Switchboard maintenance: preventive vs. corrective

Electrical panels represent a key component of every electrical installation, whether in industrial plants, commercial buildings, or residential facilities. Their proper function is crucial for the safety, reliability, and efficiency of the entire electrical system. In the field of electrical panel maintenance, we encounter two basic approaches: preventive maintenance and corrective maintenance. Each of these approaches has its specifics, advantages, and disadvantages.

What is Preventive Maintenance of Electrical Panels?

Definition and Principles

Preventive maintenance is a systematic approach to maintenance that focuses on preventing failures before they occur. It involves planned activities performed at regular intervals with the goal of keeping electrical panels in optimal technical condition.

Key Activities of Preventive Maintenance

Visual Inspections:

• Checking for mechanical damage
• Verifying cleanliness and absence of corrosion
• Checking labeling and documentation
• Verifying signaling functionality

Measurements and Testing:

• Measuring insulation resistance
• Checking connection tightness
• Testing protective elements
• Verifying functionality of circuit breakers and current protectors

Cleaning and Maintenance:

• Removing dust and dirt
• Cleaning contacts
• Checking and replacing filter units
• Maintaining ventilation systems

Advantages of Preventive Maintenance

Economic Benefits:

• Lower overall maintenance costs
• Prevention of costly breakdowns
• Extended equipment lifespan
• Reduced spare parts costs

Operational Advantages:

• Higher system reliability
• Minimization of unplanned outages
• Better production and operation planning
• Increased work safety

Technical Benefits:

• Maintaining optimal parameters
• Early detection of wear
• Prevention of secondary damage
• Preservation of warranty conditions

What is Corrective Maintenance of Electrical Panels?

Definition and Characteristics

Corrective maintenance is a reactive approach where maintenance is performed only after a failure occurs or after a problem is detected. It involves repair or replacement of components that are no longer functioning properly or are damaged.

Types of Corrective Maintenance

Emergency Repair:

• Immediate response to critical failure
• Quick restoration of basic functionality
• Often temporary solution

Planned Correction:

• Repair of known problems at a scheduled time
• Comprehensive solution to identified defects
• Replacement of worn components

Typical Situations Requiring Corrective Maintenance

Electrical Failures:

• Circuit breaker outages
• Contact damage
• Insulation problems
• Protective element failures

Mechanical Problems:

• Wear of moving parts
• Damage to cabinets and covers
• Ventilation problems
• Corrosion and oxidation

Comparison of Preventive and Corrective Maintenance

Cost Analysis

Preventive maintenance has higher initial costs due to regular investments, but brings lower long-term costs by preventing major repairs. Outage costs are minimal due to the planned nature, and spare parts are cheaper due to the possibility of planned purchasing.

Corrective maintenance has lower initial costs since payment occurs only when failure happens, but long-term costs are higher due to expensive breakdowns. Outage costs are high due to unplanned nature, and spare parts are more expensive due to urgent deliveries.

Time Perspective

Preventive Maintenance:

• Planned time windows
• Possibility of coordination with production
• Shorter intervention times
• Predictability

Corrective Maintenance:

• Unpredictable timing
• Possible operation disruption
• Longer repair times
• Stressful situations

Safety Aspects

Preventive Approach:

• Higher safety level
• Controlled working conditions
• Prevention of dangerous situations
• Adherence to safety procedures

Corrective Approach:

• Possible risks from emergency situations
• Work under pressure
• Potential personnel endangerment
• Safety compromises

Optimal Maintenance Strategy

Combined Approach

The most effective strategy combines both maintenance approaches. Eighty percent should consist of preventive maintenance including regular inspections and service, planned replacement of worn parts, and systematic condition monitoring. The remaining twenty percent represents corrective maintenance focused on solving unpredictable failures, emergency repairs, and upgrades or modernization.

Factors Influencing Strategy Choice

System Criticality:

• Critical systems require more preventive maintenance
• Less critical systems can tolerate corrective approach

Equipment Age and Condition:

• New equipment – predominantly preventive maintenance
• Old equipment – combination of both approaches

Spare Parts Availability:

• Easy availability – possibility of corrective approach
• Difficult availability – necessity of preventive maintenance

Economic Factors:

• High outage costs – preventive maintenance
• Low outage costs – possibility of corrective approach

Implementation of Preventive Maintenance

Creating a Maintenance Plan

Component Identification:

• Cataloging all electrical panel elements
• Determining criticality of individual parts
• Setting recommended maintenance intervals

Time Planning:

• Daily checks (visual inspections)
• Weekly checks (basic tests)
• Monthly checks (detailed inspections)
• Annual checks (comprehensive revisions)

Documentation:

• Keeping records of performed checks
• Tracking trends and changes
• Archiving measurement results
• Planning future activities

Personnel Training

Technical Knowledge:

• Principles of electrical panel function
• Safety procedures
• Using measuring instruments
• Problem identification

Practical Skills:

• Performing inspections
• Basic repairs
• Documentation management
• Communication with suppliers

Modern Trends in Electrical Panel Maintenance

Predictive Maintenance

IoT Sensors:

• Continuous temperature monitoring
• Vibration tracking
• Humidity measurement
• Electrical parameter monitoring

Data Analysis:

• Failure prediction
• Maintenance interval optimization
• Trend identification
• Automatic alerts

Maintenance Digitalization

Mobile Applications:

• Digital checklists
• Photo documentation
• Immediate reporting
• Access to documentation

Cloud Solutions:

• Centralized database
• Remote data access
• Automatic backups
• Information sharing

The choice between preventive and corrective maintenance of electrical panels is not a matter of “either/or,” but rather optimal balancing of both approaches. Preventive maintenance should form the foundation of the maintenance strategy, while corrective maintenance serves as a supplement for solving unpredictable situations.

Key recommendations:

• Implement a comprehensive preventive maintenance program
• Maintain capability for quick corrective interventions
• Invest in personnel training and modern technologies
• Regularly evaluate and optimize the maintenance strategy
• Document all activities and analyze trends

The right combination of both approaches ensures maximum reliability, safety, and economic efficiency of electrical panel operation while minimizing risks and unexpected costs.