of problems and return operations to normal as quickly as possible.

Adaptability and flexibility are two defining characteristics of field engineers. They must move between different environments and navigate the diverse challenges their customers present. What works in one scenario may not be appropriate in another.

Along with these general skills, you’ll also want to have technical expertise in the equipment and software of the industry and specialty you’re serving. This can involve completing certification courses, postgraduate degree programs, and gaining on-the-job experience in an entry-level role.

Examples of Field Service Engineers in Different Industries

While all field service engineers travel to their customers’ locations and perform maintenance, troubleshooting, and installation tasks, the exact nature of these tasks can vary depending on the industry. Here is a look at the types of equipment different field service engineers may specialize in and the environments in which they may work.

Medical Services

Medical machinery and equipment are vital to diagnosing and treating medical conditions. Complex medical procedures often involve equally complex technology, machines, and robotic tools that must be maintained.

Employers in this area are often the manufacturers of medical equipment and devices. The FSE will travel to the hospitals and medical offices that have purchased the equipment from the manufacturer to service and maintain it.

Manufacturing & Industrial

Field service engineers in manufacturing operations keep production lines running by servicing and maintaining industrial drives, machines, motors, PLSc, process instrumentation, and more. Many tasks are performed onsite, but new technology also allows for remote diagnostics and support of critical equipment.

Information Technology

IT field service engineers design, install, and maintain computer systems and equipment components at customer sites. They are often responsible for testing new hardware and software before deployment, documenting processes, and building networks. Diagnosing hardware faults and software problems is common.

IT field engineers are also responsible for finding and delegating work to other specialists and managing their contributions to solving a customer’s problem.

Robotics

More and more industries are putting robots to work to make jobs safer and more accessible for humans. Field service engineers in this field must have deep knowledge of robotics, along with automation and control theory. They will also need practical experience in troubleshooting and repairing robotic equipment.

Robotics field service engineers work in various industries, including medical, telecommunications, manufacturing, aerospace, and more.

Automotive

In this specialty, FSEs may work for an automotive manufacturer to service and maintain their vehicles. They may also specialize in specific vehicle types and perform service and maintenance for that type of vehicle across multiple manufacturers.

Responsibilities typically include diagnosing and troubleshooting vehicle issues, performing scheduled maintenance, and providing technical advice or guidance to customers and other technicians.

Offshore Oil & Gas

Offshore drilling operations utilize an entire class of specialized equipment and machinery. The working conditions for this equipment are often harsh, and challenging weather is often a factor in the maintenance and upkeep of tools and machinery.

Field service engineers in this industry may be required to live and work temporarily or permanently on an offshore location or traveling to different offshore locations to work on machinery.

Commercial HVAC

In this specialty, field service engineers may work for a manufacturer to support customers who have purchased their equipment, or they may specialize in a specific HVAC application and service multiple customers with a similar setup.

For example, data storage centers and medical labs must maintain exacting air quality and temperature standards. An FSE may specialize in one of these applications.

Agriculture

Farm equipment ranges from relatively small tractors and harvesters to vast networks such as dairy equipment and irrigation systems. Agricultural service technicians diagnose, repair, and overhaul farm vehicles and machinery to maintain optimal functionality. This industry often has seasonal fluctuations in work volume.

Why Field Service Engineers Are the Unsung Heroes of Your Business

When critical equipment or technology fails, production grinds to a halt. Whether it is damaged construction equipment or a faulty diagnostic machine in a hospital, the field service engineer rushes to the job site to quickly assess the problem and put solutions into motion. The issues they solve often involve complex systems and job sites present all kinds of challenging conditions.

Technology changes at breakneck speeds, and FSEs must keep up! It’s also critical to understand older and legacy systems and how they interact with new technology. When implementing solutions, they must be mindful of how a complex system works to ensure that a solution in one place does not cause problems down the line.

Field service engineers are also expected to be fast. Soft skills come in handy here as they must communicate with workers and business owners when stressed and facing their own challenges resulting from the problems being solved.

Lastly, field service engineers often work in extreme weather conditions, hazardous environments, and difficult terrain–all while under pressure to solve problems quickly and accurately so their customers can get back to work.

