Fixed Electrical Installation Inspection Fixed Electrical Instillation Inspection Client: Contact: Company Name Name Report No.: 001-01-12 Survey Date: 26 TH of January 2012 Contact: Liam Taylor Donal Guinan Tel: 0879971908 0872137047 E-Mail: ltaylor@conditionmonitoring.ie donal@conditionmonitoring.ie www.conditionmonitoring.ie
Contents Introduction Page 2 Executive Summary Page 3 Inspection Detail & Results Page 4-18 Inspection & Report compiled by: Mr. Gerald O Farrell BEng in Electronic Engineering, MSc Electrical Power Systems ger@conditionmonitoring.ie Signature Mr. Liam Taylor Taylor Condition Monitoring Ltd. Enterprise & Technology Park, Creagh, Ballinasloe Co. Galway ltaylor@conditionmonitoring.ie Signature
Introduction A fixed electrical Survey was carried out at XXXXXX, in on the 9 th January 2012 in accordance with ECTI Regulations and the Safety, Health and Welfare at Work (General Application) Regulations 2007, Part 3: Electricity. The inspection consisted of: A visual inspection was conducted on all main components of the fixed electrical installation. Items identified as requiring corrective action following the visual inspection were identified and are contained in the following report. The earth loop impedance of a proportion of the plants sockets were measured and assessed against in accordance with Annex 61F of the National Rules for Electrical Installations (4 th edition ET101:2008). The operating characteristics of a proportion of the plants RCDs were verified by injecting a test residual current and recording the time of operation by means of a proprietary instrument specifically designed for the purpose. The values obtained were assessed in accordance with Annex 61G of the National Rules for Electrical Installations (4 th edition ET101:2008). The results of this inspection together with comments and recommended corrective action, which when implemented will ensure that all main components of fixed electrical installation are in compliance with ETCI Regulations and the Safety, Health and Welfare at Work (General Application) Regulations 2007, Part 3: Electricity. Limitations The inspection was carried out where practicable at the discretion of the Inspecting Engineer, taking into account availability and accessibility. Cables concealed within trunking and conduits, or cables and conduits concealed under floors, in inaccessible roof spaces and generally within the fabric of the building or underground, were not visually inspected.
Executive Summary The panels at the XXXXXXX plant in are in good condition with some work required to bring all panels up to compliance with ETCI regulations. A procedure needs to be put in place to ensure that all fuses, MCB s and isolators are satisfactorily identified and labelled. As alterations are completed, legends and labelling should be reviewed and an annual inspection carried out. All updated legends should be dated and the previous revision discarded. There is evidence of strip connectors being used. This is not a good practice and should be discontinued. There is a potentially dangerous situation where some cable terminations have been left exposed. These could become live and cause a serious electrical shock or a fault condition. In any facility, it is important that standards are maintained to a high level. This includes maintenance and any alteration to panels or plant. It is important that all new installations or alterations are completed to a high standard and that this standard is maintained. This shall ensure a minimum amount of downtime of equipment due to faults and breakdowns and a safe plant for personnel to work in. The office was found to have insufficient earth bonding at its distribution board. This led to failures of the earth fault loop impedance of the circuits within this installation. The onsite electrical contractor sorted this issue immediately. An annual testing of the earth loop impedance and RCD trip protection should be put in place and the results recorded. This would ensure an unsafe situation does not occur.
Facility Inspection Detail & Results Periodic Inspections are completed on Electrical Installations to provide, so far as reasonably practicable for: 1) Protection against damage to property by fire and heat from an electrical defect. 2) Safety of persons against effects of electrical shock and burns. 3) Confirmation the installation is not damaged or deteriorated to impair safety. 4) The identification of installation defects and non-compliance with regulations. The following report identifies areas of the XXXXX plant in that had a visual inspection of the fixed electrical installation and the remedial action that is required as a result of this inspection.
1.01 Powerhouse/Main Switch Room Location / Equipment List Visual Insp. Action Plan Ref. No. Main Incomer CT Chamber Power Factor Correction Unit Action Required 1.011 Power Factor Correction Isolator DB at Main Incomer Action Required 1.012 1.011 Power Factor Correction Unit The PFC unit should be labelled. There are cables cut off at bottom of the panel as shown in photo 1, these should be removed. Photo 1 1.012 The distribution board for this panel is not labelled. Current Electricity at Work regulation 78 (a) requires the identification of electrical equipment, by way of labelling or otherwise, in order to prevent danger arising from confusion, mistaken identity or some other cause. Regulation 78(c) requires all electrical circuits are suitably identified at their source to allow those circuits to be safely and securely de-energised and isolated.
