-
7/30/2019 Benefits of Predictive Maintenance Latest Malaysia
1/3
Hoestar Reliability Instruments Sdn Bhd (693347-T)
CT-04-07, Subang Square Business Centre
Jalan SS 15/4G, Subang Jaya
47500 Petaling Jaya, Selangor Darul Ehsan, Malaysia
Email: [email protected]
Website: http://www.hoestarinsp.com.sg
Tel: 603-56326832 Fax: 603-56376832RELIABILITY
14 February 2007
Benefits of Predictive MaintenanceUsing Partial Discharge Test
for a Typical Plant
1.Provide a Safe Working Environment To Plant
Personnel.2.Prevent Breakdown Of Equipment Which May Cause:
a.Man Power Loss : Companys Resources Wasted.b.Reputation Lost
:Customers Confidence Level Reduced.c. Equipment Loss : RM 80K
(Est.)
i. High Repair Cost If Major Damage Occurs.ii. Longer Breakdown
Time If Damaged Devices Are Not
Available.
d.Production Loss:
RM 100K/DAY (Est.)
i. Product Couldnt Deliver On Time.ii. Product Damaged In The
Middle Of Processing.iii. Re-Planning Of Production Schedule.iv.
Resetting of Production equipment
3.Reduce Shutdown Time When Number of Equipment To BeServiced
Are Reduced.
4.Reduce Maintenance Cost for Servicing Of Equipment That
AreStill In Good Condition.
5.Extend the Service Life of The Equipment.
-
7/30/2019 Benefits of Predictive Maintenance Latest Malaysia
2/3
Hoestar Reliability Instruments Sdn Bhd (693347-T)
CT-04-07, Subang Square Business Centre
Jalan SS 15/4G, Subang Jaya
47500 Petaling Jaya, Selangor Darul Ehsan, Malaysia
Email: [email protected]
Website: http://www.hoestarinsp.com.sg
Tel: 603-56326832 Fax: 603-56376832RELIABILITY
Cost Saving
The servicing cost per Transformer is RM400 and RM550 per
switchgear
and the servicing frequency is usually yearly and the
conventional
method of servicing is as follows:-
Visual Inspection
Oil Leaks Checking
Open Connection
Polishing
Greasing
Scope of Servicing for aTransformer (22 kV / 415V)
Retightening
Visual Inspection
Vacuum Checker On Vacuum
Circuit BreakerContact Resistant Measurement
Open Connection
Polishing
Greasing
Scope of Servicing for a
Switchgear (22 kV)
Retightening
-
7/30/2019 Benefits of Predictive Maintenance Latest Malaysia
3/3
Hoestar Reliability Instruments Sdn Bhd (693347-T)
CT-04-07, Subang Square Business Centre
Jalan SS 15/4G, Subang Jaya
47500 Petaling Jaya, Selangor Darul Ehsan, Malaysia
Email: [email protected]
Website: http://www.hoestarinsp.com.sg
Tel: 603-56326832 Fax: 603-56376832RELIABILITY
Lets take a look at the below example on
Cost Saving Benefit for a Typical Plant
Servicing Cost Partial Discharge
Test Cost (RM)Type of Equipment
Qty U/Price
(RM)
Total
(RM)
U/Price
(RM)
Total
(RM)
Transformers (22kV / 415 V) 7 400 2800 350 2450
Switchgears (22 kV) 8 550 4400 350 2800
Total Servicing Cost 7200
Total Partial Discharge Test Cost 5250
Note: From our experience, based on the total number of
equipment tested,
conservatively only 20% of the equipment is in need of
servicing. Thus
the saving is as follows:-
Total Servicing Cost : RM 7200 20% of Equipment needs servicing
: (RM 1350)
after a Partial Discharge Test -------------
Total Saving from Servicing : RM 5850 (81%)========
Lets take a look at the Net Saving ** based on above
illustrations
Total Servicing Cost without Partial Discharge Test : RM 7200
20% of Equipment that Need Servicing after test - RM 1350 Partial
Discharge Test Cost - RM 5250 : (RM 6600)
Savings : RM 600
Note: * Above calculation excludes the shut-down cost and
production loss.
Total servicingcost with Partial
Discharge Test
