Client: Pharmaceutical Manufacturer
Location: South East
Company: Baldwin and Francis
Introduction Partial Discharge Testing
As a pharmaceutical manufacturer operating highly sensitive production environments, maintaining stable temperatures and ensuring uninterrupted operation of our client’s chiller systems is essential not just for product quality, but for regulatory compliance and the safety of their equipment and people.
We needed confidence that their 3.3kV medium voltage chiller motor control panels were functioning reliably, and our client required a specialist partner who could identify issues early, minimise risk, and work within tight operational constraints.
Our client engaged the team to carry out partial discharge (PD) testing across their chiller starter compartments as part of the asset resilience strategy. Their expertise and technology provided a non-intrusive, accurate way to assess insulation health and prevent failures that could lead to costly downtime or operational disruption.
Overview
Due to the critical nature of our client’s operations, any failure within the chiller motor control system could have significant consequences, including halted production, product spoilage, and emergency interventions to restore system stability.
Our client’s facilities management partner coordinated this work, but they needed a specialist who could deliver:
- Fast, reliable diagnostic testing
- Detailed insights about equipment condition
- Clear, easy-to-interpret results
- Work completed during a very limited outage window
Our team supported by using an UltraTev Plus² partial discharge meter, providing the advanced analysis we needed to protect key MV assets and avoid unplanned outages.
Scope of Work
We required a full partial discharge assessment of our client’s chiller motor control compartments.
The work covered:
- Three chiller starter compartments
- Auto-transformer
- Air Circuit Breaker (ACB) chassis
- Voltage transformer assemblies
- Current transformer assemblies
All testing was completed safely and within the restricted outage period agreed with site operations.
Key Deliverables
Our client received:
- A comprehensive suite of PD measurements
- A simple stop/go traffic-light system that made interpretation immediate
- Clear graphical representations showing acceptance/rejection thresholds
- Early identification of emerging issues
- Confirmation of equipment operating within safe limits (except where flagged)
This allowed us to prioritise maintenance quickly and make informed decisions without specialist interpretation.
Challenges
The key challenge was completing intrusive service work and PD testing within a very narrow maintenance window.
The team’s coordination, preparation, and on-site efficiency ensured all works were completed safely and without extending the outage, helping our client keep production schedules on track and avoid unnecessary disruption.
Client Benefits
Our client told us the benefits were significant:
- Reduced Downtime Risk
Early detection of PD prevented unplanned shutdown of a critical chiller system, avoiding potential production loss and emergency repairs.
- Improved Safety
By identifying insulation deterioration early, they prevented the possibility of electrical faults developing into dangerous failures.
- Cost Savings
Avoiding catastrophic failure of MV equipment, especially transformers and chiller starters, saved substantial replacement and downtime costs.
- Increased Reliability
Regular PD testing strengthens the reliability of MV network and supports compliant, stable operation in a sensitive pharmaceutical environment.
- Faster Decision Making
The team’s simple result summaries and graphical acceptance thresholds allowed our engineering teams to act immediately.
- Specialist Expertise & Niche Capability
The ability to work efficiently in a restricted outage with specialist PD equipment gave our client confidence that no issues were missed.
- Extended Asset Life
By identifying insulation issues early, we can repair components instead of replacing them, extending the lifespan of our MV assets.
Outcome
The testing provided us with a clear, accurate understanding of the health of our client’s medium voltage assets.
- Identified a voltage transformer showing PD activity up to 10 dB
- Allowed to safely isolate and plan corrective action before failure
- Prevented what could have been a major equipment outage
- Provided evidence for our asset management and maintenance planning
This early detection directly reduced risk and helped prevent a potentially costly breakdown.
Client Feedback
“Following the testing, we reviewed the findings with our Site Services Manager and identified a concerning PD peak of 10 dB on one of our voltage transformers. Because this was flagged early, we were able to isolate and schedule further investigation before the equipment deteriorated. The testing provided the clarity we needed to act quickly and prevent failure.”
