Practical Methods for Developing Electrical Operation and Maintenance Procedures

In today’s industrial world, the safe and efficient operation of electrical systems is not an option; it is essential. At Jemmatech Engineering Consult, we have worked with factories, commercial complexes, hospitals, and power utilities in Nigeria and beyond, and one thing is certain:

The best electrical systems rely on well-developed procedures, not luck.

This blog post is not just theory. It is a practical guide to developing proper electrical operation and maintenance procedures, based on years of practical engineering experience.

Let’s get started!

Why Procedures Are More Than Just Paperwork

During one of our projects at a textile factory in Aba, a minor electrical fault in a motor control center led to a half-day shutdown, resulting in millions of dollars in lost production. The problem wasn’t complicated; it was simply a loose connection. However, there was no proper maintenance procedure in place to regularly check the connections.

This scenario is repeated across all industries:

• An undetected hot spot in a control panel causes a fire.
• A circuit breaker fails to trip due to inadequate testing.
• A technician was electrocuted during maintenance because lockout and tagout instructions were not followed.

Proper operating and maintenance procedures prevent such disasters. They protect:

•  Human lives.
• Your equipment investment.
• Production schedules.
•  Compliance with regulatory requirements such as OSHA, IEC, and NFPA 70E.

How to Develop Practical Operating Procedures

Imagine you operate a facility with multiple 250 kW motors and control panels. How do you develop a safe and practical procedure for their daily use? Here’s how we at Jemmatech:

 1. Know the facility – don’t make assumptions

First, consult the manufacturer’s manual. You’ll be surprised how often this step is overlooked. For example:

A 250 kW motor may need to be preheated before starting in cold climates.

A vacuum circuit breaker may specify a minimum interval between opening and closing to prevent wear.

At Jemmatech, we examine every parameter:

• Nominal voltage and current
• Cooling methods (air, oil, forced ventilation)
• Operating procedures
• Environmental limits (temperature, humidity)

Tip: Keep a laminated quick reference sheet with the critical limits and start/shutdown sequences near the equipment.

 2. Establish clear standard operating procedures (SOPs)

A good SOP is like a navigation system: it shows you the steps to follow step by step. It should include the following:

• Pre-start checks: Check for loose wires, check the oil level, and read the temperature gauges.
• Start-up steps: For an engine, this might include turning on the auxiliaries, checking the voltage, and then starting the main drive.
• Operational monitoring: Listen for unusual noises, overheating, and excessive vibration.
• Shutdown procedure: A controlled shutdown prevents damage from sudden stops or voltage spikes.

Real-life example:

At a plastics factory in Lagos, we included the following in the SOP:

“Wait 15 seconds after starting the 400V motor before activating the extruder load to prevent inrush current from tripping the circuit breaker.”

3. Integrate Lockout and Lockout (LOTO)

Safety is essential. Jemmatech integrates LOTO procedures into all operational documents. Here’s how it works in practice:

•  Identify energy sources (electrical, hydraulic, pneumatic)
• Disconnect using switches or valves
• Attach padlocks and signs with the technician’s name and contact information
• Check energy isolation using a meter
• Keep keys in a safe place

Real-life example:

During maintenance on an electrical panel in Abuja, a technician checked the voltage and found that, even though the circuit breaker was off, it was still 415V. The upstream disconnect switch was returning power to the panel. Always check before touching anything.

Develop practical maintenance procedures.

Operating equipment safely is half the battle. The other half is keeping them in perfect working order for many years. Here’s how we create practical maintenance plans:

 1. Create Inspection Plans

Don’t wait for breakdowns. Schedule regular inspections:

• Monthly: Check for dust, corrosion, and signs of overheating
• Quarterly: Tighten connections, check protective devices
• Annually: Full thermography, insulation resistance test

Real-life example:

During a quarterly inspection at a pharmaceutical factory in Ogun State, we discovered a cable lug in a busbar compartment operating at 90°C, twice the normal operating temperature. We tightened the connection, preventing a potential fire.

