4 Steps to Reduce Downtime with Smart Electrical Asset Management

Hello, Champions of Net Zero!

In today’s fast-paced industrial landscape, unplanned downtime represents a formidable challenge for businesses striving for operational efficiency and profitability. A recent survey conducted by ABB highlights an alarming reality: unplanned outages can cost plants an average of EUR 147,000 per hour. This staggering figure translates to over one million Euros lost each day, a financial burden that many companies can scarcely afford. Moreover, a significant 69 percent of industrial enterprises worldwide report experiencing unplanned outages at least once a month. The implications of downtime extend beyond mere financial loss; they can disrupt production lines, tarnish customer satisfaction, and damage brand reputation.

As the demand for reliable and efficient operations increases, plant engineers must adopt proactive strategies to mitigate the risks associated with unplanned downtime. Here are four crucial steps that can help organisations safeguard their operations and maintain their competitive edge.

1. Embrace a Proactive Approach

In an era where electrical distribution and management systems are becoming increasingly complex, the potential points of failure multiply. Reactive maintenance, while once the norm, is becoming insufficient. Instead, plant engineers should prioritise predictive asset management. This forward-thinking approach can reduce maintenance time and downtime by an impressive 30 percent, ultimately leading to a remarkable 40 percent reduction in operational expenditure compared to traditional time-based maintenance strategies. By focusing on regular inspections, scheduled maintenance, and employing predictive analytics, organisations can stave off equipment failures before they occur, ensuring optimal asset performance and reliability.

2. Implement AI and Predictive Analytics

The digital revolution is empowering plants to maximise efficiency and performance through advanced technologies like Artificial Intelligence (AI) and Machine Learning. By harnessing these tools, maintenance managers can analyse and interpret vast datasets, identifying potential equipment failures before they manifest. Moreover, even legacy systems can benefit from modernisation; older equipment can be retrofitted with intelligent, digitally-enabled components that enhance predictive functionality. For instance, non-digital circuit breakers can be upgraded to connect with monitoring systems, allowing for real-time insights into performance. This approach not only proves more cost-effective than a complete overhaul but can also boost energy capacity by up to 20 percent while slashing operational costs by as much as 30 percent. Notable examples of this proactive strategy include ENGIE, a leading European energy supplier, and Kemijoki Oy, a key player in Finland’s carbon-neutral electricity system.

3. Modernise Electrical Assets

Another vital strategy for mitigating the risks of unplanned downtime is to modernise and upgrade existing electrical assets. This process not only extends the lifespan of equipment but also lowers operating costs and enhances sustainability. A compelling case study comes from one of Sweden’s largest cogeneration plants, Mälarenergi, which collaborated with ABB to upgrade its 16 switchgear units. By replacing ageing circuit breakers with state-of-the-art Emax2 models featuring Ekip Hi-Touch relay protection and advanced energy metering, the plant achieved full protection for its electrical circuits. The modern technology not only maximised energy efficiency but also significantly reduced resource consumption. Ultimately, extending the life of critical infrastructure not only mitigates the carbon footprint associated with manufacturing new systems but also minimises transportation costs and emissions.

4. Consider the Power Supply to Enhance Security

As businesses increasingly rely on their electrical infrastructure for continuity, ensuring a consistent power supply becomes paramount. One effective strategy is to evaluate the source of energy powering your operations. Rather than depending on volatile fossil-fuel-based power, many forward-thinking plants are investing in on-site renewable energy sources such as wind turbines and solar panels. By generating clean energy locally, organisations can exert greater control over their energy supply. These renewable sources can be integrated into Battery Energy Storage Systems (BESS) and microgrids, which reduce dependence on utility companies and traditional diesel or gas-powered backup generators. This shift not only curtails carbon emissions but also shields businesses from the financial unpredictability associated with fossil fuel markets.

In summary, while numerous factors contribute to unplanned downtime, implementing effective proactive asset maintenance and management strategies can significantly reduce the likelihood of costly interruptions. Embracing digitalisation, modernising equipment, and optimising power supply are all essential steps toward enhancing operational resilience and efficiency. As we strive for a sustainable future, adopting these strategies will not only protect the bottom line but also contribute to our collective journey towards net zero emissions.

For further insights and resources on optimising plant operations and achieving sustainability, we invite you to visit www.abbnavigate.com.

This article originally appeared in the June 2025 issue of Energy Manager magazine. Subscribe here for more valuable content.