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Make the Most of your Ethanol Plant Shutdown: Preventative Maintenance That Pays Off.

Headshot of Blaine Erkenbrak

Blaine Erkenbrack

Vice President of Power Services

Seasonal shutdowns are the ideal time to ensure your plant stays online when it matters most.

Every ethanol facility depends on precise, continuous operations—and even a short unplanned outage can be costly. As you approach your seasonal shutdown window, there’s one simple step you can take to avoid future downtime: schedule preventative maintenance with Knobelsdorff. 

During a scheduled shutdown, your systems are already powered down. This creates a safe, efficient window to inspect and service your electrical infrastructure—before small issues become major failures. 

Why Perform Electrical Testing During Shutdown?

Planned downtime is the only time your system is safe and fully accessible for comprehensive testing. Our Power Services team steps in to conduct a full range of NFPA 70B-compliant maintenance services, ensuring everything operates as it should, now and in the future. 

If we find something during testing that’s not working as intended, our team is onsite ready to mitigate any issues. We can immediately troubleshoot and repair most issues, so you’re not stuck waiting to get back online. 

Common Maintenance Services and Why They Matter

Here’s a breakdown of what we test and the real-world benefits of each: 

Breaker Testing

  • What it does: Verifies the operation of circuit breakers that protect your equipment from overloads and short circuits. 
  • Why it matters: A faulty breaker can fail to trip, or trip too soon, resulting in equipment damage or unexpected outages. 
  • What we might find: Weak trip mechanisms, worn contacts, or calibration issues. 

Protective Relay Testing

  • What it does: Confirms your protective relays are correctly calibrated and communicating properly. 
  • Why it matters: Relays are the brains of your protection scheme—when they misfire, they can take down entire systems. 
  • What we might find: Time delays out of spec, false triggering, or failure to trip on command. 

Motor Testing 

  • What it does: Evaluates motor health by checking insulation, winding resistance, and rotational integrity. 
  • Why it matters: Motors are often the heart of your operations. Early detection of issues can prevent expensive rebuilds or replacements. 
  • What we might find: Worn bearings, winding degradation, or phase imbalances. 

SWBD/MCC (Motor Control Center) Testing 

  • What it does: Inspects MCCs for loose connections, insulation integrity, and component reliability. 
  • Why it matters: MCCs house critical controls—if they fail, so do the motors and systems they control. 
  • What we might find: Corrosion, thermal hotspots, or arcing signs. 

Transformer Testing 

  • What it does: Evaluates oil, windings, and insulation systems in transformers. 
  • Why it matters: Transformers are high-value assets. Testing prevents long-lead-time failures that could halt production. 
  • What we might find: Moisture ingress, dielectric breakdown, or overheating signs. 

Cable Testing 

  • What it does: Identifies insulation integrity and potential failure points in power and control cables. 
  • Why it matters: Cables degrade silently over time. Testing avoids hidden weaknesses becoming system-wide failures. 
  • What we might find: Cable jacket damage, water intrusion, or aging insulation. 

NFPA 70B Compliance Review

  • What it does: Ensures your electrical maintenance program meets the latest industry standards. 
  • Why it matters: Staying compliant isn’t just about safety, it reduces liability, lowers insurance risk, and supports operational uptime. 
  • What we might find: Gaps in documentation, missed inspection cycles, or overlooked aging components. 

What Happens if we Find an Issue?

The beauty of partnering with KE is that you get a full-service team.

  • If our Power Services technicians find something during testing, our electricians and technicians can mobilize immediately to correct it. 
  • That means no delays, no separate contractors, and no waiting until the next shutdown. 
  • Our proactive approach minimizes downtime and maximizes your investment in maintenance. 

The Cost of Doing Nothing? Unplanned Downtime.

Unplanned outages can cost ethanol plants tens, or hundreds of thousands of dollars per hour. Even minor faults left unaddressed during planned shutdowns can lead to: 

  • Equipment damage 
  • Safety risks 
  • Compliance violations 
  • Lost production 

Planned maintenance is your insurance policy against these risks. And when timed with your scheduled downtime, it’s also the most efficient and affordable way to protect your plant. 

Ready to Take Action?

Our calendar fills quickly during shutdown season. To reserve your maintenance window or discuss a custom service package, reach out today.