In industrial facilities, periodic thermographic inspections are key to maintaining the reliability and safety of electrical equipment. However, inspecting live switchgear may require removing panels, using specific PPE, and increasing personnel’s exposure to the risk of electric arcing.
This was the challenge facing one of North America's leading bottled water companies: to improve the safety and efficiency of its electrical maintenance program across its entire network of facilities.
The solution came in the form of IRISS infrared windows, which allow for thermographic inspections of electrical equipment without having to open the panels. The project began at a pilot plant and was eventually implemented at 29 facilities in the United States and Canada.
The Challenge: Safer and More Efficient Electrical Inspections
The company was already conducting inspections using thermal imaging cameras, but to view the internal components, it was necessary to open the electrical panels, use high levels of PPE, and accept lengthy inspection times. Some equipment was even considered “uninspectable” due to its high level of incident energy.
They needed a solution that would allow them to inspect electrical equipment more frequently, reduce response times, and, above all, limit staff exposure to live equipment.
IRISS Infrared Inspection Windows for Electrical Equipment
To tackle the project, the company contacted IRISS and its authorized distributor, DTM Consulting Services. The goal was to develop a solution that would work in an initial installation and could later be replicated on a large scale across the entire network of centers.
The first step was an in-depth analysis of the pilot facility, located in Ontario, Canada. DTM assessed the environmental conditions, the design of the electrical cabinets, and the critical points that needed to be visible during each infrared inspection. Based on that study, the following were defined:
Optimal locations for installing IR windows.
The most appropriate sizes based on the geometry and internal layout of the equipment, to ensure that the components are clearly visible.
The strongest and most durable window model: the IRISS CAP-CT series.
These infrared windows, made from a proprietary transparent polymer, are ratedNEMA 4 / IP65, making them ideal for indoor industrial environments. Furthermore, their availability in standard sizes (4″, 6″, 12″, 18″, and 24″) and custom formats allows them to be adapted to a wide variety of electrical equipment without compromising the viewing area or coverage.
Once the solution was finalized, a meticulously planned window installation was carried out:
Identification of the equipment to be intervened and obtaining approvals for disconnection.
Safe de-energization, with two electricians in charge of verifying insulation and applying lockout/tagout procedures.
Removal of panels and placement of windows using the drilling and cutting templates provided by IRISS.
Reinstallation of the covers, reenergization of the equipment and waiting for the necessary time for thermal stabilization.
Initial thermographic inspection to obtain baseline temperature and verify proper operation.
This process was not only executed with total safety, but proved to be highly scalable, allowing an agile and orderly implementation in future plants.
Thanks to this solution, electrical panels can now be inspected without removing panels, without interrupting service and without exposing personnel to unnecessary risk. All in strict compliance with NFPA 70E standards and insurance inspection requirements.
The solution: safety, efficiency and a replicable strategy on a large scale
The implementation of IRISS polymer infrared windows in the pilot plant not only solved the problems identified, but completely transformed the way thermal inspections are carried out in this bottling company.
Thanks to this solution, they can now:
Conduct inspections more frequently and without interruption, which allows for the detection of hot spots and faults before they develop into serious malfunctions.
Drastically reduce the use of PPE and maintenance times by not having to disassemble panels or work under tension.
Ensure the safety of personnel, complying with NFPA 70E standards with a simpler and more operational method.
Establish a uniform and scalable work system, which has already been replicated in 29 centers in North America.
In addition, the company has integrated this solution into its long-term improvement plan, based on reliability-centered maintenance methodologies (RCM/RBM). In this way, IRISS windows not only become a one-off tool, but a key part of its electrical reliability strategy, which contributes directly to increasing Mean Time Between Failure (MTBF) and reducing structural costs.
The result: a network of centers that is safer, more efficient and better prepared to anticipate any power failure.
Want to inspect your electrical installation without removing panels or exposing your equipment?
Discover how IRISS windows can help you optimize your electrical maintenance with more safety and less cost.