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What do you do if you're an Energy Engineer faced with a major equipment failure?

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As an energy engineer, encountering a major equipment failure can be a daunting challenge. Your role involves ensuring the efficient operation of facilities that generate, distribute, or utilize energy. Equipment failure can lead to significant downtime, safety hazards, and financial losses. Therefore, it's crucial to approach such situations methodically. You must assess the situation carefully, determine the cause of the failure, and work on a solution that minimizes downtime and ensures the safety of all involved while maintaining the integrity of the energy system.

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Alireza Sarmadian

PhD | CEng MIMechE | Senior Development Engineer
Travis W.

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1 Assess Damage

When a critical piece of equipment fails, your first step is to assess the extent of the damage. This involves a thorough inspection to understand the immediate impacts on the system. You need to determine if the failure is isolated or if it poses a risk to adjacent equipment or the broader energy network. Safety is paramount, so ensure that the area is secure and that any potential hazards are contained. This initial assessment will inform the urgency and scope of your response.

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Alireza Sarmadian

PhD | CEng MIMechE | Senior Development Engineer
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While spot-welding a 6S2P battery pack, I mistakenly short-circuited two adjacent tabs. My first step was to audit the area and put in place fire safety protocols. Isolating the problem ensures that you can thoroughly evaluate the damage.

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JOEL ANKRAH

Attended Cape Coast Technical University
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One thing I have found helpful is to question the operator to give the history of the breakdown. With safety in mind I proceed to isolate the default network and physically access it.

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Aaron Dehl

Carpenter at North Fork Builders Bozeman MT.
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Sometimes equipment failures can lead to structural problems and need to be looked for. Carpenter by trade. Sometimes it's structural that will cause an in-balance.

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2 Identify Cause

Once the damage is assessed, your next move is to identify the root cause of the failure. This often requires a combination of hands-on investigation and analysis of data from monitoring systems. Understanding why the equipment failed is essential for preventing future incidents. You might need to examine maintenance records, consult with other engineers or specialists, and consider external factors such as environmental conditions or operational errors.

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Nolan Lee

Maintenance Technician at UniFirst Corporation
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As soon as you can figure out why and isolate the issue if need be then you can correct the issue and also create a way for that issue to either not happen again or a way for it to not happen as often or to be able to know when it will happen and create a schedule to conduct preventative maintenance to make sure you take measures to ensure that it will be something you are ready for and/or prevent from happening just with a preemptive response

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3 Plan Repair

After pinpointing the cause, you'll need to plan the repair process. This involves sourcing replacement parts, tools, and manpower necessary to restore the equipment. It's important to prioritize actions that will get the system back online quickly while ensuring long-term reliability. A well-thought-out plan will help streamline the repair process, minimize downtime, and prevent a recurrence of the failure.

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4 Implement Solution

With a repair plan in place, you're ready to implement the solution. This stage requires careful coordination with maintenance teams, operators, and possibly external contractors. Your role is to oversee the repair work, ensuring it adheres to technical specifications and safety standards. Effective communication and project management skills are crucial during this phase to keep the repair on schedule and within budget.

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Alireza Sarmadian

PhD | CEng MIMechE | Senior Development Engineer
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Using heat shrinks near the tab insulators, I made sure that I eliminated the risk of shorting. I replaced damaged cells and prepared the rig for testing.

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5 Test System

Before declaring the equipment fully operational, a rigorous testing phase is necessary. You must verify that the repairs have restored full functionality and that the equipment can handle the required loads and stresses of normal operation. Testing may involve simulations, load tests, or trial runs to ensure everything is working as expected. This step is critical to confirm that the issue has been resolved and to regain confidence in the system's reliability.

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Alireza Sarmadian

PhD | CEng MIMechE | Senior Development Engineer
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To test the repaired battery pack, I used a Neware battery cycler to obtain OCV and polar curves. I also used potentiostat to conduct EIS and collected data to be used for equivalent circuit models. I also used embedded thermocouples and heat flux sensors along with an emus BMS for logging useful data for system-level model-based control.

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6 Monitor Progress

Finally, after repairs are completed and testing is successful, continuous monitoring is essential to ensure the equipment operates smoothly going forward. You'll need to track performance indicators and any anomalies that may suggest potential issues. Ongoing monitoring not only helps in early detection of future problems but also contributes to the optimization of the energy system's overall performance.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Travis W.

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Assess the situation, and find out what exactly is happening. Once you know what is happening, decide what steps are needed to stabilize the situation. Once no more damage is happening we can look to damage control, and finally to a long term solution.

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What do you do if you're an Energy Engineer faced with a major equipment failure?

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1 Assess Damage

2 Identify Cause

3 Plan Repair

4 Implement Solution

5 Test System

6 Monitor Progress

7 Here’s what else to consider

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