Skip to content 
EN 
DE 
العربية 
Summary: You rely on electrical systems every day to keep operations stable, compliant, and productive. Yet maintenance is often handled through fragmented inspections, manual records, or reactive interventions that leave critical risks undetected until failures occur – a challenge familiar to maintenance managers and electrical engineers responsible for facility reliability.
Hidden defects such as loose connections, insulation degradation, and protection device malfunctions can develop over time without visible symptoms. Structured inspection protocols, predictive testing methods, and consistent documentation are essential to detect these risks early and avoid costly disruptions.
In this guide, you will learn how to establish an effective preventive electrical maintenance program by combining clear maintenance planning, standardized procedures, and consistent documentation, complemented by a practical checklist for operational use.
What is Electrical Maintenance?
Electrical maintenance is the systematic inspection, testing, servicing, and repair of electrical systems to ensure safe, reliable, and efficient operation. It includes infrastructure such as wiring and distribution panels as well as industrial assets like motors, transformers, switchgear, and control systems. The primary goal is to detect deterioration early and prevent failures before they disrupt operations.
Importance of Electrical Maintenance
Electrical maintenance ensures safety, reliability, and stable operations in facilities that depend on electrical systems. Neglected components such as loose connections and overloaded circuits can escalate into fires, equipment failure, or costly downtime. Regular inspections and preventive measures detect problems early and maintain safe operating conditions in line with standards from the International Electrotechnical Commission (IEC) and the National Fire Protection Association (NFPA).
Structured maintenance delivers:
- Reduces risk of electrical fires
- Prevents equipment breakdown
- Extends equipment lifespan
- Improves energy efficiency
- Ensures regulatory compliance
- Lowers long-term repair costs
➤ Electrical maintenance protects people, assets, and business continuity while ensuring consistent system performance.
Is your electrical maintenance fully under control?
Discover how maintenance management software keeps inspections, assets, and corrective actions in one structured system.
What Are the Main Types of Electrical Maintenance?
No single maintenance strategy is sufficient for modern electrical systems. Effective programs combine preventive, predictive, and corrective approaches depending on equipment criticality and operational risk.
Preventive Maintenance
Scheduled maintenance performed at defined intervals to reduce failure probability.
Best for:
- Safety-critical systems
- Predictable wear
- Manufacturer service intervals
Typical Tasks:
- Visual inspections
- Connection tightening
- Cleaning panels and enclosures
- Protective device testing
- Grounding checks
- Thermal inspections
Predictive Maintenance
Maintenance triggered by condition data indicating early degradation.
Best for:
- Critical assets
- High-value equipment
- Data-driven operations
Common Methods:
- Thermal imaging
- Motor current analysis
- Ultrasonic testing
- Partial discharge detection
- Power quality monitoring
- Condition monitoring sensors
Corrective Maintenance
Repairs performed after a defect is identified but before total failure.
Best for:
- Detected issues
- Non-critical equipment
- Scheduled repair windows
Examples:
- Insulation repair
- Component replacement
- Loose connection correction
Emergency Maintenance
Unplanned repair after a system breakdown or electrical fault.
Typical Cases:
- Short circuits
- Equipment breakdowns
- Protection failures
- Overheating risks
- Power interruptions
Electrical Preventive Maintenance Checklist for Industrial Systems
A structured electrical maintenance checklist ensures inspections are performed consistently, risks are identified early, and documentation remains complete for compliance and reliability tracking. The following checklist provides a practical foundation for industrial facilities and should be adapted to specific equipment, operating conditions, and manufacturer recommendations.
Get our free Electrical Preventive Maintenance Checklist here
Common Electrical Hazards Found During Maintenance
Many electrical hazards remain hidden until inspections reveal early warning signs. Identifying these risks during routine maintenance is essential to prevent failures, fires, or safety incidents:
❌ Frayed or damaged wires
Can cause short circuits, fires, or electrocution.
❌ Overloaded circuits
Lead to overheating and increased fire risk.
❌ Inadequate grounding
Increases shock hazard and equipment damage risk.
❌ Faulty circuit breakers or fuses
Fail to protect against overcurrent conditions.
❌ Improperly labeled panels
Create confusion and safety risks during emergencies.
❌ Signs of electrical burns or overheating
Indicate serious underlying problems requiring immediate attention.
❌ Loose connections
Cause arcing, overheating, and eventual equipment failure.
❌ Moisture or corrosion
Compromise insulation and create shock hazards.
❌ Overcurrent conditions
Stress equipment and reduce operational lifespan.
❌ Inadequate clearances
Violate safety codes and increase arc flash risk.
❌ Outdated wiring systems
May not meet current codes or handle modern industrial loads.
❌ Missing or damaged cover plates
Expose live components and create shock hazards.
