Industrial Wire and Cable Maintenance: An Overview

 Industrial automation systems, and other electrical systems, are only as good as the summative functionality of the components used within them.

Something as simple as a frayed cable can cause a fire, and a loose connection can utterly shut down an electrical system by interrupting the circuit.

Failing to plan with the proper electrical infrastructure, components, and undertaking preventive inspection and maintenance is, in its own way, planning - to fail.

Be sure to observe these best practices in and around your workplace, which together will help improve safety, prevent electrical system failure, and help eliminate costly downtime associated with it.

Why Industrial Wire and Cable Maintenance Matters

Unlike comparatively simple residential and even commercial electrical infrastructure, industrial electrical systems are complex, often contain numerous sensitive connections (each of which is a potential failure point), and are often subjected to less than ideal conditions. Frankly, some are operable under quite adverse chemical and physical conditions.

Failing to properly set up, and then subsequently failing to periodically inspect and maintain an industrial electrical system, can incur failures that will shut down the entire process, incurring costly downtime, or worse, dangerous conditions.

Moreover, the size and complexity of some industrial electrical systems can make it difficult to find and diagnose failures, which compounds the issue of downtime.

However, routine inspection and preventive maintenance can help prevent these issues. These are our tips.

Tips to Protect Your Systems and Extend the Life of Your Electrical Wire, Cable, and Components

Ultimately, investing a few minutes each day or hours each month inspecting and repairing your facility’s electrical system can save you bigger headaches in time, money, and resources in the long run.

Installation Recommendations: Set Up for Success

The most important recommendation we have is to install the appropriate wire, cable, switches, and connectors in the first place.

Electrical wire and cable are variously rated according to conditions and usability. Some cables are made with special insulation, or even armor, that makes them suitable for use as tray cable, in marine environments, or for direct burial, among other niche uses. Always use an appropriate electrical wire or cable for the conditions in your industry.

Also, be cognizant of factors such as voltage rating and voltage drop, as using inappropriate cable can cause procedural inefficiencies at best and cause fires or increase the risk of electrical shock at worst. Pay attention to factors such as mechanical strength and temperature rating as well.

The installation environment should never exceed the manufacturer recommendations of the cable or wire in terms of temperature, exposure to chemical or corrosive agents, or other similar factors.

When configuring an electrical system, always use appropriate electrical industrial connectors that are rated for use in your facility’s environment. Use cable relief, such as Sealcon glands, where necessary, and always utilize electrical enclosures that are appropriate given the conditions of your workplace.

Where necessary, certain electrical enclosures might also be indispensable for protecting the contained connections, switches and other electrical interfaces against electromagnetic interference or other hazardous environmental factors, like liquid and particulate ingress.

Preventive Measures and Maintenance

Next to ensuring that you have installed suitable electrical equipment in accordance with the requirements and conditions of your workplace, the next most important step is to undertake routine preventive maintenance.

Be cognizant of a wire or cable’s bend radius, which is the maximum amount by which the manufacturer rates it to be bent at an angle. Take steps to rectify any adverse conditions in the workplace. Also, be aware of strain on cables; use strain relief connections like Sealcon connectors where suitable, but prevent excess strain on cables nonetheless.

It is also important to protect wire, cable, and connectors from abrasive damage, or from being crushed. Prolonged pressure or repeated impact or physical strain on a cable can compromise its general durability and mechanical properties.

During and after installation make sure that the wires are not subject to any kinking, twisting or abrasion that can damage them, compromising their insulation and durability.

Where possible, keep electrical wire and cable away from contact with frames, supports and other structures that can harm them.

Inspection and Repair

As important as proper installation is, inspecting and repairing your electrical system’s infrastructure on an ongoing basis is the key to preventing costly long-term damage and expensive downtime and repairs.

Periodically inspect electrical cables for signs of stress, twisting, crushing, or abrasive damage to the insulation. Wherever you note damage to electrical cables or connectors, replace them with the appropriate parts as soon as possible.

It is beneficial in certain instances to maintain spare cables, glands and connectors, in order to make repairs as needed where damage is observed instead of having to wait for a supplier’s lead time.

Even if no visible damage is noted, it helps to keep spare cables on hand and to maintain them as well; store them somewhere safe and free from hazardous conditions so they will be ready if and when you ever need them.

The Importance of Record Keeping

Whenever you inspect your electrical infrastructure, always take thorough notes, even if you observe no damage. If you observe no damage, report it; that way, if there is damage the next time you investigate, you may be able to accurately pinpoint the source of the issue.

Moreover, record keeping will help you keep track of repairs, which will help keep you on a maintenance schedule while managing costs, as well.

Knowing when and why you replaced a section of cable or a Sealcon electrical connector will also keep you up to date on how long your electrical wires, cables and connectors have been in service, so you will know when it might be appropriate to replace them again in the future.

Sealcon Cable Glands and Strain Relief, Boxco Electrical Enclosures, and Other Industrial Electrical Necessities

Products for Automation carries a large variety of industrial electrical connectors and other electrical components necessary for maintaining or upgrading industrial automation systems.

We carry electrical connectors, cable entry systems and carrier chains, electrical enclosures, switches, thermal management systems, lighting, cable glands and other components from Sealcon, Hirschmann, Boxco, CNLINKO, and many other manufacturers. If you have any questions about our products or accessories, get in touch with us at 800-966-2345.