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Case Study:

Facility Assessment Services
Industrial Salt Facility

Situation

Encouraged by a progressive plant management team, the client’s team was working on a standardization and modernization initiative. The initiative was focused on the reliability and safety of the electrical and controls systems. However, they couldn’t truly get started without first assuring they had reliable documentation of their systems. Some of the client’s key questions were:

  • Do we have contingency plans for a power fault?
  • If we have a power fault, what is the repair time?
  • How much production will we lose during the outage?
  • Can we reduce control system repair time?
  • Can we reduce planning time for new equipment and expansion projects?
  • What risks exist in our controls and electrical systems?
  • Do we know all of our safety risks?
  • Are all of our safety risks labeled and documented?

TEC Systems Group was selected by the client to perform a Facility Assessment.

Solution

The result was a complete health analysis of the network, controls and electrical systems and a safety risk assessment. Included was an accurate accounting and documentation for all programmable logic controllers, human-machine interfaces, motor control centers, motors, panels, breakers, feeders, transformers and network infrastructure.

The Facility Assessment uncovered several risks which could cause extended planning time for facility changes and longer repair time for failures, including:

  • No up-to-date documentation on the electrical or control systems. This lack of documentation increases repair times, project planning and maintenance labor.
  • No reports on system status. The plant could not use their control system efficiently due to lack of knowledge of its current status, available expansion capacity, software version, or overall health.

Results

The Facility Assessment service produced an estimated one-time labor savings of $350,000 and annual savings of $100,000. For the client, this project provided a payback period of 3 months and enabled their standardization and modernization efforts to move forward.