Methodology

Our team of experienced engineers adopted a multi-pronged approach:

1. Thermography:

• Trained thermographers utilized advanced thermal imaging cameras to capture temperature variations across all critical electrical components, including furnaces, transformers, control panels, and motors.
• These infrared images revealed hidden issues like:
  • Overheating components indicating potential wear and tear or overload.
  • Imbalanced loads leading to inefficiencies and reduced lifespan of equipment.
  • Faulty connections and loose contacts posing safety hazards.

2. Earth Pit Testing:

• We assessed the effectiveness of the earthing system, crucial for safety and equipment protection from lightning strikes.
• Soil resistivity measurements were taken to ensure proper grounding conductivity.
• Earth pit leakage currents and voltage drops were analyzed to evaluate system performance.

3. Lightning Arrester Testing:

• We verified the functionality and performance of lightning arresters installed to protect equipment from damaging surges caused by lightning strikes.
• Specialized testing equipment was used to assess their ability to safely divert current surges to the ground.

Combining Insights:

By analyzing the data from all three methodologies, we were able to paint a comprehensive picture of the electrical health and vulnerability of the glass manufacturing facility. This allowed us to identify not only immediate concerns but also areas for preventive maintenance and optimization.

Findings and Recommendations:

The combined assessment revealed several issues, including:

• Overheating bearings in a critical furnace motor, indicating potential wear and tear requiring immediate maintenance.
• Imbalanced load distribution on a transformer panel, leading to decreased efficiency and increased risk of overload.
• Inadequate earthing in certain locations, compromising safety and equipment protection from lightning strikes.
• Deterioration of lightning arresters on some structures, reducing their effectiveness against voltage surges.

Based on these findings, we provided a detailed report with prioritized recommendations, including:

• Prompt maintenance of the furnace motor bearings to prevent potential breakdowns and production disruptions.
• Load balancing adjustments on the transformer panel to improve efficiency and extend equipment lifespan.
• Upgrade and improve earthing systems in vulnerable areas for optimal safety and lightning protection.
• Replacement of deteriorated lightning arresters with high-performance, functioning units to ensure complete surge protection.

Results:

By implementing our recommendations, the glass manufacturer achieved significant improvements:

• Enhanced production efficiency: Reduced risk of equipment failures and downtime resulted in smoother operations and consistent output.
• Improved quality control: Optimized equipment performance ensured consistent glass quality and minimized rejects.
• Enhanced safety: Upgraded earthing and lightning protection safeguards minimized the risk of electrical accidents and lightning damage.
• Extended equipment lifespan: Proactive maintenance and preventive measures helped maximize the life of vital equipment.
• Peace of mind for management: Knowing their electrical infrastructure was optimized and protected created a safer and more efficient production environment.