Factory Electrical System Maintenance: Process, Standards and Technology

Maintaining the factory electrical system is a critical process to ensure the safety and efficiency of electrical equipment operations. The standard maintenance process includes preparation, scheduled inspections, cleaning, and component replacement. Technical requirements and management recommendations are also set to optimize performance and ensure compliance with safety standards.

Standard Maintenance Process for Factory Electrical Systems

The maintenance of factory electrical systems begins with thorough preparation, ensuring safety by isolating the maintenance area and equipping necessary protective gear such as insulating gloves, boots, and safety goggles. Scheduled inspections help in the early detection of issues like electrical leaks or breakages by measuring insulation resistance and continuity. Periodic cleaning and maintenance, from dust removal to checking and tightening connections, along with replacing damaged components like electrical cables or expired breakers, ensure optimal system operation.

Electrical system maintenance is an indispensable factor for each factory, helping the factory electrical system operate stably and safely. This process must be conducted strictly and in a specific sequential order.

Before Maintenance

1. Thorough Preparation: Ensure that personnel conducting the electrical system maintenance have all necessary protective gear such as insulating gloves, boots, and safety goggles. This prevents electrical safety risks.
2. Area Isolation: Power should be cut off, and the maintenance area isolated to ensure no live currents are present during maintenance, preventing accident risks.
3. Specific Planning: Identify clearly the areas needing maintenance and create a detailed plan for each part of the factory electrical system.

During Maintenance

1. Check Electrical Equipment:

• Check insulation resistance to ensure the entire system is insulated according to safety standards.
• Measure continuity to identify connection issues.
• Check the operation of transformers and BUSWAY bars to ensure they operate stably and without errors.
• Measure voltage and current to ensure they are within allowable limits, preventing hazardous overload situations.

1. Clean and Maintain Electrical Equipment:

• Conduct thorough cleaning to remove dust and debris that may affect performance or pose electrical safety risks.
• Oil the equipment that requires it to ensure smooth operation.
• Inspect and maintain moving parts to prevent operational failures.

1. Replace Damaged Components:

• Damaged parts should be replaced immediately to maintain system performance.

1. Ensure Electrical Safety Standards:

• Conduct a thorough review to ensure compliance with safety standards and perform tests to ensure the system is ready for safe operation.

After Maintenance

1. Operational Testing: After completing electrical system maintenance, carry out a test run to ensure all components operate stably and match the design capacity.

2. Documentation and Reporting: Record all maintenance activities and prepare a detailed report on issues and solutions implemented.

3. Staff Training: Staff must be regularly trained in technical and safety procedures, and update knowledge to meet the requirements of the factory electrical system.

Conducting periodic maintenance can optimize performance, extend equipment lifespan, and ensure safety for production activities in the factory.

In-depth Technical Requirements in factory electrical maintenance

In electrical system maintenance, compliance with safety standards like QCVN and IEC 60364 regarding insulation and grounding is very important. No-load tests help detect hidden issues by measuring leakage voltage. Lightning surge inspection ensures SPD devices operate as per specifications, protecting the system from unwanted natural incidents.

Factory electrical maintenance is a field requiring in-depth technical expertise and strict adherence to safety standards. To succeed in this work, the following basic steps are required.

Monitoring Skills and Standard Procedures

• Monitoring Equipment Skills: Engineers need the ability to detect and handle abnormalities through signs such as vibrations, temperature, and sound of the equipment. Quickly and accurately identifying the cause of the issue is crucial.
• Electric Network Analysis: Technicians must evaluate the impact of maintenance on the entire system, especially when combining new devices with old ones.
• Check Insulation Resistance and Continuity: Using devices such as insulation resistance meters to detect leaks or breaks in the system.

Safety and Preparation Before Maintenance

• Protective Gear: Fully using insulating gloves, boots, and goggles is mandatory to ensure safety.
• Area Isolation: Fully disconnect power and set up protective barriers to prevent electrical accidents during maintenance.

Detailed System Inspection

• Measure Electrical Parameters: Technicians need to measure the voltage of each phase, balance the load and compare power consumption with the set standard.
• Device Calibration: Devices such as electric meters, circuit breakers, protective relays must be calibrated according to standard technical specifications.

