Preventive Maintenance

Electrical equipment is most important part in supporting process of production plant. Reliability of the equipment is the top priorities for monitoring periodically. Its current condition should be known in detail for preventing unpredictable situation occur.

How to know current condition of our electrical equipment are doing regular check, predictive maintenance and preventive maintenance. Regular check is activity that conduct by check list within trained and certified man power for doing periodically check the equipment online condition within limited scope of work  in safe condition. In a way to know current condition in detail of electrical equipment is doing predictive maintenance by expert engineer for checking electrical equipment within several special tools without shutdown, eg. thermography (infra red), partial discharge scanning (corona detection), oil quality measurement for transformer and power quality measurement.

The result of predictive maintenance will be analyzed  in finding incorrect item to be verified and fixed in waving forward action while shutdown. Maintenance on shutdown condition is called Preventive Maintenance, this activity is planned and scheduled. By using the result of predictive maintenance the activity of preventive maintenance properly arranged, effective work, reduce time lost of time and planned shutdown schedule still on track.

All of electrical maintenance activity is described in detail scope of work and it has own goal at every activity services item. It might be different in each plant or factory to be services while implementing maintenance strategy, the key point is supporting core process of plant. Maintenance plan and scope of work can be discussed to related part on operation. It will help much to get decision in create service level agreement of maintenance and also will make easier when we want to apply maintenance contract by the way.

Carrying out field maintenance on electrical distribution equipment provides four important
benefits.

    1. Increased safety: protecting people, equipment and goods
      One of a plant manager’s most crucial responsibilities is to ensure the sustainable development of their business. Plant managers are obligated to adopt all available measures technically and economically available to them to minimize the risk of unwanted events, such as those that harm personnel, assets, or the business, while following international standards for environment, health, and safety. Some electrical distribution equipment is designed to minimize the risk and severity of accidents or process breakdowns, such as circuit breakers, fuse-contactors, etc. The highest priority of maintenance is to ensure that role is performed.
    2. Availability enhancement: maximizing service continuity
      Maintenance maximizes uptime. Maintenance is commonly conducted on scheduled outages during off-peak business periods, thereby mitigating its impact on operations with less disruption to activities, and less stress is generated. It takes less time to perform proactive maintenance than emergency repair (immediate corrective), while mitigating the risk of emergency shutdown, where the consequences of even an hour-long production shutdown can be enormous. Annual industrial losses due to power infrastructure disruptions reach 10 billion euros in Europe alone. (Source: Leonardo Power Quality initiative – European Copper Institute)
    3. Aging asset performance: CapEx optimization
      Considering the significant costs of equipment acquisition (CapEx), plant managers want their electrical distribution equipment to run safely for longer with maximum availability. Stress accelerates equipment wear (aging), shortening endurance. When wear is under control (within functional limits) endurance is secured or even extended.
    4. Exploitation cost efficiency: OpEx optimization
      Without maintenance, industries suffer emergency shutdown situations that cause
      spare parts to be purchased at a premium. Maintenance can cut these costs by reducing faults within complex parts and using efficient on-site spare parts management.
      labor to be purchased at a premium.
      process shutdown costs (no production, ramp-down/up production, waste, etc.)

However, these are only the visible operating costs. Maintenance helps ensure energy-efficient equipment. Research shows that unmaintained devices are less energy efficient. Wear and tear causes stress to components, which diminishes devices’ energy efficiency over time, and wastes energy while in operation.
Modern and up-to-date maintenance practices have become a vital competitive advantage thanks to their use in early detection by identifying problems before they require a major repair. Knowing when scheduled outages will occur also allows managers to staff accordingly. It delivers a unique opportunity to achieve more rigorous cost controls.
Carrying out maintenance that is professionally executed by highly qualified technicians is a unique opportunity to optimize Total Cost of Ownership (TCO), and both CapEx and OpEx, creating more value for businesses by enhancing availability at lower operating costs.

(Source: David Morte –  Strategies for Maintaining Electrical Distribution Equipment )

Our expert engineers conduct maintenance program in rule of standard maintenance of manufacture and our improvement strategic method to increase efficiency in optimizing maintenance cost.