❌ Improper use of extension cords
Using them as permanent wiring creates fire risks.
❌ Arc fault conditions
Result from damaged insulation, loose connections, or pierced cables.
❌ Inadequate GFCI/AFCI protection
Especially critical in wet or hazardous industrial locations.
Building a Reliable Electrical Maintenance Program
A reliable electrical maintenance program is not created by isolated inspections but by structured processes, responsibilities, and continuous improvement. Based on NFPA 70B requirements, your Electrical Maintenance Program (EMP) should include:
1. Comprehensive Asset Inventory
Document all electrical equipment and systems, including panels, transformers, switchgear, motors, generators, UPS systems, lighting, and protective devices. Assign criticality ratings based on safety impact, operational importance, and replacement cost.
2. Maintenance Procedures and Schedules
Develop written procedures for each maintenance task. Base schedules on manufacturer recommendations, NFPA 70B guidelines, equipment condition assessments, and your facility’s specific operating environment.
3. Personnel Responsibilities
Clearly identify who is responsible for each element of the program, including qualified electricians, maintenance technicians, facility managers, and contractors. Ensure all personnel have appropriate training and certifications.
4. Safety Program Integration
Your EMP must include electrical safety protocols aligned with NFPA 70E, lockout/tagout (LOTO) procedures, arc flash protection requirements, personal protective equipment (PPE) standards, and emergency response plans.
5. Documentation and Record Keeping
Maintain detailed records of all maintenance activities performed, findings and observations, corrective actions taken, equipment condition over time, test results and measurements, and personnel training and qualifications.
6. Continuous Improvement Process
Regularly review program effectiveness, analyze failure data and trends, update procedures based on findings, incorporate new technologies and best practices, and adjust schedules based on equipment performance.
What Standards Regulate Electrical Maintenance Globally?
Electrical maintenance programs must comply with multiple standards and regulations, depending on the country, industry, and operating environment.
United States
- NFPA 70 (National Electrical Code): Installation standards
- NFPA 70B: Electrical equipment maintenance standard
- NFPA 70E: Electrical safety in the workplace
- OSHA 1910 Subpart S: Electrical safety requirements for general industry
- OSHA 1926 Subpart K: Construction electrical safety
- IEEE Standards: Equipment-specific maintenance guidelines
International and Regional Frameworks
- International Electrotechnical Commission (IEC): Global electrical and safety standards (e.g., IEC 60364 for low-voltage installations)
- EN 50110: Operation of electrical installations (Europe)
- National wiring regulations and occupational safety laws: e.g., BS 7671 (UK), DIN VDE standards (Germany)
- Local and state electrical codes: May impose stricter requirements than national standards
➤ Failure to comply can result in citations, fines, increased insurance costs, legal liability in the event of incidents, and, in severe cases, operational shutdowns or loss of operating licenses.
How does Digital Maintenance Management Improve Electrical Reliability?
Digital maintenance management significantly improves electrical reliability by creating structured processes, consistent inspections, and real-time visibility into equipment condition. Instead of reacting to failures, organizations can identify risks earlier and maintain electrical assets more effectively.
✔️ Stronger preventive maintenance: Automated scheduling helps maintain electrical assets at the right intervals before failures occur.
✔️ Predictive insights: Data trends and monitoring integration enable early detection of overheating, insulation issues, or abnormal loads.
✔️ Complete asset history: Centralized records improve troubleshooting, root cause analysis, and long-term reliability planning.
✔️ Improved compliance: Digital documentation supports electrical safety regulations and provides audit-ready records without additional administrative effort.
✔️ Faster issue response: Real-time reporting allows quicker identification and correction of electrical defects.
✔️ Data-driven decisions: Analytics help prioritize high-risk equipment and optimize maintenance strategies based on actual system condition rather than fixed schedules.
✔️ Higher uptime and reliability: Organizations benefit from fewer failures, reduced downtime, and longer equipment lifespan.
Perform Electrical Inspections and Maintenance with flowdit
Electrical maintenance programs generate large volumes of inspection data, test results, corrective actions, and compliance documentation. When this information is distributed across multiple systems or stored in inconsistent formats, it becomes difficult to maintain full traceability, identify emerging failure patterns, or demonstrate compliance during audits. A centralized approach ensures that every inspection, repair activity, and preventive task is recorded consistently, providing clear visibility into asset condition, maintenance performance, and operational risk.flowdit is a mobile-first CMMS that enables maintenance teams to conduct electrical inspections, document findings in real time, and automate preventive maintenance schedules directly from mobile devices. Whether you're managing a single facility or multiple sites, flowdit centralizes your electrical maintenance data, standardizes workflows, and detects potential issues earlier, before they affect uptime or safety.
Try flowdit free for 30 days to see how structured digital maintenance supports safer, more reliable electrical systems.