The Toughest Parts of Being a Field Service Engineer

Most field service engineers would agree that the amount of travel required is the most challenging part of the job. You must often be ready to depart for a job site with very little notice. The location of many job sites can be remote, in small towns, or away from population centers, although many types of field service engineers work for urban customers.

Many field service engineers spend 50% or more of their time away from home. For some people, this can make it tricky to maintain friendships and relationships. Evenings in hotel rooms can get lonely and dull after a while.

However, for outgoing and adventurous people, these downsides are often considered the job’s perks. Seeing different parts of the state or country, meeting new people, and enjoying new experiences in new places is an exciting lifestyle. Many companies also offer additional pay for travel time and a generous expense account while on the road to make traveling easier and more enjoyable.

Thinking About Becoming a Field Service Engineer? Here’s What You Need to Know

Becoming a field service engineer starts with a bachelor’s degree. Engineering is the most common choice of majors, but technology and computer science degrees are another possibility. It’s not uncommon for FSEs to complete a master’s program as well.

Next, it’s time to consider a specialty. Some choose to specialize in trades such as electrical or plumbing. Other options include biomedical, high-tech and telecom, data storage, and more. Depending on the specialization, additional coursework and certifications can be pursued.

Beyond education, on-the-job experience is an important part of developing a career as a field service engineer. Entry-level positions can include working as a field service technician in your chosen industry to gain hands-on knowledge of the equipment and machinery or obtaining an apprenticeship in your field of expertise.

What is the Average Salary and Career Outlook for Field Service Engineers?

The average starting salary for entry-level field service engineers in the United States is around $65,000 annually. Experienced and specialized positions can pay up to $150,000 per year or more. Many positions also provide additional compensation in the form of bonuses, commissions, overtime, and generous travel expenses.

The career outlook for this field is very good as the demand is currently high and expected to continue growing. Depending on their expertise and education level, FSEs can progress to senior engineer positions and then to a role in field service management.

Field Service Management

Field service management involves managing the logistics and supporting activities when coordinating field resources, including technicians and other workers. Typical components of this job field include scheduling and dispatching workers, reporting, managing contracts, and invoicing. Field service management positions often include fewer travel requirements, more responsibilities, and a higher salary than a field service technician or engineer.

The Best of Skilled and Hands-On Work

Field service engineers can specialize in nearly any industry or branch of engineering. This career provides opportunities to use highly specialized knowledge to solve various problems and involves a lot of hands-on work rather than time behind a desk. Solving urgent and mission-critical customer problems can be very demanding and rewarding.

Quad Plus offers advanced industrial and manufacturing field services. Our field technicians are trained by manufacturers and have access to our extensive library of OEM documentation, manuals, and schematics.

When you need your issues expertly diagnosed and resolved as quickly as possible, count on the experts at Quad Plus.

Electrical substations play a critical role in ensuring efficient and reliable power distribution. These facilities act as pivotal points within electrical networks, facilitating the transmission, distribution, and management of electrical energy.

This guide explores the purpose of substations and their importance to help you understand critical role in electrical systems, especially in industrial settings.

What is a substation?

A substation is a key component of an electrical network that facilitates the transformation of voltage levels, switching of electrical circuits, and distribution of power from transmission systems to end-users.

Substations ensure the safe and efficient transmission of electricity across different voltage levels, making it compatible with various industrial machinery and equipment. Essentially, substations play a key role in adapting and delivering electrical power effectively within an infrastructure.

What is the difference between a substation and a power station?

The difference between a substation and a power station lies in their primary functions within the electrical grid:

Power Station:

• A power station, also known as a generating station or power plant, is where electricity is generated from various energy sources such as coal, natural gas, nuclear fuel, hydroelectric dams, wind turbines, or solar panels.
• The main function of a power station is to convert mechanical or chemical energy into electrical energy through generators. This electricity is then transmitted over high-voltage transmission lines to substations.
• Power stations are typically located away from urban areas and are large-scale facilities designed specifically for electricity generation.

