Panel Asset Review Service
Comprehensive control panel health assessment using advanced diagnostics to prevent catastrophic failures and optimise maintenance strategies.
A Panel Asset Review is our most comprehensive electrical control panel assessment, combining detailed component testing, advanced diagnostics, and risk analysis. This deep-dive service provides critical insights into your panel’s health, helping prevent unexpected failures before they occur.
What is an Asset Review?
A thorough health check involving detailed electrical testing, thermal imaging, vibration analysis, and comprehensive component evaluation. Our team conducts intrusive testing of components while documenting every finding with precise measurements and analysis.
This service includes advanced predictive diagnostics that can identify potential component failures weeks or months before they occur, allowing for planned maintenance instead of emergency repairs.
In-Depth Testing Coverage
Thermal Analysis
Infrared camera scanning to detect:
Imbalanced loads across phases
Loose connections creating hot spots
Overloaded circuits and components
Deteriorating insulation
Failing components showing heat signatures
Component Integrity
Physical component assessment:
Contact resistance measurements
Relay coil testing
Capacitor health evaluation
Breaker trip curve verification
Terminal block torque testing
Circuit board visual inspection
Predictive Analysis
Advanced failure prediction:
Component MTBF tracking
Failure mode effect analysis
Trend analysis of test results
Reliability curve modeling
Risk prioritisation matrix
Maintenance scheduling optimisation
Electrical Testing
Comprehensive electrical diagnostics:
Voltage and current measurements
Insulation resistance testing
Ground fault resistance
Connection torque verification
Power quality analysis
Arc fault detection
Environmental Impact
Environmental stress analysis:
Dust and contamination measurement
Humidity level assessment
Temperature cycling effects
Vibration impact evaluation
Chemical exposure assessment
Cooling system effectiveness
Modernisation Planning
Strategic upgrade recommendations:
Obsolete component replacement paths
Technology upgrade opportunities
Safety system improvements
Energy efficiency enhancements
Digital connectivity upgrades
Budget and phasing plans
When to Choose a Panel Survey
1
Pre-Assessment
Review historical data and operating conditions
2
Baseline Testing
Initial measurements of all critical parameters
3
Thermal Imaging
Detailed infrared scanning of entire panel
4
Intrusive Testing
Component-level evaluation and testing
5
Risk Analysis
Failure probability and impact assessment
6
Strategy Development
Maintenance and modernisation planning
MTBF and Reliability Assessment
Our engineers use Mean Time Between Failures (MTBF) – the statistical average run-time before a failure – to gauge component reliability. By applying MTBF data from component datasheets, we:
- Predict component lifespan and schedule replacements
- Apply the “bathtub” reliability curve to understand panel lifecycle
- Set appropriate preventive maintenance intervals
- Model how your panel’s failure risk grows over time
The Bathtub Curve: New systems may have early “infant mortality” failures, followed by a long stable period, and finally an increasing failure rate in the wear-out phase. Understanding this curve helps us target maintenance efforts effectively.
Comprehensive documentation package including:
- Detailed technical report with all test results
- Color-coded thermal images with analysis
- Component reliability assessment charts
- Prioritised maintenance action plan
- Cost-benefit analysis for upgrades
- Predictive maintenance schedule
- Spare parts recommendations
- Risk mitigation strategies
- Modernisation roadmap
- Executive summary with ROI projections
Panel Lifecycle Risk Profile
Control panels have a shifting risk profile as they age, following the classic reliability bathtub curve:
Year 1:
New installations carefully tested – primarily infant mortality failures (warranty covered)
Years 5-10:
Components approach end-of-life – failure rates rise due to accumulated stress
Years 1-5:
Low-failure “useful life” phase – most stable operational period
Year 10+:
Wear-out phase – significantly increased
risk from insulation degradation, terminal loosening, component aging
Our review includes analysis of where your panel sits on this curve and what maintenance strategies are most appropriate for its lifecycle stage.
Critical Failure Indicators
Warning Signs
Common indicators of impending failure:
Increasing component temperatures
Escalating PLC fault frequency
Unusual electrical noise or vibration
Erratic equipment performance
Voltage fluctuations
Unexplained circuit breaker trips
Age-Related Risks
5-7 years: PLC battery deterioration
7-10 years: Cooling fan bearing wear
8-10 years: Capacitor dry-out
10+ years: Insulation degradation
Panel Lifecycle Risk Profile
Four distinct lifecycle stages based on the bathtub curve
Specific risks and characteristics for each stage
How the review analyses the panel’s position on this curve
Business Value
5:1 ROI on preventive maintenance
400% ROI on preventive programs
12-18% reduction in maintenance costs
Weekly downtime statistics
Welcome To Sull Systems 