Maintain power01 October 2006

With the cost of unscheduled downtime for some engineering and manufacturing companies running into hundreds of thousands of pounds a day, plant engineers are under pressure to ensure continuous production. Yet with more pressure being put on machines, due to smaller equipment running at faster speeds, correct maintenance is critical.

In many cases, the servicing and maintenance of critical equipment within a plant can only be done during a scheduled shutdown period. This is the time when all essential maintenance can be carried out on machinery throughout the plant, which during day-to-day operations is either too inaccessible or plays too crucial a role in the company's operations to warrant any scheduled stoppages. With just two weeks to flush, clean and fix all of this critical machinery, careful planning is essential to ensure that the plant is back up and running come day 15.

In many plants, all mains power is switched off during shutdown to ensure the health and safety of workers, but power is still required to ensure there is enough light for engineers to carry out their work and power any equipment.

Currently, the majority of companies are just taking a stab in the dark as to how much power they think they'll need during this period. For although businesses spend a great deal of time planning for a maintenance shutdown, few plan the power requirements during this period. Some adopt the approach of 'more is better', while others try to guesstimate the least amount of power required. Both can be wide of the mark, with some paying for unnecessary generators and, at the other end of the scale, companies potentially putting lives at risk and causing a stoppage in maintenance, on account of a power shortage.

Assessing the power requirement during this period is no easy job, with a 'one size fits all' approach not feasible, due to a number of varying factors such as the amount of machinery operating at one time. Engineering and manufacturing companies need to select a temporary power hire and lighting supplier that will work with them to develop the most effective solution.

Short-termism must be avoided. Don't phone and order 'x' amount of generators and expect the equipment to be dropped off the next day. The sooner a power generator hire company is consulted, the better. They can review the work to be carried out during this period and effect a detailed power needs analysis. This will also identify any potential distribution, safety and environment issues. Safety during this period is of the utmost importance. Businesses should be using braided or steel-wire armoured cables for all temporary power supplies. This will avoid cables being easily damaged, thus ensuring the security of supply.

Some plants, where gas and vapour may be present, require specialist knowledge and it is important that only equipment that is certified for use in an explosive atmosphere is installed.

Also, companies need to make sure they have enough lighting in place so that tasks are completed quickly and safely. While a 30/40 lux (brightness) reading may be okay when carrying out an initial check of machinery, it will need to increase significantly if any maintenance is required. It all depends on how hazardous the required work is and experienced power hire suppliers will be able to advise on required lux levels, if the expertise is not available in-house.

Hire companies that offer this sort of attention to detail stand out from the rest. Engineering and manufacturing companies can no longer rely on 'drop off and see you later' suppliers in an environment where directors are extremely conscious of the bottom line, and increasing health and safety legislation.

Once the generators, lighting and associated accessories have been fitted, engineering and manufacturing companies need to ensure that their supplier is on hand 24/7.

The last thing that any company needs is for the lights to cut out and then to discover its supplier is not available until the morning after. Not only has the night been wasted, but there is then an additional wait for an engineer to arrive. Most suppliers claim to provide a 24-hour support service, but it is best to try calling a few at random times to be certain this is the case before considering taking them on board.

During the shutdown period, plant managers usually have their hands full, ensuring things run smoothly. As such, many of them choose to put the fuel management of the generators into the hands of the supplier. Any reputable power hire supplier offers this service to alleviate the burden of making sure that adequate fuel is on hand for the duration of the hire period.

In conclusion, whether a scheduled shutdown, a plant upgrade or a back-up power solution, the sooner companies engage with a reputable power hire and lighting company that truly understands its business, the sooner they will begin to enjoy the associated benefits - improving profit, performance and safety.

Adopting best practice

1 Always consider power requirements at the early stages of planning a shutdown
2 Choose a supplier that can assist in recommending the correct amount of power
3 Ask for a power needs analysis report. That way, you can check to ensure you are being given the correct amount of power
4 Always consider any potential health, safety and environmental issues
5 Ensure your supplier can provide all of the relevant accessories, such as braided or steel wire armoured cables for all temporary power supplies
6 Consider outsourcing the management and servicing of power generators and lighting during the shutdown period to ensure equipment is properly maintained and does not run out of fuel
7 Check to see that your supplier offers a 'true' 24/7 assistance service
8 Ensure your supplier has experience of working within your specific sector

SOE

This material is protected by MA Business copyright
See Terms and Conditions.
One-off usage is permitted but bulk copying is not.
For multiple copies contact the sales team.