FIPRES - Electrical Fire Prevention and Overheating Control system

Key benefits    

• 24/7 control of concerning points in LV and MV electrical panel of any configuration
• Detects hot spots long before a dangerous situation arises, hence avoiding material damage, stop of production process and threats to life
• Increases equipment safety and reliability of operation
• Can be integrated to SCADA/BMS and local alarm systems
• Quick and easy installation even for existing systems

Problem

Every year fire causes an enormous amount of damage to all kinds of facilities, social and private possessions. It can lead to life threatening incidents and huge losses because of material damage of assets, power supply interruption, production loss and business opportunity cost. Global statistics show that around 30% of the fires are caused by electrical faults:

25% – of building fires are due to electrical malfunctions according to European Fire Academy (EFA)

32% – of fires in Germany are related with electricity according to German Insurance Association

3,2B – USD annual cost of damage in the U.S. and Europe due to electrical fires according to the National Fire Protection Association (NFPA) and the European Fire Safety Alliance (EFSA)

In practice, the most common cause of fire and damage to equipment in electrical panels are loose connections, especially those made on site. The connection may become loosened due to improper tightening torque during assembly, constant vibration, corrosion or mechanical wear of moving contacts, such as withdrawable contacts of a circuit breaker. Another reason which can lead to a worsening of the contact condition is temperature cycling through the day. Heating at high current and cooling at low current causes expansion and contraction of contact and may lead to contact loss. And even if an insufficiently tightened connection can still provide an acceptable level of mechanical reliability of the connection, it worsens electrical and thermal reliability:

FIPRES. How it works 

FIPRES works on principle of early detection. Indeed, usually fire starts with melting of cable insulation, which is the weakest point in terms of withstanding temperature. Depending on the material and thickness, generally there are 2 critical temperatures for cable insulation: 200 °C, when insulation to deteriorate and 280°C, when insulation material starts to melt and smoke. FIPRES works way below these temperatures, providing detection of overheating in a range up to 110 °C, which are abnormal temperatures for electrical equipment, but still months before any dangerous situation. 

Typical scenario of fire inside electrical cabinets is shown below:

The technology involves the placing of self-adhesive temperature sensitive labels (rFPT) on connection points (busbar contacts, cable lugs, contacts of circuit breaker, fuses, current transformer etc.) inside LV or MV electrical panel of any configuration.

FIPRES

FIPRES Thermal Watch – Infrared Monitoring System 

FIPRES Thermal Watch – Infrared Monitoring System
Smart, Wireless Temperature Monitoring for LV and MV Electrical Panels

Key benefits    

• 24/7 temperature monitoring of concerning points in LV and MV electrical panel of any configuration
• Wireless temperature monitoring
• Detects hot spots long before a dangerous situation arises, hence avoiding material damage, stop of production process and threats to life
• Increases equipment safety and reliability of operation
• Can be integrated to SCADA/BMS and local alarm systems
• Quick and easy installation & maintenance even for existing systems

How it works 

Thermal Watch sensors (TWS) are installed directly on key connection points – such as busbar contacts, cable lugs, circuit breaker contacts, fuses, and current transformers – inside LV or MV panels. The sensors monitor temperature continuously and wirelessly transmit data to the Infrared Receiver (TWR-IR), which is installed in the same enclosure.

Thermal Watch sensor TWS

1. TWS should be installed on the cables/busbars close to the contact connection points. Installation can be done either with cable ties, screws or metal plate. Infrared receiver (TWR-IR) should be installed into the same volume 2. TWS will send information about the current temperature 24/7 every set temperature monitoring schedule duration together with information about battery condition, ID of the device, and current mode of operation. 3. In emergency situations when the temperature rises above 30-110 °C the TWS goes into Alarm mode, starting blinking with a visual red LED on the sensor, and sending information to TWR-IR.

Thermal Watch Receiver TWR-IR, TWR-DIN

4. From TWR-IR infrared receiver information is transferred to the main body – DIN-receiver (TWR-DIN), which transmits an ALARM signal to SCADA or BMS system by Modbus or to any other external system via dry contact output.

Alarm mode of operation

Technical comparison with thermal imaging control

Regularly checking contact connections is complex due to their large number, the constant operation under-voltage, and often the lack of access for the inspection. The most popular method - scheduled infrared thermography inspections has several significant disadvantages.

Monitors temperature 24/7 Allow to check equipment in locked (explosion-proof) enclosures Checks all spots at the same time Does not depend on the human factor

Works only at the time of inspection Doesn’t allow to check equipment in locked (explosion-proof) enclosures The load at the time of inspection should be at least 60% to see weak points Depends on the human factor Risky for personnel because the inspection should be done near to live electrical equipment

Scope of application

• Low/medium voltage electrical panels up to 36 kV
• Switchgear cells
• Any electrical equipment, including equipment in explosion-proof housings