2. Conduct diagnostic tests

Tests uncover hidden problems. The most common tests include:

• Insulation resistance testing: Measures the effectiveness of insulation to prevent current leakage. Essential for cables and motors.
• Thermal imaging: Identifies hot spots in electrical panels and connections.
• Contact resistance testing: Checks switchgear and circuit breaker contacts for excessive resistance.

Real-life example:

A bank’s data center in Port Harcourt was experiencing frequent circuit breaker trips. Thermal imaging showed a circuit breaker with a hot terminal operating at 75°C. We replaced it and stopped the annoying trips.

 3. Cleaning and environmental control planning

Dust is the enemy of electrical equipment. Consider the following in your procedures:

• Blow down control panels with dry compressed air
• Clean insulation surfaces
• Check HVAC filters in control rooms

In humid regions like Calabar, Jemmatech systematically recommends installing dehumidifiers in control rooms to prevent condensation.

 4. Calibrate protective devices

Protection relays, residual current devices, and circuit breakers must trip when needed. Calibrate them annually:

• Compare settings with design values.
• Check actual trip times and currents.
• Document results for audit purposes.

Real-life example:

At a brewery in Benin City, the relays were set too high, allowing fault currents to damage motors before they tripped. We recalibrated the settings to prevent future damage.

Documentation: Your Legal and Technical Protection

Everything you do must be documented:

• Test Reports
• Test Results
• Maintenance Logs
• Deviations and Corrective Actions

This allows for:

•  Proof of Compliance during Audits
•  Planning Future Budgets for Repairs or Upgrades
• Rapid Troubleshooting of Malfunctions

Jemmatech offers digital logbooks and QR codes so its clients can track the history of all their equipment components.

Training: The Human Connection

Even the best procedures fail if employees don’t follow them. At Jemmatech, we focus on:

• Regular safety workshops
• Equipment-specific training
• LOTO exercises
• Real-life scenario simulations

Real-life example:

During a training session, we asked technicians to identify ten safety defects in a mock control room. The exercise revealed knowledge gaps, which we immediately addressed.

Practical Benefits of Effective Procedures

Well-designed procedures offer the following benefits:

• Fewer breakdowns – Fewer unplanned shutdowns
• Safer workplaces – Fewer accidents and injuries
• Regulatory compliance – Avoid fines and legal issues
• Extend equipment life – Protect your investment
• Predictable budgets – No unpleasant surprises in the event of emergency repairs

Jemmatech Engineering in Practice: Case Study

We recently supported a food factory in Kano. Frequent faults on the 11 kV power line were disrupting production. After developing and implementing customized operation and maintenance procedures, the result was:

• 70% fewer faults
• Zero equipment failures in six months
• 18 million naira saved through avoided downtime and repairs
• That’s the power of proper procedures.

FAQ

Q1: How often should electrical equipment be serviced?

A1: It depends on the type of facility. However, typical maintenance intervals include monthly visual inspections, quarterly tests, and a full annual inspection.

Q2: What is the main benefit of procedures?

A2: Safety and reliability. Good procedures help prevent accidents, reduce downtime, and extend the life of equipment.

Q3: Can Jemmatech help me develop these procedures for my company?

A3: Absolutely! We specialize in creating practical standard operating procedures (SOPs), maintenance plans, and training programs tailored to your operation.

Q4: Is lockout/tagout mandatory?

A4: Necessary for safety and legal reasons. It’s the only way to ensure that equipment is safely de-energized during maintenance.

Would you like these procedures adapted to a specific industry or facility type?

Conclusion

Whether it’s a factory, bank data center, or hospital, the message is clear:

“Electrical systems don’t maintain themselves. Proper procedures are your best insurance.”

If you want to develop the right procedures for the operation and maintenance of your electrical systems, Jemmatech Engineering Consulting can support you, from documentation and audits to training and practical implementation.