Life cycle extension of electrical equipment and systems in a large metallurgical plant — A case Study

摘要

Industrial facilities, especially chemical process plants, face accelerated aging due to the operational environment. The conditions for operation of electrical facilities and equipment in such environments - even if appropriate selection was made during design stages, are difficult in the normal conditions while it may be outright safety-compromised in extreme cases. Usually forming a core part of processes, problems arising in electrical facilities have serious implications in any manufacturing industry. This paper discusses the approach taken for ensuring continued reliable operation of the electrical systems and major electrical equipment in a large metallurgical plant producing primary zinc metal by electrowinning through hydrometallurgical route. The approach is a fairly general one and shows how planned lifecycle interventions of equipment can incrementally add capacity as well as increase reliability of such systems without compromising on the availability of systems for production processes. Commercial viability dictates the requirement of higher production even in the face of aging infrastructure requirement. The approach to Life Cycle Management has been elaborated from multiple solution perspectives utilized : upgrades, retrofits, re-engineering, replacement and modifications. Review of the maintenance strategies contributing to performance enhancement successfully implemented include equipment dependent condition monitoring while opportunity maintenance and preventive maintenance plans with a focus on utilizing past equipment performance data models have been touched upon. The paper concludes by highlighting the methods employed to enhance the productivity and safety of electrical equipment and systems in an old chemical process plant which can be used in similar plants.