UK Automotive Manufacturer Enhances Arc Flash Prevention with IRISS Infrared & Ultrasound Solutions

Executive Summary

A UK-based automotive manufacturer experienced an arc flash incident that dislodged a transformer’s cable connection door due to the extreme pressure generated. Although no injuries occurred, the event underscored the urgent need for a comprehensive preventative maintenance strategy.

With global demand increasing, unplanned downtime posed a significant risk to production and profitability. After evaluating available solutions, the company implemented a two-stage approach using thermal imaging inspections and ultrasound partial discharge monitoring.

IRISS infrared windows and ultrasound ports were selected for their rugged reliability, safety enhancements, and cost-effectiveness. The installation was completed during a planned holiday shutdown, minimizing disruption. As a result, the manufacturer now benefits from safer, more efficient electrical inspections while reducing the risk of future incidents.

Challenge: Arc Flash Incident Highlights Risks

A well-established UK automotive manufacturer faced a critical safety event when an arc flash incident on a transformer caused the cable connection door to dislodge under pressure.

• Operational Risks: The facility’s electrical infrastructure, particularly its 11kV substations, was vulnerable to failure.
• Safety Concerns: Arc flash risks posed significant hazards to personnel.
• Downtime Costs: Growing global sales placed increasing demands on production, making unexpected downtime a serious financial liability.
• Equipment Durability Issues: The company had previously experienced failures with competitor products due to vibration and water ingress.

Recognizing the severity of these risks, the company sought a robust solution that would enhance safety, improve inspection efficiency, and minimize unplanned downtime.

Solution: IRISS Infrared and Ultrasound for Arc Flash Prevention

The manufacturer selected IRISS infrared windows and ultrasound ports to enable a proactive, condition-based maintenance strategy.

• Technology Implementation:
  • Partial discharge monitoring (ultrasound) for early fault detection.
  • Infrared thermal imaging for proactive temperature-based inspections.

• Key Benefits of IRISS Solutions:
  • Rugged Reliability – Designed to withstand the harsh automotive manufacturing environment.
  • Optimized for Critical Components – Installed on switch connections and cable crutches, the most vulnerable points.
  • Proven Durability – Unlike competitor products, IRISS polymer-based IR windows resist vibration and water ingress.
  • Cost-Effective Maintenance – Backed by a lifetime warranty, eliminating future replacement costs.
  • Enhanced Safety – Personnel can now conduct routine inspections without opening energized panels.

To further ensure safety and efficiency, the company opted for IRISS’s installation and training service. As an approved safe contractor and infrared thermography training provider, IRISS provided hands-on guidance to maximize the solution’s effectiveness.

The installation was strategically completed during the company’s Christmas shutdown, demonstrating IRISS’s commitment to seamless integration with minimal production disruption.

Outcome: Improved Safety and Reduced Downtime

By implementing IRISS infrared windows and ultrasound ports, the automotive manufacturer significantly improved the safety and reliability of its electrical maintenance program.

Key Results:

• Reduced Arc Flash Risk – Safer inspections with zero exposure to live electrical components.
• Increased Inspection Efficiency – Routine thermal and ultrasound inspections can now be performed without downtime.
• Enhanced Equipment Longevity – Proactive monitoring prevents failures before they escalate.
• Cost Savings – Eliminating the need for frequent panel access reduces labor and equipment wear.

With this solution in place, the company has transitioned from reactive maintenance to a proactive, data-driven strategy, ensuring long-term reliability and safety.

Key Takeaways

• Arc flash incidents can be prevented through proactive maintenance and monitoring.
• IRISS infrared and ultrasound solutions provide durable, cost-effective inspection capabilities.
• Routine electrical inspections can be performed safely without production downtime.
• Proper installation and training ensure maximum return on investment.

Want to enhance electrical safety in your facility? Learn how IRISS solutions can protect your operations. Contact Us Today.