Lighting and Wiring System Maintenance

• Replace Damaged Lights/Wires: Prioritize using lights and wires with the appropriate IP rating for the factory environment.
• Check Connections: Ensure connections are properly soldered and clean electrical rooms to prevent fire risks.

Inspection and Technical Documentation

• Record Logs: Electrical parameters, detected errors, and remedial measures should be documented after every maintenance.
• Incident Prediction: Analyze historical data to predict failure trends and plan effective spare parts replacements.

Support Diagnostic Technology

• Temperature Measuring Devices: Use infrared cameras to detect overheating points on busbars or circuit breakers.
• Monitoring Software: Track real-time power consumption to quickly detect anomalies.

In the process of maintaining factory electrical systems, prioritizing the use of specialized equipment such as high-quality insulation resistance meters and amp clamps, along with regular training for technicians, is very important. Ensuring teams are continually updated on IEC, NFPA standards, and electrical incident handling processes helps optimize system safety and efficiency.

Management and Technological Support Recommendations in electrical maintenance for factories

Management recommendations include conducting maintenance at appropriate frequencies: monthly inspections of devices like circuit breakers, relays, and grounding; quarterly cleaning of electrical cabinets, measuring insulation resistance; annual comprehensive system checks. Staff need training in fire prevention and electric shock first aid. Support technologies such as Thermal Imaging Cameras and SCADA software help quickly detect potential issues and effectively monitor the electrical system.

Managing electrical maintenance in factories plays a crucial role in maintaining stable operation of the electrical system. An effective maintenance management system not only ensures safety but also enhances the operational efficiency of the factory.

Maintenance Management:

1. Planning and Maintenance Scheduling

• Periodic: Conducting periodic maintenance helps detect and address issues promptly, ensuring stable equipment operation and avoiding unexpected operational halts.
• Preventive: Implementing preventive maintenance is crucial in maintenance management, helping minimize production downtime.

1. Asset Information Management

• Information Storage: Use a database to store and manage equipment information, maintenance history, and repair parts to increase management efficiency.

1. Spare Parts and Inventory Management

• Material Management: Ensure the availability of materials for conducting maintenance quickly, avoiding resource wastage.
• Inventory Control: Proper inventory control is an essential part of the maintenance management process.

1. Labor Force Tracking and Management

• Human Resource Management: Ensure that team members possess the necessary qualifications and skills to perform maintenance effectively.

Technological Support in Maintenance:

1. Computerized Maintenance Management System (CMMS)

• Functionality: Automating scheduling processes, work order management, and providing real-time information for managers.
• Analytics: Leverage intelligent data analytics to predict equipment conditions and optimize maintenance operations.

1. Real-time Tracking Technology

• Equipment Status Monitoring: Applying sensor and IoT technology in maintenance supports continuous monitoring of electrical equipment status.
• Automatic Alerts: Timely alerts of potential issues help significantly reduce equipment failure risks.

1. Predictive Maintenance

• Utilizing Data: Analyze data based on historical and real-time information, supporting the prediction of maintenance timing for equipment.
• Reducing Downtime: Predictive maintenance helps optimize operation efficiency and reduce machine downtime.

1. Using Electronic Tools

• Work Instruction: Electronic work guidance documents with multimedia features help staff perform tasks accurately.
• Mobile Access: The ability to access and manage via mobile devices increases flexibility in the maintenance process.

General Recommendations:

• Integrating Technology: Integrating advanced technologies such as IoT and AI into maintenance management systems helps optimize operational efficiency.
• Staff Training: Training personnel is necessary to maximize the benefits of new technology.
• Data Analysis: Applying data analysis to continuously improve maintenance processes, enhancing the efficiency of the factory electrical system.

Maintaining factory electrical systems not only ensures stable operations but also optimizes costs and minimizes electrical safety risks. Integrating advanced technologies and adhering to safety standards are key factors that help improve performance and protect investments in the long term.

Contact QuangAnhcons now via hotline +84 9 1975 8191 for optimal and safe electrical maintenance solutions advice.

QuangAnhcons provides factory electrical system maintenance services with a commitment to quality, applying safety standards and modern technology to ensure customer systems always operate efficiently and safely.