Substation:

• A substation is a part of the electrical grid that acts as an intermediary between the power station (or transmission system) and the end-users (homes, businesses, industries).
• The primary function of a substation is to transform voltage levels, switch electrical circuits, and distribute electrical power to different regions at suitable voltage levels for consumption.
• Substations receive high-voltage electricity from power stations or transmission lines and reduce the voltage to safer and usable levels for local distribution.

Substations also play a crucial role in maintaining grid stability, managing power flow, and ensuring electrical safety and reliability.

Substation Types & Design

There are different designs and types of substations that are tailored to meet the specific needs of electrical power systems, ensuring reliable and efficient transmission, distribution, and control of electricity across various voltage levels and operational scenarios within the grid.

Here’s an overview of common substation types and design considerations:

Transmission Substations:

Transmission substations are critical in the high-voltage transmission network, where electricity is received from power plants or other transmission substations at high voltages and then transmitted over long distances to distribution substations or large industrial consumers.

Transmission substations typically include transformers, circuit breakers, and other equipment to manage voltage levels and ensure efficient transmission.

Types of transmission substations include:

1. Step-Up Substations: Step-up substations are located near power plants. They increase the voltage of electricity generated by generators, making it suitable for long-distance transmission over high-voltage lines. These substations use large transformers for voltage stepping.
2. Step-Down Substations: Step-down substations are closer to end-users. They receive electricity at high voltages from transmission lines and lower the voltage to safer levels for distribution to homes, businesses, and industries. Step-down substations use transformers to reduce the voltage.

Distribution Substations:

Distribution substations serve as intermediaries between transmission systems and distribution networks. They receive electricity from higher-voltage transmission lines and further step down the voltage to levels appropriate for local distribution.

Collector Substations:

Collector substations are used in renewable energy systems such as wind farms or solar power plants. They collect electricity generated by multiple turbines or panels and step up the voltage for transmission to the main grid via transmission lines.

Substation Design Considerations:

• Layout and Arrangement: Substation layout is designed to optimize space utilization and ensure efficient flow of electrical components. Components such as transformers, circuit breakers and control systems are strategically arranged based on functional requirements and safety considerations. Circuit breakers play a crucial role in substation design by interrupting faulty currents and isolating sections of the electric power system during abnormal conditions.
• Voltage Levels: Substations are designed to handle specific voltage levels based on the requirements of the electrical network. Transformers are used to step-up or step-down voltages as needed for transmission and distribution.
• Safety and Security: Substation design incorporates safety measures such as grounding systems, fencing, and protective enclosures to prevent unauthorized access and ensure personnel safety.
• Reliability and Redundancy: Redundant components and backup systems are integrated into substation designs to minimize downtime and ensure continuous operation of critical infrastructure.
• Environmental Considerations: Substations are designed to comply with environmental regulations and minimize impact on surrounding ecosystems. Measures such as noise reduction, landscaping, and eco-friendly construction materials are implemented where applicable.
• Automation and Control Systems: Modern substations utilize automation and remote-control systems for efficient operation and monitoring. SCADA (Supervisory Control and Data Acquisition) systems allow for centralized control and real-time monitoring of substations remotely.

Electrical substation operators need access to advanced designs and tools that assist in generating and maintaining electricity grids. This capability enables them to effectively manage, monitor, and control electricity.

Our Quad Plus team are experienced with specialist knowledge to help design, install and maintain your electrical substation infrastructure and power systems. Get in touch to talk to us about your substation design and automation needs.

What are industrial circuit breakers?

Industrial circuit breakers are specialized electrical components designed to protect electrical circuits and equipment within industrial environments.

Often classified by voltage class and type, they serve a crucial role in safeguarding against overloads, short circuits, and other electrical faults that could lead to damage, fires, or injuries. Industrial circuit breakers are typically more robust and capable of handling higher voltages and currents compared to residential or commercial circuit breakers.

Types of industrial circuit breakers include:

• Molded Case Circuit Breakers (MCCBs):

  MCCBs are compact, enclosed circuit breakers commonly used in industrial applications. They feature a molded case housing containing the circuit breaker mechanism and are available in various voltage and current ratings.

