Electricity and Control August 2022

PLANT MAINTENANCE, TEST + MEASUREMENT

Moving a production line This maintenance note on moving a production line is presented by Comtest, local representative for Fluke, a leading supplier of a wide range of electrical and electronic test and measurement tools. Here, Fluke highlights key considerations in planning a production line move, implementing it efficiently, and seeing to the start-up and testing once the move is complete, with particular attention given to the electrical systems.

M oving or reconfiguring a production line can disrupt a complex and finely tuned system. When a line is moved, electrical distribution systems, variable frequency drives (VFDs), programmable logic controllers (PLCs), lighting, communication circuitry, controls, emergency stop systems, and more are susceptible to unanticipated changes ranging from glitches to outright failures. Glitches and failures at the unit level can, in turn, cause failures at the system level, such as unexpected tripping of conveyor drive systems, failures of the plant floor communication system, equipment overheating, unsafe electrical systems – and potentially a lot of headaches and downtime. Problems caused by a move may not be immediately visible when a line is returned to service. Some symptoms of potentially serious problems may appear only long after installation and setup are complete. These may crop up in: - Motors that become noisy or burn out prematurely - Equipment shutting down for unclear reasons - Sensors and detectors not functioning properly - Operators complaining of ergonomic problems.

plant maintenance personnel are often fully occupied in just keeping the facility operating and, as a result, electrical work for the move is often outsourced. Although electrical con tractors can usually be relied on to follow the requirements of the National Electrical Code (USA) for all the electrical work they do, it is important to keep in mind that the code does not require a contractor to address many of the less obvious and frequently overlooked problems, such as voltage drops, harmonics, and EMI (electromagnetic interference). The contractor’s job is to provide an electrical installa tion “essentially free from hazards but not necessarily ef ficient, convenient, or adequate for good service or future expansion of electrical use,” according to Article 90 of the National Electrical Code. Unless particular contractual pro visions have been made to upsize conductors, use cable specifically designed for VFDs where needed, and the like, the plant owner should not rely on the electrical contractor to anticipate and solve many of the subtler issues that may arise, or to plan for future control and equipment concerns or enhancement. What needs to be done? Many of the things that need to happen when moving or reconfiguring a production line are obvious.

Outsourcing electrical work is not always the answer During a production line move, in-house electricians and

Issues faced: • System configuration, optimisation and analytics • Minimization of system/line downtime • Process and system integration • Technology integration

Issues faced: • Ongoing demand to reduce operating costs • ROI of resources • Increasing plant productivity

Issues faced: • Troubleshooting equipment • Servicing complex systems and machinery • Electro-mechanical installation and maintenance

Issues faced: • Efficient, consistent power delivery • Power installation and reworks • Troubleshooting electrical equipment

Moving a production line can disrupt a complex and finely-tuned system. (Diagram not to scale, for illustration purposes only)

24 Electricity + Control AUGUST 2022