During a recent infrared inspection, a significant hot spot on a client’s medium voltage transformer termination was identified. Elevated temperatures on medium voltage connections are often caused by deteriorating contact surfaces, loose connections, contamination, or internal component failure.
During the scheduled maintenance outage, we prepared the circuit for inspection and offline testing. As our technicians attempted to remove the loadbreak elbow from the loadbreak insert, they immediately noticed the connection was unusually difficult to separate.
At that moment, the decision was made to stop.
Rather than forcing the connection apart and risking damage to the cable or transformer termination, our technicians chose the safer approach and reassessed the situation. In medium voltage systems, taking the extra time to evaluate an abnormal condition can be the difference between a controlled repair and a major outage.
Had the connection been forcefully removed, the client may not have been able to return to service that same day. Because our technicians recognized the abnormal condition early, we were able to create a repair plan, return with the correct materials, and complete the repair safely with minimal downtime.
The safest solution was to cut off the existing loadbreak elbow and replace both the elbow and loadbreak insert. Fortunately, there was enough cable length remaining to complete a new termination without requiring additional cable replacement or splicing.
After the repair was completed, we brought the removed loadbreak insert back to our shop for further inspection. Once disassembled, the cause of the overheating became clear. The internal connection surfaces showed severe thermal damage and burning, and the elbow’s conductive pin appeared to have partially melted and fused inside the loadbreak insert — creating excessive resistance and heat buildup.
Had this issue gone undetected, it could have resulted in:
- Equipment damage
- Unplanned outages
- Emergency repair costs
- Extended downtime
This project serves as a reminder that in electrical maintenance, being safe rather than sorry is always the right decision.
