Better maintenance for more safety – Who is authorized and how often is necessary?

Maintenance – Who is Authorized and How Often?

Dear Readers,

In our last technical report, we discussed the importance and benefits of maintenance. Regular maintenance not only ensures the optimal functioning of your systems but also protects the safety of your employees and the longevity of the components. Today, we will dive deeper into the subject and address the question of who is allowed to carry out such inspections and how often they should be performed.

As described in the technical report of January, the legal foundation for the necessity of inspections is regulated in the Operational Safety Ordinance (BetrSichV), the regulations of the German Statutory Accident Insurance (DGUV), and in detail in the DIN standards DIN VDE 0105-100 and DIN VDE 0100-600. These regulations mention “competent persons.”

Competent Persons – Who Can Perform Maintenance?

The Operational Safety Ordinance (§ 2 and § 10) and the Technical Rules for Operational Safety (TRBS 1203) set clear requirements for who may perform inspections. Only competent persons—professionals with relevant vocational training, appropriate work experience, and up-to-date expertise—are authorized to inspect work equipment. These skills must be kept up to date through participation in training sessions. Additionally, they must meet the requirements of DGUV Regulation 3, which mandates that inspections be carried out either by a qualified electrician or under their supervision. It is crucial that the electrician has specific knowledge of the system being inspected. This ensures accurate assessment and minimizes the risk of errors. Furthermore, DIN VDE 0105-100 must be adhered to, which specifies that inspections must be carried out by electricians who have expertise in comparable systems.

Our KBR service technicians exceed these requirements by far. Not only are they specially trained for inspecting compensation systems, but they also bring extensive experience from numerous maintenance operations. With their in-depth knowledge of system structure and function, they will work quickly and efficiently while identifying potential issues early. In addition, they are well-versed in KBR systems and can also work on third-party equipment. We recommend: If you want to have additional safety, opt for our maintenance service and benefit not only from operational and system safety but also from convenience.

How Often Should Maintenance Be Performed?

The frequency of inspections is a central aspect of legal requirements and depends on multiple factors, including system usage, environmental conditions, and operational safety. According to the Operational Safety Ordinance (§ 3 and § 14), the employer must determine the type, scope, and deadlines for inspections as part of a risk assessment. Factors such as environmental conditions, operational intensity, and the age of the system are considered. As a general rule, you must ensure that the system can be safely operated until the next inspection.

DGUV Regulation 3 and DIN VDE 0105-100 provide guidelines for the basic inspection intervals of electrical systems:

Fixed electrical systems should be inspected every four years at the latest.
Systems in special operating areas (e.g., damp rooms or explosion-prone areas) require more frequent inspections, typically every year or every two years.
Residual current devices in non-stationary systems should be inspected monthly.
Portable electrical equipment usually undergoes an annual inspection cycle, though this may be shorter depending on operating conditions.

Annual Maintenance for Safe and Efficient Compensation Systems

Although compensation systems may appear to fall under “fixed electrical systems” at first glance, annual maintenance is absolutely necessary. These systems are under constant load, causing components such as capacitors and contactors to age quickly due to the high thermal, mechanical, and electrical stresses they endure. Additionally, they are sensitive to harmonics, which can lead to damage or system failures. Therefore, they are considered systems that are continuously and intensively operated, and according to DIN VDE 0105-100, they should be inspected more frequently. With annual maintenance, you ensure that your compensation system complies with legal requirements, operates efficiently, and potential risks such as wear or harmonics can be detected in an early stage.

Important: Pay attention to unusual events, such as damage or significant changes to the system! In addition to the intervals mentioned above, an inspection may be required at any time. These so-called event-based inspections serve to identify and address unforeseen risks.

Additionally, all inspections must be thoroughly documented. This is not only a legal requirement but also facilitates tracking maintenance actions and creates transparency regarding the condition of the system. We recommend: Create a well-defined inspection plan tailored to the specific requirements of your system.

