by IRISS Staff Report

Executive Summary

Vandolah Power, a power generation plant in Florida, faced a critical issue with degraded factory-installed inspection windows on their 18 kV, 8000-amp generator breaker. The deterioration, caused by UV exposure, rendered the crystal optic windows opaque, making  inspection impossible. IRISS partnered with Vandolah Power to replace the failed windows with durable, state-of-the-art FlexIR infrared (IR) windows. This solution restored inspection capabilities, improving  equipment lifespan and reliability, and ensured long-term safety while reducing maintenance time.

Challenge

Vandolah Power operates a power generation plant critical to local energy needs. The plant faced operational challenges when the factory-installed viewing windows on their generator breaker suffered severe degradation. These windows, designed for routine inspections, had become visually opaque due to prolonged UV exposure, compromising the ability to verify breaker condition. Key challenges included:

• Operational Issues: Inability to conduct visual, infrared, or UV inspections.
• Safety Concerns: Increased risk due to undetectable faults in high-voltage equipment.
• Compliance Risks: Potential non-compliance with maintenance safety standards.

These challenges resulted in elevated stress among the maintenance team, potential equipment damage and subsequent downtime risks, and safety concerns.

Solution

Vandolah Power required a robust and versatile solution to replace their degraded factory-installed viewing windows, which had compromised their ability to conduct essential equipment inspections. The FlexIR Series was uniquely suited to meet these challenges due to its advanced polymer optic and unmatched durability. Unlike traditional inspection windows, FlexIR is a complete panel replacement solution, where the entire panel—custom-fitted with the inspection window—is designed to be a direct replacement for the existing equipment panel. This innovative approach eliminates complex retrofits and ensures a seamless, easy installation process. With IRISS as the only company in the world offering this solution, Vandolah Power gained access to a level of convenience and precision unmatched in the industry.

The FlexIR Series not only simplified installation but also enhanced inspection capabilities by integrating visual, infrared, and UV inspection options into a single, durable panel. Its UV-resistant polymer construction, backed by a lifetime warranty, ensured long-term reliability even in harsh operating conditions, guaranteed for the lifetime of the installation.

Steve Watson, owner of Connected Power (an electrical service contractor located in Brandon, Florida) introduced Vandolah Power to IRISS and the FlexIR solution. During a facility visit, the Vandolah team observed the manufacturing processes and rigorous quality standards that set IRISS products apart. This experience confirmed that FlexIR windows were not only the right replacement for their failed components but also an upgrade that would enhance safety, efficiency, and compliance for years to come. These industrial-grade IR windows offer:

• Enhanced Inspection Capabilities: Visual, infrared, and UV inspections through a single window.
• Customizable Sizing: Flexible options tailored to replace factory-installed components.
• Durability: UV-resistant polymer construction backed by a lifetime warranty.
• Ease of Installation: Minimal disruption to existing operations.

IRISS collaborated closely with Vandolah Power to ensure a seamless integration process, providing training and support to maximize the effectiveness of the new system.

Outcome

The adoption of IRISS FlexIR windows delivered transformative results for Vandolah Power. By replacing the failed factory-installed windows, the plant regained the ability to perform visual, infrared, and UV inspections seamlessly. Maintenance teams could now proactively address potential issues without resorting to time-consuming shutdowns, resulting in significant time savings and operational efficiency. Additionally, early fault detection capabilities reduced unplanned outages and extended the lifespan of critical equipment, boosting overall reliability. In addition, the team experienced peace of mind knowing their system was equipped with state-of-the-art safety features backed by IRISS’s lifetime warranty. Key outcomes included:

• Reduced Maintenance Time: The ability to conduct inspections without full system shutdowns significantly reduced the time required for each session.
• Improved Equipment Reliability: Enhanced inspection capabilities allowed maintenance teams to detect faults early, reducing unplanned outages and extending equipment lifespan.
• Reliability and Compliance Improvements: Improved confidence in equipment reliability and enhanced compliance with safety standards.

Key Takeaways

• Reliable Solutions: IRISS’s FlexIR windows provide long-term durability and safety for high-voltage equipment.
• Enhanced Inspections: The ability to conduct comprehensive inspections through one versatile window.
• Operational Efficiency: Faster, simpler inspections reduced downtime and improved overall plant efficiency.
• Collaboration Matters: Successful implementation achieved through consultation and support.

Ready to enhance the safety, reliability, and efficiency of your inspection processes? Discover how IRISS FlexIR windows can solve your operational challenges and future-proof your electrical systems. Contact us today to learn more about our solutions or to schedule a consultation with one of our experts.