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The Best Way to Manage Tools and Equipment in Power Plants
Jul 8, 2025
Power plants operate using complex systems of machinery, tools, and safety-critical equipment. From turbines and pumps to handheld tools and calibration devices, every asset must be accessible, functional, and safely maintained.
This article explains the best practices for asset tracking in power plants, helping operations teams, maintenance engineers, and plant managers improve visibility, safety, and operational efficiency.
Why Power Plants Need Robust Asset Tracking
High Safety Requirements and Regulatory Compliance
Power plants must follow strict safety protocols to protect workers and ensure reliable energy production.
Challenges
Missing tools during maintenance
Incomplete inspection histories
Poor documentation during audits
Potential use of unsafe or uncalibrated equipment
Summary: Strong tracking improves compliance and reduces safety risks.
Extensive Inventory Across Large Facilities
Power plants contain thousands of assets spread across turbines, boilers, substations, control rooms, and storage areas.
Common Issues
Tools misplaced between maintenance teams
Poor visibility of equipment availability
Unproductive time spent searching for tools
High-value equipment stored inconsistently
Summary: Centralised visibility improves workflow efficiency and prevents loss.
Maintenance-Driven Operations
Planned and unplanned maintenance activities depend on tool availability and accurate asset condition data.
Without Tracking
Preventive maintenance gets delayed
Tools remain out of service longer
Breakdowns occur unexpectedly
Spare parts inventory becomes inaccurate
Summary: Digital tracking supports predictable, safe maintenance.
Harsh Environments Impacting Asset Lifespan
Heat, vibration, moisture, and dust cause faster wear on equipment.
Risks
Unreported damage
Unsafe equipment returning to use
Reduced reliability of critical tools
Summary: Photo-based condition reporting reduces operational risks.
Best Practices for Asset Tracking in Power Plants
Use Durable QR or RFID Labels on All Assets
Industrial environments require identification tags that withstand heat, dust, and impacts.
Recommendations
High-temperature resistant labels
RFID tags for automated detection
Clear asset ID visible on equipment
Summary: Tough labelling improves tracking accuracy throughout the plant.
Implement Digital Check-In/Check-Out for Field Tools
Assigning tools and equipment ensures accountability at all times.
Benefits
Trace responsible users
Reduce tool hoarding
Minimize loss during outages
Improve operational discipline
Summary: Assignments ensure every tool has an accountable user.
Conduct Digital Condition Reports and Safety Checklists
Technicians should inspect tools before and after use, capturing photos and notes.
What to Include
Damage identification
Calibration status
Wear and tear indicators
Safety qualification checks
Summary: Digital inspections increase reliability and safety.
Track Asset Locations in Real Time
Knowing where assets are stored or last used reduces downtime.
Useful For
Turbine halls
Pump rooms
Maintenance workshops
Control rooms
Electrical substations
Summary: Location visibility prevents delays caused by missing equipment.
Automate Preventive Maintenance Scheduling
A digital system should trigger reminders for inspection, testing, and calibration.
PM Components
Scheduled intervals
Technician assignments
Parts usage tracking
Historical maintenance logs
Summary: Automated PM reduces failures and improves equipment uptime.
Analyse Asset Utilisation and Maintenance Trends
Understanding which equipment is used most frequently helps with planning and budgeting.
Insights Enable
Optimal purchasing
Balanced equipment distribution
Predictive maintenance
Lifecycle forecasting
Summary: Data-driven asset management improves long-term reliability.
Practical Example: Asset Tracking During a Planned Shutdown
A power plant schedules a 14-day shutdown for turbine maintenance.
Before Digital Tracking
Tools misplaced between teams
Delayed maintenance tasks
Lost inspection reports
Poor visibility of tool status
After Implementing a Tracking System
All tools labelled with QR/RFID tags
Technicians check out and return equipment digitally
Condition issues logged instantly with photos
Supervisors see tool location and availability in real time
Outcome: The shutdown finished on schedule, with fewer delays and clearer accountability.
How MapTrack Helps Power Plants Manage Assets
MapTrack provides a modern asset tracking platform ideal for power plant environments.
Real-Time Visibility of All Equipment
MapTrack shows asset location, condition, assignments, and usage history.
Fast Check-In/Check-Out Workflows
Technicians scan tools with mobile devices, ensuring accurate and reliable recordkeeping.
Digital Condition Reports and Checklists
MapTrack enables easy inspections with photo documentation, improving safety compliance.
Smart Lock Integrations
High-value or restricted tools can be stored securely with automated access logs.
Summary: MapTrack gives power plants the visibility, accountability, and safety assurance they need to operate efficiently.
FAQ
What power plant assets should be tracked?
Hand tools, calibration devices, PPE, electrical tools, GSE, maintenance equipment, and high-value parts.
Does asset tracking improve power plant safety?
Yes—tracking ensures only safe, inspected equipment is used in maintenance and operations.
Can QR or RFID tags withstand harsh environments?
Industrial-grade tags are designed for heat, vibration, and chemical exposure.
How does digital tracking reduce downtime?
By preventing missing tools, speeding inspections, and improving preventive maintenance.
Is mobile tracking suitable for field technicians?
Yes—MapTrack’s mobile-first design is ideal for turbine halls, workshops, and substations.
Can MapTrack integrate with maintenance programs?
Yes—MapTrack complements CMMS systems by providing real-time asset data and inspection results.
Conclusion & Actionable Takeaways
To improve asset tracking in power plants, organisations should:
Use durable QR/RFID labels
Digitise tool assignments
Capture condition reports with photos
Implement real-time location tracking
Automate preventive maintenance
Analyse usage data for better planning
MapTrack strengthens asset control, reduces downtime, and supports safety compliance across complex power plant environments.
