Keeping Complex Facilities Running Smoothly
Our work with ABB Australia at their Moorebank HQ shows how Protex delivers planned preventative and reactive electrical maintenance that keeps even the most demanding facilities safe, compliant, and running without disruption.
Project spotlight
Powering Performance at ABB’s Moorebank HQ
ABB Australia is a global technology leader serving the utility, industry, transportation, and infrastructure sectors. Their Moorebank headquarters is an extensive, high-demand site spanning 84,000 m², comprising a multi-storey office building and nine medium-to-large industrial warehouses.
The facility operates with a complex range of electrical assets — including three main switchboards, twenty distribution boards, advanced control panels, high-load industrial machinery, solar systems, and extensive interior and exterior lighting, such as high-bay warehouse lights requiring specialised boom-lift access. With a workforce that ranges from daytime office staff to night-shift warehouse teams, the site required a tailored approach to keep operations running smoothly. Protex designed and delivered a planned preventative maintenance program that minimises disruption while maintaining the highest standards of safety, compliance, and performance across this complex, high-risk environment.
How We Work
A Systematic Approach to Asset Management
When we took over the site, we began with a comprehensive multi-day audit conducted by two senior technicians. Every electrical asset — from main switchboards and distribution boards to solar systems, lighting, power outlets, hot water services, exhaust fans, and ceiling fans — was meticulously catalogued. We built a detailed asset register within our job management system, assigning each asset a unique number and barcode, complete with its location, images, and descriptions for easy reference. Using this data, we designed a custom maintenance schedule aligned with all relevant legislation, standards, and client requirements. This structured approach allows us to proactively manage and maintain every electrical asset, ensuring compliance and consistent reliability.
Proactive Protection
A Tailored Preventative Maintenance Program
The ABB site required an extensive range of planned preventative maintenance (PPM) tasks on monthly, half-yearly, and yearly schedules to maintain safety, efficiency, and compliance.
Monthly Planned Maintenance
On a monthly basis, our technicians conduct visual inspections of all electrical equipment, including power cords, extension leads, main switchboards, and circuit breakers. We clean electrical panels, switchboards, and other critical components to prevent dust buildup, maintain the light-timing systems, and carry out relamping and minor corrective works as needed.
Half Yearly Planned Maintenance
Every six months, the program expands to include test-and-tag services for appliances in factories, workshops, and assembly areas in line with AS3000 standards. We also inspect and test hot water services, clean and test exhaust fans to remove dust and debris, check and test ceiling fans, and carry out thorough inspections and cleaning of distribution boards.
Yearly Planned Maintenance
On a yearly cycle, we perform test-and-tag services for all office appliances, conduct trip tests on the main switchboards, and complete thermographic scanning of both main switchboards and distribution boards to detect potential issues before they arise. This is complemented by insulation testing of main switchboards and a full inspection and testing of the site’s solar system.
Compliance Made Simple
Transparent Reporting & Continuous Improvement
After each inspection and corrective task, our technicians compile a comprehensive maintenance report detailing: - All inspections, tests, and repairs conducted. - Any identified non-compliance issues with recommended remediation actions. - Quotations for any additional remediation work outside the scheduled scope. This approach ensures complete transparency and keeps the client informed before any further work is undertaken.
Asset Register Updates
We update the asset register and log the maintenance report in our system, sending it to the client along with any relevant quotes. These records provide a clear history of maintenance activities, demonstrating compliance with regulations and supporting proactive asset management.
Updated schematics and schedules
Our supervisors review and amend electrical schematics and schedules as required, providing updated versions alongside the maintenance report. This ensures clients have the most accurate, up-to-date documentation for their site.