• Air Circuit Breakers (ACBs):

  ACBs are larger, open-frame circuit breakers designed for higher current applications. They use air as the arc extinguishing medium and are suitable for protecting large motors, generators, and distribution systems.

• Vacuum Circuit Breakers:

  Vacuum circuit breakers use a vacuum to extinguish the arc when the contacts separate. They offer fast and reliable interruption of currents and are commonly used in medium and high-voltage applications.

• SF6 Circuit Breakers:

  Sulfur Hexafluoride (SF6) are medium circuit breakers that are compact and suitable for applications where space is limited, such as high-voltage substations.

How do industrial circuit breakers work?

Industrial circuit breakers work by monitoring the flow of electrical current within a circuit, interrupting it when necessary to protect equipment and personnel from overloads, short circuits, and other electrical faults.

When the electrical current exceeds a predetermined threshold, such as during an overload or short circuit, the circuit breaker’s trip mechanism is activated, causing the contacts to rapidly separate. This interruption of the electrical circuit prevents the flow of current, effectively isolating the fault and preventing damage to the equipment.

After the fault is cleared and the circuit breaker is reset, normal operation can resume. Industrial circuit breakers employ various mechanisms, such as thermal, magnetic, or electronic trip units, to detect abnormal currents and initiate tripping. Additionally, advanced features like selective coordination and arc flash mitigation help enhance the safety and reliability of industrial electrical systems.

Can industrial circuit breakers be repaired?

Playing a critical role in maintaining the safety and efficiency of electrical systems, industrial circuit breakers, like any mechanical or electrical component, can malfunction over time.

Factors such as wear and tear, environmental conditions or improper use can all cause issues and potential damage, so it’s important to know how to repair your industrial circuit breaker to ensure your operations are uninterrupted and costly downtime is little to none.

When circuit breakers become damaged or broken, the quickest solution to prevent downtime is to get a replacement. However, this can be a costly business decision to make, which is why it’s important to continually monitor and maintain your machinery to avoid having to spend thousands of dollars on buying a replacement. If you catch a problem before it’s too late, you can repair an industrial circuit breaker to get it up and running again, saving precious time and money on waiting for a replacement.

Here we explain how our Quad Plus technicians make repairs and what to look out for:

1. Identify the problem: The first step in repairing an industrial circuit breaker is identifying the underlying issue. There are several signs that you need an industrial circuit breaker repair, so it’s important to look out for potential early issues such as, frequent tripping, burning or scorching and components that feel hot to the touch.
2. Follow proper safety precautions: Before attempting any repairs on an industrial circuit breaker, it’s crucial to follow proper safety precautions to prevent electrical accidents and injuries. This includes de-energizing the circuit, using appropriate personal protective equipment (PPE), and following lockout/tagout procedures to isolate the power source.
3. Disassemble and inspect components: Once the circuit breaker is safely de-energized and isolated, it can be disassembled for inspection. We carefully examine each component for signs of damage, wear, or corrosion, cleaning any dirt or debris that may have accumulated inside the circuit breaker, as this can affect its performance.
4. Replace parts and components: If any components are found to be damaged or faulty during the inspection, we replace them with new ones. Common replacement parts include contacts, springs, trip mechanisms, and arc chutes.
5. Calibrate and test: After replacing any faulty components, we calibrate and test the industrial circuit breaker to ensure proper operation. This may involve adjusting the trip settings, testing the functionality of the trip mechanism, and conducting a series of electrical tests to verify that the circuit breaker can handle the expected load.

Repairing industrial circuit breakers requires a combination of technical knowledge, careful inspection, and adherence to safety protocols. That’s why we ensure all our experienced maintenance personnel have extensive circuit breaker knowledge and follow proper repair procedures to ensure the continued reliability and safety of electrical systems in industrial settings.

Regular preventative industrial circuit breaker maintenance and inspection is crucial to help identify potential issues before they escalate into major problems, minimizing downtime and maximizing productivity. Remember, when in doubt, consult with qualified electrical professionals, like our experienced Quad Plus team, to ensure the safety and integrity of your industrial circuit breakers.

Get in touch for industrial circuit repair services by certified Quad Plus breaker technicians.