Industrial Electrical Failures: Risks, Costs, and Solutions with the Vigilant

Electrical system failures are a pervasive issue across European industries, causing an estimated €150 billion in annual downtime costs.

Manufacturing, which consumes 36% of Europe’s electricity, relies heavily on uninterrupted operations. A single fault can halt production, resulting in immense financial losses, safety hazards, and environmental impacts. Recent studies highlight that downtime costs in high-output sectors, such as automotive and food production, can reach €10,000 per minute, while short-term outages have risen by 29% since 2009.

These failures are not merely financial liabilities; they also threaten workplace safety. Electrical anomalies, including partial discharge (PD) and arcing, account for over 25% of workplace fires annually. The growing complexity of industrial systems amplifies the need for early anomaly detection and effective condition monitoring.

Understanding electrical failures

Partial discharge is one of the most destructive issues in electrical systems, responsible for more than 80% of high-voltage equipment failures. It occurs when localized electrical discharges weaken insulation materials, eventually causing catastrophic breakdowns. This phenomenon is influenced by system voltage, insulation condition, and environmental factors such as humidity and pollution.

Another critical issue, known as tracking, involves carbonized pathways forming on insulating surfaces. Though less severe in its early stages, tracking can escalate into dangerous arcing, particularly in dusty or moist environments. Addressing these anomalies promptly is key to avoiding significant repair costs and operational delays.

Enhanced condition monitoring

SDT Ultrasound Solutions’ Vigilant system is designed to proactively detect these anomalies. It is a turn-key condition monitoring solution that combines ultrasound and vibration analysis with advanced software for real-time diagnostics. The Vigilant ensures early detection, allowing maintenance teams to intervene before issues escalate.

How the Vigilant Works

The Vigilant is equipped with 8 ultrasound or vibration channels and 4 auxiliary channels for temperature, tachometer, and process data, making it versatile for various electrical applications. Its onboard analytics software visualizes asset health through real-time data, trends, and spectral analysis, accessible from any web browser.

The system also integrates with SDT’s CONMONSense Airborne Sensors. These sensors, available in IP40 and IP65 configurations, provide precise and repeatable measurements, continuously monitoring electrical cabinets and ensuring plant safety.

Applications of Vigilant in electrical monitoring

The Vigilant excels in diverse industrial scenarios:

Early detection of partial discharge, preventing catastrophic dielectric failures.

Identifying tracking and arcing in MCC panels, transformers, and switchgear.

Monitoring thermal fluctuations in critical electrical components, mitigating fire risks.

Predicting degradation trends for effective maintenance planning.

Enhancing safety and sustainability

The Vigilant contributes significantly to workplace safety by identifying risks like arc flashes, which can release energy equivalent to several kilograms of TNT. Real-time monitoring reduces exposure to such hazards, ensuring compliance with stringent EU electrical safety standards.

From a sustainability perspective, the system supports efforts to reduce waste and extend the lifecycle of electrical assets. Proactive maintenance minimizes unplanned shutdowns, conserving resources and aligning with net-zero emissions goals.

Preparing for the future

The rise of Industry 4.0 demands innovative solutions like the Vigilant. Its integration of ultrasound and vibration technologies equips businesses with a proactive approach to electrical system monitoring. By adopting it, industries can safeguard operations, enhance safety, and contribute to a sustainable future.

Electrical failures are no longer unpredictable disruptions. With the Vigilant, they can become manageable challenges, empowering industries to operate with confidence.