

Customer
AEP
Location
West Virginia
Highlights
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Hidden Electrical Hazard Detected Just in Time
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Root Cause Traced to Installation & Inspection Gaps
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Improvements Implemented Across Wiring Practices
How a Simple Wiring Oversight Could Have Triggered a Major Outage
The Challenge
Root Cause Analysis
- Improper Installation: The wire had not been properly terminated, tightened, or locked into its breaker position.
- Inadequate Inspection: The loose connection had been missed during prior checks, indicating a gap in inspection protocols or procedural follow-through.
The Solution
- Immediate Remediation
- The wire was properly secured and re-terminated to eliminate the failure risk.
- Inspection Protocol Reinforcement
- A more rigorous inspection checklist was implemented to ensure all wiring is both secured and adequately insulated.
- Personnel Training
- A refresher training was delivered to relevant crew members, emphasizing:
- Proper termination and torqueing techniques
- Visual indicators of poor wire seating
- The critical link between tight connections and system reliability
- A refresher training was delivered to relevant crew members, emphasizing:
Key Benefits
- Outage Risk Eliminated: Quick action prevented a probable breaker failure or electrical event.
- Quality Assurance Enhanced: Inspection protocols were tightened, reducing the likelihood of similar misses.
- Field Awareness Improved: Crews were reminded that visually benign errors can hide severe failure points.
- Training Investment Reinforced: The event justified further investment in continuous improvement through field-focused technical training.
The Results
- No operational disruptions occurred.
- Protection & Control teams validated all related connections in the area.
- The event is now used internally to underscore the importance of proper wiring practices and second-layer verification.