Master Power Maintenance and Diagnostics Plan · Morón Petrochemical Complex

• Scope of Service: Comprehensive preventive and corrective maintenance of a transformer fleet (12 units), advanced dielectric diagnostics and optimization of availability across plant substations.

1. Executive Summary

Key Impact: Assured operational continuity of the petrochemical complex through technical intervention on 12 power transformers (from 500 kVA to 20 MVA), mitigating the risk of unplanned outages and catastrophic failure in the main electrical distribution system.

2. Technical Challenge (The Problem)

• Industrial Context: The Morón complex depends on a stable electrical infrastructure for critical chemical processes. Exposure to saline and corrosive environments, typical of the coastal area, accelerates the degradation of external components and transformer insulation.
• Pain Points: The need to identify signs of thermal ageing or oil contamination in equipment of different ratings that had not been serviced at the same time, which represented a latent risk to the production of fertilizers and basic chemicals.
• The Logistical Challenge: Carrying out the maintenance within the client's strict outage schedule, guaranteeing that each substation returned to service without affecting active production lines.

3. Comprehensive Solution (Engineering by CA Mantenimiento Eléctrico Costel)

Grupo Costel implemented a predictive and corrective maintenance protocol based on IEEE and IEC standards:

• Comprehensive Dielectric Diagnostics:
• Dissolved Gas Analysis (DGA): To detect incipient faults (arcing, overheating or partial discharge) before they become real failures.
• Physical and Chemical Analysis: Assessment of dielectric strength, interfacial tension, acidity and moisture content.
• Treatment and Recovery: Dielectric oil processing to restore its insulating and cooling properties.
• Validation Electrical Testing: Insulation resistance and turns ratio (TTR) protocols to certify the health of the active part of all 12 units.
• Corrective Maintenance: Adjustment of connections, leak sealing and upgrading of protection systems in substations.
• Voltage Range: Operating voltages (e.g. 13.8 kV, 4160 V, 480 V).
• Treatment Equipment: A thermal vacuum plant was used for oil treatment on all units.
• Findings: Mechanical faults were detected, leading to depressurization; pressure gauges were installed as a result.

4. Results and Value Metrics

• Prevention of Critical Failures: Early detection of deviations in the chemical analyses prevented at least 3 potential catastrophic failures that would have taken entire substations out of service.
• System Reliability: 100% availability of the serviced equipment was achieved after start-up, meeting the manufacturer's design parameters.
• Targets Met: Full execution within the timeframe estimated by the client, allowing production to continue at pace with no electrical setbacks.

5. Technical Data · Summary of Assets Serviced