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This case study pertains to a prominent manufacturing facility specializing in high-precision electronics. Located in an industrial zone noted for its robust manufacturing sector, the facility is equipped with complex electrical systems that are essential for its high-stakes production processes.
PROBLEM STATEMENT
The manufacturing facility faced significant challenges with its electrical systems, which were affecting operational efficiency, safety, and compliance with regulatory standards. Key issues included outdated installations, frequent electrical disturbances such as voltage fluctuations and harmonics, and general non-compliance with the latest electrical safety standards. These challenges not only threatened the safety of the workforce but also risked production downtime and increased operational costs.
SOLUTION PROVIDED BY 3PHTECH
Three Phase Techno Solutions implemented a comprehensive approach to conducting the Electrical Safety Audit:
1. Initial Assessment:
- Reviewed and verified Single Line Diagrams (SLDs) and existing maintenance records to establish a baseline for the audit.
- Set up and calibrated specific testing equipment needed for an in-depth analysis of the facility’s electrical systems.
2. Systematic Testing and Inspection:
- Conducted electrical measurements including voltage, current levels, and insulation resistance to evaluate the overall power quality.
- Performed a thorough physical inspection of Main and Sub-Main Distribution Boards and tested the operational efficacy of circuit breakers and safety interlocks.
3. Advanced Diagnostics:
- Utilized thermography techniques to identify hot spots and other potential electrical issues that could lead to failures.
- Undertook a detailed harmonic analysis to pinpoint sources of electrical disturbances and assess their impact on system stability.
4. Safety Compliance Verification:
- Reviewed safety protocols, emergency response procedures, and local and international safety regulations compliance.
5. Implementation of Corrective Measures:
- Assessment of overcurrent and earth fault protection systems to verify their settings and functionality.
6. Cable and Circuit Breaker Adequacy:
- Upgraded outdated electrical components and systems to enhance safety and efficiency.
- Installed harmonic filtering systems to stabilize power quality and reduce electrical disturbances.
CLIENT BENEFITS
The Electrical Safety Audit provided several substantial benefits:
Enhanced Safety
The audit and subsequent upgrades significantly mitigated the risk of electrical accidents, creating a safer work environment.
Improved System Reliability
Stabilization of the electrical infrastructure reduced incidents of downtime and enhanced production efficiency.
Cost Efficiency
By addressing inefficiencies and enhancing system operations, the facility saw a reduction in energy costs and maintenance expenses.
Regulatory Compliance
The audit ensured that all electrical installations and practices met the stringent requirements of current safety standards, protecting the facility from potential legal issues.
CONCLUSION
The Electrical Safety Audit by Three Phase Techno Solutions was crucial in identifying and rectifying critical safety and efficiency issues within the manufacturing facility’s electrical systems. This intervention not only enhanced operational capabilities but also ensured compliance with safety standards, thereby supporting the client’s commitment to maintaining a safe and efficient production environment.
