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Reliability Improvements Using PQI (Parts Quality Initiative™)

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Minimize Equipment Failures with Our PQI Testing and Predictive Maintenance Services

Are unexpected equipment failures causing downtime in your operations? Are you confident that the parts you procure are reliable, or do you find yourself reacting to failures instead of preventing them?

With Constellation PowerLabs’ Parts Quality Initiative™ (PQI), you can take control of your equipment’s reliability. Our predictive maintenance services can help you stock dependable, high-quality parts but also identify existing critical parts in inventory that are prone to failure. From transformers to circuit breakers and relays, PQI reduces the risk of critical equipment failures, keeping your operations running smoothly and minimizing costly disruptions.

PQI leverages an unmatched database of failure rate trends for critical components, enabling utilities, aerospace, biotechnology, pharmaceuticals, and manufacturers to proactively identify potential issues before installation. This helps reduce downtime and optimize performance while keeping costs under control.

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Extensive Electrical and Mechanical Testing Services

At Constellation PowerLabs, our electrical and mechanical testing laboratory offers two tailored services to meet your critical equipment testing needs. Whether you're doing in-house analysis or using our detailed predictive maintenance testing services, we help keep your critical parts reliable and ready to be used in the field. For ongoing support, our PQI subscription gives you access to the data you need to make smart, proactive decisions about your inventory.

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Subscription for PQI Predictive Maintenance Services (Data Only)

For those who prefer to manage their own testing, the Parts Quality Initiative™ (PQI) subscription grants access to our extensive database of failure rate trends. You’ll gain insights into historical data and identify parts in your inventory that may be at risk of failure. This enables your team to analyze whether newly procured equipment or existing parts need testing, whether in-house or through Constellation PowerLabs’ PQI predictive maintenance services.

  • Extensive Database Access: Gain insights from over 2,000+ proven test plans and failure trends for more than 80,000+ critical parts.
  • Flexible Data Management: Export and manipulate data to perform your own analysis, allowing you to track performance trends and benchmarks.
  • Proactive Decision-Making: Use the data to identify potential failures and take action before problems arise, helping maintain system reliability and extend the life of your equipment.
  • Full Control: The PQI subscription gives you the tools and insights needed to manage your inventory and procurement decisions with confidence.

Use our PQI predictive maintenance database subscription service to make smarter, data-driven decisions about your equipment.

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PQI Subscription with Mechanical and Electrical Component Testing (Subscription + Critical Component Testing Services)

For companies looking to go beyond failure rate data analysis, the PQI Subscription combined with Mechanical and Electrical Component Testing offers a full-service solution. This option not only grants access to our vast PQI database of failure trends but also adds the advantage of having your critical components tested and verified to the manufacturer’s specifications.

Together, these services provide a complete solution that reduces operational risks, maximizes the value of your equipment, and minimizes downtime, ultimately supporting lower CAIDI scores by reducing the time required to restore service after an interruption.

  • Tailored Test Plans: Our PQI testing protocols are specifically designed for individual parts, offering a more accurate assessment than standard in-house testing.
  • Early Failure Detection: Customized critical component testing services that help identify potential failures early, reducing the risk of unexpected breakdowns.
  • Save Time and Money: Detect issues during the warranty period to replace faulty equipment without purchasing new parts, helping you avoid unnecessary costs.
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Experience the Benefits of Our PQI Predictive Maintenance Services

Subscribing to the Parts Quality Initiative™ (PQI) predictive maintenance services is a cost-effective way to protect your operations. By identifying and replacing faulty parts before installation or warranty period, you can prevent expensive equipment damage, reduce downtime, and improve safety. In many cases, catching just one defective part can justify the entire program’s cost by lowering operational disruptions and supporting a better SAIFI—reducing the number of interruptions that impact your customers.

