Shutdown for maintenance can be essential but expensive. David Sanderson, sales and marketing director at Power4, looks at planning for emergency or temporary power to avoid unwanted and costly hitches
The chemicals market is one of only a handful of genuine 24/7, 365 days a year industries, meaning it is essential to keep plants well maintained to remain constantly in operation. So, what happens when it comes to undertaking routine maintenance, statutory inspections or upgrades?
The importance of a well-maintained power supply is essential and the question remains how this can be cost-effectively maintained during a plant shutdown.
Initially, it may seem as simple as ensuring the right generators are hired to temporarily replace the mains power supply or choosing between fixed temporary lighting and mobile lighting towers, but this couldn't be further from the truth. It takes significant planning and expert advice to find the most efficient temporary power and lighting solutions to best suit the needs of your operation. Making a mistake can have a significant impact on operational costs.
Some installations of temporary power may take as long as a month to complete, therefore it is essential to get this right from the start. These businesses can't afford to stop and start the plants again - it is too time consuming and can cause untold problems.
"Installing temporary power and lighting isn't a case of just ordering the equipment and waiting for the delivery, it requires a thorough assessment of the site and in-depth understanding of the business" exact needs. Everything needs to be carefully evaluated including operational requirements, amount of generator and lighting usage, the time period and of course, what technical support is needed."
These factors affect the size, type and quantity of required equipment and are used to calculate hire and running costs. Determining feasibility allows the appropriate power generation solution to be developed.
Extreme care must be taken when selecting and installing the apparatus and in the training and instruction of personnel to ensure a high level of safety can be achieved. All portable equipment must undergo portable appliance testing (PAT) before installation; repairs are essential and are carried out throughout the duration of the shutdown period.
Transformers, 110 volt or 25 volt, must be installed with great care to ensure that all cables and extension leads are positioned to avoid mechanical damage or tripping hazards. "Safety on any site is paramount and must remain as a high priority throughout the shutdown period." All 110 volt lighting should be fixed and 25 volt lighting should be used as hand held equipment. As an additional safety feature the cable Power4 uses for its temporary equipment is braided, for additional strength and it is also colour coded, i.e. violet for 25v and yellow for 110v.
Sites should also ensure that in hazardous areas that the generators and mobile lighting towers supplied by hire companies are fitted with spark arrestors and Chalwyn valves. Sanderson says that "all Power4's equipment is fitted with spark arrestors and Chalwyn valves as standard."
It is important that those involved with the installation and on-going maintenance are fully aware of the following:
- Not to use any apparatus unless it has an inspection tag fitted
- Report any apparent defects
- Always switch off apparatus at the end of a work period
- Never handle damaged cables or coupler's
- Do not insert implements of any kind into socket outlets or connectors
- Selecting a Supplier
Companies must remember that selecting the right supplier is as important as hiring the right equipment, and understanding the skills of your staff should be taken into consideration when making this decision, as Sanderson explains: "We've been working in the chemicals industry for over 30 years and we often come across companies that don't fully understand their onsite technical resources, often because different people are involved at different stages in the decision making process."
"It is important that the company you select should act as a strategic partner as well as a service provider. A good supplier should be able to provide customers with the added value of a dedicated technical service team which will work with them to design, plan and project manage their contract."
In order to help businesses differentiate between suppliers, Power4 has also designed a checklist to ensure businesses receive a cost-effective service and that the equipment they supply performs at an optimum level:
Effective planning
- A plant shutdown for routine maintenance or upgrade should be planned well in advance with a contingency plan to avoid any potential pitfalls, essential in this industry.
- Selecting a preferred temporary power and lighting equipment provider should happen in the early stages of that process to ensure the equipment you need is available when you need it.
- Products such as mobile lighting towers for example, are mainly only used during winter months and most suppliers, therefore, only carry limited stock and the equipment will be in great demand.
- For those companies conducting internal inspections, it is good practice to provide a minimum of two hand lamps per entry man-way, and if there is no external local permanent lighting a floodlight should be installed. The supplier will be able to meet this need.
Check quality and range of equipment
- Quality and range are equally important, and not only in the main hire fleet of temporary power and lighting equipment. A supplier offering an extensive fleet of high-quality generators (from 7.5kVA - 1250kVA) and a fleet of modern mobile lighting towers for example, should also provide a good quality range of associated ancillary equipment - from extension leads to distribution equipment.
- Look for a supplier which offers a good range of high-quality equipment - they will be best placed to meet operational needs in any eventuality.
Always ask to see the maintenance schedule of equipment.
- Power generators should be fully serviced and inspected by the supplier when they have returned from hire and checked again before being delivered to another customer to ensure they operate at optimum level.
- A quality temporary power and lighting solutions supplier should have a maintenance schedule in place to ensure its equipment is inspected on a regular basis and high operating standards are maintained.
If required, can your supplier deliver and help install the equipment?
- Not all plants have the suitably trained staff that can safely and effectively install temporary lighting and power equipment.
- Look for a supplier that offers a delivery service where the driver is also specially trained in the positioning and configuration of the equipment they deliver.
- Select a supplier that always delivers its own equipment and uses its own trained staff to prove that the company is fully knowledgeable about the equipment it provides and any additional assistance required.
Is there a service level agreement in place?
- A service level agreement should always be put in place when hiring equipment - and one size doesn't fit all, the service agreement should be tailored to suit each customer's individual requirements.
- Whether it means field engineers will service generators onsite on a weekly or monthly basis, a supplier with the relevant expertise and infrastructure will be able to provide scheduled maintenance specific to running hours, ensuring that the equipment you hire remains in optimum condition.
24 Hour Call Out?
- A 24 hour support service is essential when hiring temporary power and lighting equipment. A plant upgrade for example, can often need to maintain continuous operation for long periods - in this instance a 24/7, high standard technical support service is vital to ensure the operation is not compromised by poorly maintained equipment.
- Many suppliers claim to provide a 24 hour support service but try calling a few at 3am on a Saturday morning and see how many you can get through to!
- To minimise costly business downtime select a reputable supplier with a reliable and proven customer support service which is available when and where you need it - 24 hours a day, 7 days a week, 365 days a year.
Should you hire or buy?
- It is often assumed that generators required for long periods, for more than 52 weeks for example, should be purchased. However, when it comes to back-up or stand-by power generation, there is no one size fits all. solution.
- In some instances for example, due to the size and number of generators, or where the equipment is going to run frequently, it is often most cost-effective to hire a generator on a long-term basis - as a quality hire plan should include round-the-clock maintenance, breakdown and service call-out.
Fuel management - keep the tank topped up?
- Fuel management services are available to ensure continuous running of equipment. Selecting a supplier with a fuel management service in place will alleviate you from the burden of ensuring that adequate fuel is on hand for the duration of the hire period and minimise the scope for costly downtime.
Always check the small print.
- A quality supplier will be transparent when it comes to its fees so you shouldn't be shocked by any hidden extras. However, not all suppliers are upfront and honest and you may find that the cost of hiring equipment escalates as previously unquoted callout charges are added.
- The chemicals industry has very stringent quality control procedures and only work with accredited suppliers. Make enquiries to ensure the equipment supplier you select is suitably accredited to avoid any costly mistakes and unplanned downtime.
There are many factors that affect a decision to hire temporary power and lighting equipment, from what best suits your operation's needs to budget constraints but, ultimately, supplier expertise is key. Sanderson concludes: "Choosing a supplier with the relevant capabilities, knowledge of the industry and a real understanding of a client's needs will be able to evaluate the situation and make the right recommendations that is both fit-for-purpose and cost-effective."