It is important to emphasize that inadequate or insufficient inspections not only jeopardize operational safety but can also lead to legal consequences. A well-documented inspection plan helps fulfill these requirements and ensures the safe operation of the system.

secureC: Maximum Safety and Reliability

Safety plays a vital role in the operation of reactive power compensation systems. With the secureC safety and maintenance concept developed by KBR, maximum system availability is guaranteed—even in networks heavily burdened with harmonics. This system combines high-quality KBR components with well-thought-out monitoring functions.

secureC continuously monitors the capacitor capacities and simultaneously checks the stage fuses and contactors for functionality—across all three phases. This ensures safe operation even under challenging conditions.

Additionally, the intelligent, temperature-controlled ventilation system ensures an optimal temperature range and significantly extends the system’s lifespan. Malfunctions are detected via an integrated fault signal contact and via the bus interface, and are displayed directly on the built-in display, enabling quick and targeted troubleshooting.

A smoke detector can also be integrated, which, via an internal BUS system, autonomously activates additional functions in the event of a fire, such as automatically shutting down the affected system. Furthermore, an innovative extinguishing capsule is available, which quickly extinguishes flames within seconds. Thus, you get comprehensive security – just according to our 360° approach.

Maximum Reliability Through KBR’s 360° Service

One key advantage of secureC is its ease of maintenance: Due to the numerous safety components, no maintenance by a specialist company is required during the first three years of operation. After this period, we recommend annual inspections to ensure long-term high operational safety—preferably by our experienced customer service team. By opting for one of our maintenance contracts, you benefit from fixed prices, regular maintenance appointments, and clear planning. Additionally, secureC provides further benefits: We will commission your system on-site free of charge. Plus, you will enjoy an extended warranty for 3 years. With secureC, you invest in a solution that reduces your operating costs while keeping your system safe and efficient.

Another important aspect of the safety and efficiency of your systems is monitoring harmonics. These can cause severe damage to your system if left undetected, ranging from overheating and premature wear to failure of critical components. With our Power Quality Maintenance service, we offer continuous real-time monitoring of your voltage quality. If, for example, voltage drops or other deviations occur, you will be immediately informed and can take countermeasures. This helps protect your systems from damage while improving operational safety and extending the lifespan of your equipment.

KBR Service Technicians: Expertise You Can Rely On

Our service technicians are highly skilled and experienced. They are specifically trained to understand and implement the requirements for regulatory compliance and modern compensation systems. Thanks to their specialization in compensation systems, they are not only faster but also more precise in carrying out inspections and maintenance. This results in significant time and cost savings for you as a customer.

Our experts know what’s important during inspections: from measuring capacitor currents to checking screw connections and regulator settings, to visually inspecting your system and cleaning the filter mats. They ensure compliance with all legal requirements and actively contribute to optimizing system performance. If components are defective, our technicians can usually perform minor repairs on-site. If this is not possible, you will receive a corresponding offer afterwards. Additionally, we provide advice on how to keep your system up to date with the latest technology.

A key advantage of our maintenance contracts is the nationwide flat rate in Germany. You pay no additional travel costs, regardless of your location. Our technicians are available Monday to Thursday and can be reached via our service hotline if needed. Additionally, our comprehensive documentation of maintenance work provides you with a clear overview of your system’s condition and the measures taken.

Conclusion: Safety Through Standards and Expertise

Regular maintenance is far more than a legal obligation—it is the foundation for the long-term safety and efficiency of your systems. However, several rules must be observed: It is important not only to adhere to maintenance intervals but also to carry out extraordinary inspections if necessary. The qualification of those performing the inspections and the manner in which they are conducted is also relevant.

We recommend: If you want to focus on your core business while benefiting from maximum operational and system safety, rely on KBR’s service and product portfolio. With our specially trained service technicians, flexible maintenance contracts, and innovative solutions like secureC, we offer you a comprehensive service that leaves nothing to be desired. secureC is just one part of our 360° approach.

360° energy management means for us not only monitoring but also the active maintenance of your systems. From regular maintenance and optimization of your energy optimization systems to maintaining active power filters and implementing and maintaining your EDM software—our solutions ensure that your energy infrastructure remains efficient and reliable. Contact uss today to plan your next maintenance and sustainably benefit from our expertise.