Below is a breakdown of how PQI benefits your operations compared to not utilizing it:

FeatureWith PQIWithout PQI
Part QualityRigorous testing identifies defective parts before they enter your inventory. These can then be returned to the manufacturer with no additional costs if under the warranty period.Risk of receiving and installing faulty parts, potentially leading to equipment failures.
Cost AvoidancePQI testing identifies faulty parts before they are installed, allowing them to be returned under warranty, saving on replacement costs and avoiding significant costs in downtime per critical failure.Faulty parts go undetected until failure, leading to costly replacements, potential downtime, and operational disruptions, with no opportunity for preemptive cost recovery.
Equipment ReliabilityImproved reliability and reduced risk of unplanned outages due to faulty parts with our predictive maintenance services.Higher likelihood of equipment failures and downtime due to undetected faulty parts.
Maintenance CostsReduced maintenance costs and downtime due to fewer equipment failures.Potentially higher maintenance costs and downtime due to more frequent equipment failures.
SafetyEnhanced safety by minimizing the risk of equipment failures that could lead to safety hazards.Without our PQI predictive maintenance services, the risk of safety incidents due to potential equipment malfunctions is increased.
Operational EfficiencyImproved operational efficiency due to reduced downtime and fewer interruptions, leading to better SAIFI scores and a more reliable system.Increased frequency of interruptions, resulting in a higher SAIFI and decreased operational efficiency due to unplanned outages.
ComplianceHelps maintain compliance with industry standards for part quality and reliability through our predictive maintenance services.May face challenges in meeting industry standards and regulatory requirements.
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How Our PQI Predictive Maintenance Software & Testing Services Work

The first step in the Parts Quality Initiative™ (PQI) predictive maintenance process focuses on analyzing critical data. We compare historical failure trends and performance data to assess the reliability of your components.

Using our OneLab software platform and the expertise of our mechanical testing laboratory, you can:

  • Access a database of over 80,000+ parts and 2,000+ models.
  • Track parts and monitor testing progress in real time.
  • View detailed test results and certificates.
  • Export and manipulate data for further analysis and decision-making.

This gives you full control over your component’s performance, helping you decide which parts need testing or replacement.

Once the data analysis is complete, the next step is testing. You can:

  • Send existing or newly procured parts to our Constellation PowerLabs through rigorous testing.
  • If a part passes, it is returned to your inventory, ready for operation.
  • If a part fails, it will be: sent back to the manufacturer for a replacement (if under warranty), OR shipped back to you for further action.
  • Once a replacement part is received from the manufacturer, we test it again to confirm it meets the required standards.
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Common Equipment Types Prone to Failure

Through our Parts Quality Initiative™ (PQI) program, we’ve identified key components that are critical to your operations—and that are most prone to failure if left unchecked.

Here are some of the most common equipment types that experience failures identified through our Parts Quality Initiative™ (PQI) predictive maintenance services. These critical components are necessary for maintaining operational stability and preventing costly downtime, which directly impacts SAIDI.

If you need more specific data or have equipment not listed here, please contact our predictive maintenance service laboratory to discuss how we can assist in analyzing and testing your components.

CategoryNumber of Samples TestedNumber of Failed SampleFailure Rate
Relays12,946 Tested1,029 Failed7.95% Failure Rate
Regulators3,474 Tested270 Failed7.77% Failure Rate
Circuit Breakers3,914 Tested354 Failed9.04% Failure Rate
Fuses12,239 Tested287 Failed2.34% Failure Rate
Solenoid Valves4,332 Tested102 Failed2.35% Failure Rate
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Your Trusted Partner for Reliable Equipment Testing Solutions

For over 100 years, Constellation PowerLabs has been one of the laboratories for ISO-accredited calibrations and testing across North and South America. Our expertise spans various quality-driven industries including utilities, energy generation, pharmaceuticals, biotechnology and manufacturing, making sure that critical equipment remains reliable and safe.

Our commitment to quality and customer service extends beyond testing, we also provide full logistical support, including procurement services and shipping, making us a reliable partner for all your testing and calibration business needs. Whether you need high-voltage testing, ISO 17025 calibrations, or ongoing PQI predictive maintenance services, we’re here to help.

We proudly serve customers across the US and Canada, while also supporting rapidly growing energy markets in Texas, North Carolina, South Carolina, and beyond. Contact us today to discover how a reliable electrical testing company with accredited mechanical testing laboratory services can help you minimize risks and maximize efficiency.

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View PQI Case Studies

Find Out Why 6 Out of 7 Regulators Failed PQI Testing

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Constellation Nuclear Improves MWh Output with PQI

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PQI Saved Plant $3 Million in Savings Due to Avoided SCRAM

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