1.02 Control Room Main Board Location / Equipment List Visual Insp. Action Plan Ref. No. Cableway Distribution Action Required 1.01 Sw./Fuse 1 Vacuum Sw./Fuse 2 Shed Supply Sw./Fuse 3 Conveyor Panel Sw./Fuse 4 Monson Isolation Distribution Action Required 1.022 Main MCCB Incoming cableway Garo Junction boxes x 2 Action Required 1.023 Dryer 2 Control Panel Monson Control Panel Action Required 1.024 Silo Fans Action Required 1.025 SWEGMA Action Required 1.026 Dryer Burner (Kiln) Control Panel Action Required 1.027 1.21 The cables shown in photo 1 are left dangling in this panel. It would be good practice to bolt these cables together and to earth. Photo 1
1.022 Control Room Dist. Board The identification of all components in this distribution board have not been identified as shown in photo 2. Photo 2 1.023 Garo Junction Boxes There are two Garo junction boxes located at the side of this panel. These junction boxes should be labelled as to their function. 1.024 Monson Control Panel At the Monson control panel, a cable has been left exposed as can be seen in photo 3. This is a dangerous situation and needs to be rectified immediately Photo 3
1.025 Silo Fans Control Panel The labelling is poor on this panel as can be seen in photo 4. Current Electricity at Work regulation 78 (a) requires the identification of electrical equipment, by way of labelling or otherwise, in order to prevent danger arising from confusion, mistaken identity or some other cause. The labelling on this panel is insufficient to comply with this regulation. Photo 4 There are strip connecters used in this panel. The correct panel terminals should be used to connect cables. This panel needs to be cleaned out, it is full of a strawy substance. 1.026 SWEGMA There are strip connecters used in this panel. The correct panel terminals should be used to connect cables. There is a wire left exposed in this panel and could be live. This needs to be terminated in a suitable manner.
1.027 Kiln Control Panel There are black cables and also a yellow cable used as an earth. This installation does not comply with ETCI regulation 514.3.4 as shown in photo 5. This cable should be sleeved as per ETCI regulation 514.3.10 Supplementary colour marking or the cables replaced entirely with green/yellow coloured cable. Photo 5 Loop Impedance & RCD Operation Test Results SOCKET LOOP IMPEDANCE TEST DATA ETCI Regulation 613.6.1 requires that the effectiveness of the measures for fault protection by automatic disconnection of supply is verified. This verification can be determined by measuring or calculating the earth fault loop impedance of the circuits within an installation. The table below are the results of the sockets tested and assessed against in accordance with Annex 61F of the National Rules for Electrical Installations (4 th edition ET101:2008). Test Socket Location Socket Voltage Loop Impedance /Fail No. Test Results 1 Main Sw Room 222V 0.23 Ω PASS 2 Control Room 220V 0.1 Ω PASS 3 223 >8.28 Ω FAIL Loop impedance test were conducted using a ROBIN digital PSC Loop tester, Model no. KMP 4120
Test No. 3: The office sockets all tested in excess of 8Ω. This is a serious situation and required immediate attention. The manager of the office was informed and we also discussed the results with the on-site electrical contractor, Noel Fitzgerald of Millennium Electrical. He checked the cable earth bond and found these to be insufficiently bonded. He replaced the earth bond and the earth loop impedance at the distribution board measured 0.35Ω on his instrument. All the socket circuits should be measured to ensure they comply with ETCI Regulation 613.6.1. VERIFICATION OF OPERATION OF RCD s For compliance with 613.14, the operating characteristics of RCDs should be verified by injecting a test residual current and recording the time of operation by means of a proprietary instrument specifically designed for the purpose. Tests were carried out using a UNITEST Telaris 0100 plus. The values obtained were assessed in accordance with Annex 61G of the National Rules for Electrical Installations (4 th edition ET101:2008). Area Panel Location Socket Location Phones only socket under stairs 30 ma Trip time / Fail FAIL 5 x rated residual operating current verification / Fail FAIL Corridor 51 ms 13 ms Socket FAIL FAIL below DB Lobby 50 ms 13 ms Reception 39 ms 13 ms Front office off of reception 44 ms 13 ms Back office 38 ms 13 ms off of reception Canteen 38 ms 12 ms Canteen 38 ms 12 ms Locker room 39 ms 14 ms