FAQ | Electrical Maintenance
What is electrical preventive maintenance?
Electrical preventive maintenance is the planned inspection, testing, and servicing of electrical systems to identify issues before they lead to failures, safety risks, or unplanned downtime. It typically covers equipment such as switchgear, motors, protection devices, wiring, and grounding, with intervals defined by risk, operating conditions, and standards like NFPA 70B. The goal is to improve reliability, extend asset life, and maintain safe operation.
What are the key differences between electrical maintenance, repair, and inspection?
- Electrical inspection evaluates equipment condition and safety without changing it, using measurements and visual or functional checks.
- Electrical maintenance involves planned actions such as cleaning, tightening, or replacing wear parts to prevent failure.
- Repair is corrective work performed after a fault occurs to restore operation.
In simple terms, inspection identifies risk, maintenance prevents it, and repair fixes it.
Who can do electrical maintenance?
- Qualified electricians or licensed electrical technicians
- Certified maintenance technicians with electrical training
- Authorized personnel trained for specific low risk tasks
- Specialized contractors for testing, protection systems, or high voltage work
- Engineers or technical experts for diagnostics and complex systems
What should be included in an electrical maintenance checklist?
- Visual inspection items
- Cleaning and servicing tasks
- Test methods (e.g., thermography, insulation resistance)
- Acceptance criteria
- Documentation requirements
What equipment requires electrical maintenance?
Power generation and transformation equipment (generators, transformers)
Electrical distribution systems (switchgear, panels, cabling, protection devices)
Control and automation components (PLCs, drives, control cabinets)
Electrically powered machinery (motors, pumps, production equipment)
Backup and safety systems (UPS, emergency power, protective circuits)
What data should be documented during electrical maintenance?
Equipment ID, location, circuit reference
Work performed and scope
Measured values (voltage, current, insulation, continuity, temperature)
Condition before and after
Defects, deviations, safety risks
Replaced parts with part numbers
Test results and instrument IDs
Safety checks and lockout-tagout confirmation
Standards or regulatory references
Technician, date, signature
Corrective actions and recommendations
How often should electrical equipment be inspected?
Frequency depends on criticality, environment, and equipment history.
Standard intervals:
- Monthly: Visual walkdowns
- Quarterly: Critical distribution points
- Annual: Documented inspections
Adjust based on:
- Prior issues or harsh conditions require more frequent checks
- NFPA 70B recommends minimum annual inspections
- Use risk-based approach for final schedule
Do companies need external contractors for electrical maintenance?
Not necessarily. Many organizations adopt a hybrid approach where trained internal staff handle routine inspections and monitoring, while specialized contractors perform advanced testing, repairs, and compliance-related work.
Which KPIs should be tracked in electrical maintenance?
Reliability and Maintenance Efficiency
- Mean Time Between Failures (MTBF): time between failures
- Mean Time To Repair (MTTR): time to restore equipment
- Preventive Maintenance Compliance (PMC): on time completion of scheduled tasks
- Maintenance Backlog: pending maintenance workload
- Planned Maintenance Percentage (PMP): planned versus total maintenance effort
- Reactive Maintenance Ratio: emergency versus scheduled work
- Overall Equipment Effectiveness (OEE): availability, performance, and quality
- Emergency Work Order Rate: share of urgent repairs
Safety
- Electrical Incident Rate: number of electrical accidents or events
- Lost Time Injury Rate (LTIR): injuries causing work absence
- Near Miss Reporting Rate: frequency of reported hazardous situations
- Total Recordable Incident Rate (TRIR): OSHA recordable incidents
What documentation is required to prove compliance in electrical maintenance audits?
• Maintenance and inspection records
• Test reports with measurements
• Calibration certificates for instruments
• Safety and lockout tagout records
• Personnel training and qualification proof
• Equipment maintenance history
• Corrective action documentation
What is the difference between NFPA 70B and NFPA 70E?
NFPA 70B focuses on electrical equipment maintenance practices, including inspection procedures, testing methods, and maintenance program management.
NFPA 70E addresses electrical safety in the workplace, covering arc flash risk assessment, safe work practices, and personal protective equipment requirements.
How do you diagnose and fix voltage fluctuation issues in industrial systems?
Voltage fluctuations are diagnosed by measuring system performance under real load to identify the source of instability.
• Measure voltage with a power quality analyzer
• Check load variations and starting currents
• Inspect connections, grounding, and transformer settings
• Detect imbalance, harmonics, sags, or swells
Fixes may involve tightening connections, redistributing loads, or adjusting equipment settings.
Image: Adobe Stock – Copyright: © JD Studio – stock.adobe.com
Image: Adobe Stock – Copyright: © Jakub – stock.adobe.com
